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User Manual - PMC Rentals

1. Section 4 2 1 Step 4 Section 4 2 1 Step 1 M2 2_ ACW Test T e ACW Settings iius aaa 4360V Max Lmt 20 00mA 4 2000v Kee Min Lmt 9 999mA y E 20 00mA Step Ramp UP 999 9s Edit 1 00mA Dwell 999 9s 999 9s Exit Ramp DN 999 9s Exit Arc Sense 9 Press the Edit soft key Section 4 2 2 Step 2 Select the memory and step number using their corresponding softkeys Section 4 2 1 Step 2 Test Type ACW Voltage 4360V Max Lmt 20 00mA 4 Min Lmt 9 999mA mi Ramp UP 999 9s Dwell 999 9s Ramp DN 999 9s Arc Sense 9 TIT 36 e ASSOCIATED RESEARCH INC 4 2 2 Editing Test Parameters Refer to FIG 2 1 From the Test parameter review screen refer to section 4 2 1 scroll the cursor to the test parameter you wish to edit using the up and down arrow soft keys 2 Press the Edit soft key The Test parameter edit screen will now be displayed 3 You may now change the value of the test parameter with the up and down arrow soft keys 4 Press the Enter soft key to accept the new value or press Esc to escape from the edit All available test parameters may be edited using this procedure 4 2 3 Reviewing Test Results Method 1 Hot key 1 Pressing the bottom soft key at the Perform Test screen will display the Results screen Method 2 Menu Selection 1 From the Perform Test screen press the Menu soft key The Main Menu will now be di
2. Description AR Part Number Hypot III Instrument 36XX High Voltage Cable 04040A 08 Return Cable 02100A 13 Qty 2 Fuse 37880 3 15 Amp fast acting 250VAC Line Cord 33189 Standard Adapter Box 36544 Standard The Adapter Box and Line Cord listed are American Other combinations of Line Cord and Adapter Box are available upon request 2 1 3 Returning the Instrument When it is necessary to return the instrument for servicing or calibration repackage the instrument in its original container please include all accessories and test leads Indicate the nature of the problem or type of service needed Also please mark the container FRAGILE to insure proper handling Upon receipt your instrument will be issued an AR service number Please refer to this number in all correspondence If you do not have the original packaging materials please follow these guidelines e Wrap the instrument in a bubble pack or similar foam Enclose the same information as above 17 e ASSOCIATED RESEARCH INC e Use a strong double wall container that is made for shipping instrumentation 350 lb test material is adequate e Use a layer of shock absorbing material 70 to 100 mm 3 to 4 inch thick around all sides of the instrument Protect the control panel with cardboard e Seal the container securely e Mark the container FRAGILE to insure proper handling e Please refer in all correspondence to your AR service number 2 2 I
3. Voltage 1000v m Max Lmt 2000MO Min Lmt 1000MQ y Ramp UP 999 9s zm Delay 999 95 4 Edit Ramp DN 999 9s Exit Connect ON From the Insulation Resistance parameter setting screen the following parameters may be selected for editing Voltage Max Limit Min Limit Ramp Up Delay Time and Ramp Down 41 e ASSOCIATED RESEARCH INC 4 3 4 Default Test Parameters Each of the test types AC withstand DC withstand and IR have specific default test parameters that automatically load when test type is selected from the parameter edit screen The following table is a listing of the Default Parameters for each of the different types of tests that are available in the Hypot III The Default Parameters are as follows Test Type Parameter Voltage Max Lmt current Min Lmt current Ramp UP Dwell Ramp DN Arc Sense Frequency Continuity Max Lmt Continuity Min Lmt Continuity Offset Continuity Connect Voltage Max Lmt Current Min Lmt Current Ramp UP Dwell Ramp DN Arc Sense Continuity Max Lmt Continuity Min Lmt Continuity Offset Continuity Connect Voltage Max Lmt Min Lmt Ramp UP Delay Ramp DN Connect 42 e ASSOCIATED RESEARCH INC 4 3 5 Memory Step and Default System Parameter Initialization Warning Initializing the instrument will overwrite all memories and steps with ACW default parameters Press the two bottom soft keys and power the instrument
4. 3 1 Hypot III Functional Specifications INPUT Voltage 115 230 VAC 10 user selectable Frequency 50 60 Hz 5 Fuse 3 15 Amp fast acting 250VAC DIELECTRIC WITHSTAND TEST MODE Output Rating 5000V 20 mA AC 6000V 7 5 mA DC Voltage Setting Range 0 5 00KV AC 0 6 00KV DC Resolution 0 01KV Accuracy 296 of setting 5V Can be adjusted during operation Disabled when key lockout is active Maximum Limit Range 0 00 20 00 mA Resolution 0 01 mA Range 0 7500 uA Resolution 1uA Accuracy AC and DC 2 of setting 2 counts Minimum Limit Range 0 000 9 999 mA Resolution 0 001 mA Range 0 0 999 9 uA Resolution 0 1 uA Accuracy AC and DC 2 of setting 2 counts Ground Fault Interrupt GFI Trip Current 450uA max AC or DC HV Shut Down Speed 1ms Voltage Display Range 0 00 5 00KV AC 0 00 6 00K V DC Resolution 0 01KV Accuracy 2 of reading 0 01KV 20 ef ASSOCIATED RESEARCH INC DIELECTRIC WITHSTAND TEST MODE Current Display Auto Range AC Range 1 0 000mA 3 500mA Resolution 0 001mA Range 2 3 00 20 00 mA Resolution 0 01 mA DC Range 1 0 0 uA 350 0 uA Resolution 0 1 uA Range 2 0 300 mA 3 500 mA Resolution 0 001 mA Range 3 3 00 mA 7 50 mA Resolution 0 01mA Accuracy All Ranges 2 of reading 2 counts Discharge Time lt 200 ms The maximum capacitive load vs output voltage 0 20 uF lt IKV 0 050 uF lt 4KV 0 10 uF lt 2KV
5. Voltage XXXXV lt TEST gt to Start lt RESET gt to Exit lt RESET gt to Exit 63 e ASSOCIATED RESEARCH INC Calibration of DC Hipot Voltage Calibration Connect the standard 6KVDC kilovolt meter from H V to Return Calibration Enter standard Voltage reading Voltage XXXXV lt TEST gt to Start lt RESET gt to Exit lt RESET gt to Exit Calibration of IR DC Voltage Calibration Connect the standard 1KVDC kilovolt meter from H V to Return lt TEST gt to Start Calibration Enter standard Voltage reading Voltage XXXXV lt RESET gt to Exit lt RESET gt to Exit Calibration of AC Current 20 00mA range Calibration Connect the 100KQ Load in series with the 20mAAC standard current meter TEST to Start lt RESET gt to Exit Calibration Enter standard Current reading Current XXXXV lt RESET gt to Exit Calibration of AC Current 3 50mA range Calibration Connect the 100KQ Load in series with The 3 5mAAC standard current meter lt TEST gt to Start lt RESET gt to Exit Calibration Enter standard Current reading Current XXXXV lt RESET gt to Exit 64 e ASSOCIATED RESEARCH INC Calibration of DC Current 7
6. a special procedure is required to defeat the security To defeat the security press the top soft key while powering up the instrument Now you may access the system menu and turn the security function OFF Mem Lock Scroll the cursor to the Mem Lock parameter using the directional soft keys When the cursor is pointing to the Mem Lock parameter you may turn the function ON and OFF by pressing the soft key Mem Lock is a sub function of the Lock setting In order for the Mem Lock function to work the Lock must first be turned ON Selecting the Mem Lock OFF will allow the user to access all available Memory locations and steps but restricts access to memory and step editing capabilities Selecting the Mem Lock ON will allow the user to only run the currently loaded memory Smart GFI Scroll the cursor to the Smart GFI parameter using the directional soft keys When the cursor is pointing to the Smart GFI parameter you may turn the function ON and OFF by pressing the soft key 32 e ASSOCIATED RESEARCH INC The High Voltage power supply of the instrument is internally referenced to earth ground The leakage current measuring circuits monitor only currents that flow through the Return lead Therefore the possibility exists for current to flow directly from the High Voltage output to earth ground that typically would not be monitored GFI is a circuit that monitors the current between the High Voltage o
7. 50 6 1 Eer INIA ZATION Ss 50 a NEE 50 52 1 Continuity E 51 6 2 2 AC Hipot Verification iras 52 6 2 3 DC Hipot ee 53 5 24 IR Verificati essiri r vun xe na aea 54 TREO Coli is 55 7 1 Signal Outputs on Remote VO A 55 7 2 Signal Inputs of Remote I O and Memory Access ccoooocccconononcnonooncccnconanonoss 56 M n me 59 9 Calibration Proc 62 9 1 Warranty Requirements nr 62 9 2 Calibration Initialization eege eneen 63 9 2 1 Calibration of Parameters essei IA c er piso teens gereest 63 10 Replacement Parts boe X c 67 11 Schematie Mr 68 2 SSOCIATED RESEARCH INC e 12 Index e ASSOCIATED RESEARCH INC 1 Introduction 1 1 Warranty Policies Associated Research Inc certifies that the instrument listed in this manual meets or exceeds published manufacturing specifications This instrument was calibrated using standards that are traceable to the National Institute of Standards and Technology NIST Your new instrument is warranted to be free from defects in workmanship and material for a period of 1 year from date of shipment You must complete the on line registration at www asresearch com register or call 1 800 858 TEST ext 210 to register over the phone 5 Year Program AR recommends that your instrument be calibrated on a twelve month cycle Instruments purchased and used in North America only may h
8. 62 Eonnecied Pa 17 30 31 45 47 63 A 11 15 24 39 40 Sn EES 23 29 31 43 GOBLTOIS iia aia aos 14 20 24 25 29 45 46 DEW rg E E 36 40 41 42 47 48 49 Default Parameters EN 27 42 hr AA 22 38 41 42 48 Dielectric Withstand Test 8 9 42 45 48 Dischat Sv ee A 7 10 11 21 DUT T o d r 6 7 12 13 14 16 27 28 39 40 44 47 48 49 KEE 15 21 38 39 40 42 48 Edit Parameters 0 cccccccssccsessseececccccesseeseseescessessessseescesssesseeunees 34 36 37 39 40 41 42 63 A SERERE E EE e UI 8 14 A eebe Eege 9 15 20 21 38 39 40 42 Front Panel Controls eese nennen e a a aE esa a assit estes esse nana 14 24 Elo 3 EE eebe 3 Insulation Resistance cererii aa ia 3 8 11 13 41 48 49 lnrgdudque T 15 23 25 27 57 op m oHe V A 14 24 31 48 Lear il iros 3 6 10 11 12 13 14 15 19 33 IMMO cane MM MEE MM M 37 38 42 48 49 59 69 e ASSOCIATED RESEARCH INC Ee E 23 29 32 43 48 10 0 0 1 Pe RF ee E 20 27 57 A EE 37 42 48 49 Medical RestriGLIOfls a 6 jani qe 15 23 25 27 32 36 38 39 40 41 45 46 47 56 57 I KL ENTRE A 12 14 26 29 32 36 37 44 45 46 47 50 Mid 38 42 49 59 A eege 5 6 10 14 15 18 24 26 33 56 uh asi aos 34 59 Parameters System Paramelers ds 27 29 30 46 Test Ee 14 23 36 37 42 45 4
9. CONTACT for plug 745253 7 CRIMP SNAP IN SOCKET CONTACT for receptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 747784 3 JACKSCREW SET 2 Remote Interface Rear Panel SIGNAL OUTPUT SIGNAL INPUT i as es ech INTERLOCK ele eo aN PROCESSING r vi MEMORY 1 oe MEMORY 2 MEMORY 3 7 1 Signal Outputs on Remote I O The rear panel connector provides three output signals to remotely monitor PASS FAIL and PROCESSING conditions The monitoring signals are provided by three normally open internal relays that toggle on and off to indicate the condition of the tester These are normally open free contacts and will not provide any voltage or current The ratings of the contacts are 1 AAC 125 VAC 0 5 ADC 30 VDC The signal outputs are provided on the 9 pin female D connector Below is a listing that indicates what conditions activate each pin When a terminal becomes active the relay closes thereby allowing the external voltage to operate an external device 55 e ASSOCIATED RESEARCH INC Pins 1 and 2 provide the PASS signal Pins 3 and 4 provide the FAIL signal Pins 5 and 6 provide the PROCESSING signal Pins 7 and 8 provide the RESET OUT signal The following describes how the relays operate for each test condition PROCESSING The relay contact clos
10. ON of the AC DC Withstand test Cont Min This message appears on the display if the measured reading drops below the Min Lmt continuity resistance setting and the Continuity function is set to ON of the AC DC Withstand test Arc Fail This message appears on the display if the DUT arcing current exceeds the Arc Sense limit and Arc function is active Arc Sense 1 9 of the AC DC Withstand test Short This message appears on the display if the DUT current is well beyond the metering range of the test Breakdown This message appears on the display if the DUT current is well beyond the metering range of the test and the arcing condition is beyond the arc sense limit GND Fault This message appears on the display if the GFI threshold is exceeded during the test Out Error This message appears on the display after exiting from the Output Error screen If the instrument has an internal problem and the TEST button is pressed the Output Error screen will appear as follows Output Error Device malfunction Setting x xxkV Reading x xxkV Press Exit to continue or call 1 800 858 8378 Exit TIT The RESET button is not active while this screen is displayed To clear this screen and return to test mode the Exit soft key must be pressed When the Exit soft key is pressed the instrument will continue with its normal failure indication process The failure light and Alarm can then be cleared by pressing
11. a three wire power cable When the cable is connected to an appropriate AC power source the cable will connect the chassis to earth ground The type of power cable shipped with each instrument depends on the country of destination 18 e ASSOCIATED RESEARCH INC Return Connection CAUTION The output power supplies of this instrument are referenced directly to earth ground Any conductor that completes a path between the high voltage and earth ground will form a completed circuit When the instrument Return is grounded any internal and external stray leakage will be monitored due to currents that flow from High Voltage to earth ground such as from HV to the chassis of the instrument This current is inherent and will cause errors when trying to monitor very low leakage currents in the micoamp range 2 2 4 Environmental Conditions This instrument may be operated in environments with the following limits Temperature 32 104 F 0 40 C Relative humidity 0 80 PUTA ias 6560 feet 2 000 meters Storage and Shipping Environment This instrument may be stored or shipped in environments with the following limits Temperature 40 167 F 40 75 C A 50 000 feet 15 240 meters The instrument should also be protected against temperature extremes that may cause condensation within the instrument 19 e ASSOCIATED RESEARCH INC 3 Specifications and Controls
12. at the same time then press the soft key next to the word Yes All memories and steps will be loaded with the ACW default parameters and the System parameters will be set to the factory defaults The default system parameters are as follows Setup Sys PLC Remote Single Step Alarm Contrast Results Lock Mem Lock Smart GFI The following System parameters will not be affected by the system initialization Setup Sys Cal Alert No change Cal Date No change Cal Due No change Alert No change No change N Date m d y Time No change 43 e ASSOCIATED RESEARCH INC S Operating Instructions 5 1 Instrument Connections 5 1 1 Adapter Box Connections The adapter box provides an easy way to connect a DUT to the HYPOT III that is terminated in a two or three prong line cord The following diagram shows how to connect the adapter box to the Hypot III and to the device under test 36544 Test Connections CAUTION HGH VOLTAGE 50 KVAC MAX 0 KVDC MAX OCIATED RESEARCH INC TEST RESET e The rear output connections on the Hypot III may be used as well 5 2 Perform Tests Main Menu and Results Screens The Hypot III automatically defaults to the Perform Tests screen upon power up The Perform Tests screen will appear as follows ACW Settings M2 2_ 999 95 d 3b5w I2 89 From the Perform Tes
13. for arcing The numbers corresponding to the different arc sensitivity levels are 0 through 9 1 meaning the maximum threshold of allowable arcing 9 meaning the minimum threshold of allowable arcing and 0 0FF After the or is pressed the arc sensitivity will automatically adjust to the new setting Frequency This parameter is available in AC tests only and is selectable using a softkey between 50 and 60Hz Continuity This function checks for a connection between the cont check and return lead This is a basic DC continuity check that measures the continuity value but does not display it Continuity may be selected ON or OFF using a softkey Connect This function when turned ON will connect or link the current step to the next step The third step in a Memory will not have this function because it is the last step of the Memory location 38 e ASSOCIATED RESEARCH INC 4 3 1 AC Withstand From the Test parameter review screen refer to section 4 2 1 scroll the cursor using the up and down arrow soft keys to the Test Type parameter Press the Edit softkey Select the AC Withstand parameter using the and soft keys and press the Enter soft key The default AC Withstand parameters will now be loaded into the currently selected memory and step Press the Enter softkey to accept the parameters or press Esc to escape The AC Withstand parameter review screens will now be displayed The AC Withst
14. item being tested has virtually no capacitance it is necessary to raise the voltage gradually from zero to the full test voltage The more capacitive the item the more slowly the voltage must be raised This is important since most DC hipots have failure shut off circuitry 10 e ASSOCIATED RESEARCH INC which will indicate failure almost immediately if the total current reaches the leakage threshold during the initial charging of the product under test Since a DC hipot does charge the item under test it becomes necessary to discharge the item after the test DC testing unlike AC testing only charges the insulation in one polarity This becomes a concern when testing products that will actually be used at AC voltages This is an important reason that some safety agencies do not accept DC testing as an alternative to AC When performing AC hipot tests the product under test is actually tested with peak voltages that the hipot meter does not display This is not the case with DC testing since a sinewave is not generated when testing with direct current In order to compensate for this most safety agencies require that the equivalent DC test be performed at higher voltages than the AC test The multiplying factor is somewhat inconsistent between agencies which can cause confusion concerning exactly what equivalent DC test voltage is appropriate 1 6 2 Insulation Resistance Test Some dielectric analyzers today come with a built in insulatio
15. press the Select soft key An instructional prompt will now be displayed The prompt will appear as follows AC Hipot DUT H Do tes to to Short between Return during lt TEST gt lt RESET gt Verification connection V and not t Begin Exit touch TIT Follow the instructions given in the prompt and then press TEST to begin the verification process At the end of the Verification process a message will appear indicating the outcome of the process Ifthe instrument passes the Verification test failure indicating the fail detectors are working properly the RESET button will illuminate the alarm will sound and the following message will appear ACW M1 1 AC Hipot RESET Verification detected to kV OK failure Exit gt 20mA 0 0s If the instrument fails the Verification test pass indicating the fail detectors are not working properly the following message will appear ACW M1 1 AC Hipot not Leads or TEST to RESET detected to 0 99kv failure call 1 800 858 8378 Retest Exit Check 1 0s 0 00mA 52 e ASSOCIATED RESEARCH INC 6 2 3 DC Hipot Verification From the Verification screen press the Up or Down soft keys to select DC Hipot then press the Select soft key An instructional prompt will now be displayed The prompt will appear as follows DC
16. protect the user from any serious electrical shock International compliance agencies such as CSA IEC TUV VDE BABT and others have requirements calling out this test This test should not be confused with low current continuity tests that are also commonly called out in some safety agency specifications A low current test merely indicates that there is a safety ground connection It does not completely test the integrity of that connection 11 ef ASSOCIATED RESEARCH INC Compliance agency requirements vary on how different products are to be tested Most specifications call for test currents of between 10 and 30 amps Test voltages at these currents are typically required to be less than 12 volts Maximum allowable resistance readings of the safety ground circuit are normally between 100 and 200 milliohms If you are testing a product that is terminated in a three prong plug you are required to perform a continuity or ground bond test on the ground conductor to the chassis or dead metal of the product 1 6 4 Run Test All manufacturers of a product that runs on line power normally need to run the DUT Device Under Test after final safety testing so that they can verify the functionality of their products In addition to running the DUT to test its basic functionality many customers also require some basic test data to be recorded while the DUT is powered up A Run Test System allows the product to be powered up immediately after the
17. safety tests are completed with a single connection to the DUT Measurements that are commonly made while the DUT is running can include Amperage Voltage Watts and Power Factor 1 6 5 Line Leakage Test The Line Leakage test is one of many product safety tests that are normally specified for electrical products by safety testing agencies such as Underwriters Laboratories UL and the International Electrotechnical Committee IEC The line leakage specifications vary as well as the method in which the measurements are taken depending upon the application or function of a product and the standard to which the product is being tested Current Leakage or Line Leakage tests are general terms that actually describe three different types of tests These tests are Earth Leakage Current Enclosure Leakage Current and Applied Part Leakage Current The main differences in these tests are in the placement of the probe for the measuring device The Earth Leakage Current is the leakage current that flows through the ground conductor in the line cord back to earth The Enclosure Leakage Current is the current that flows from any enclosure part through a person back to ground if it were contacted by a person The Applied Part Leakage Current or Patient Lead Leakage Current is any leakage that flows from an applied part between applied parts or into an applied part The Applied Part Leakage Current test is required only for medical equipment All of these tests are
18. test from being activated through this switch For safety the front panel RESET switch remains active even when a remote reset switch is connected so that high voltage can be shut down from either location The Hypot III also allow access to three MEMORY PROGRAMS through the remote control connector This gives the user the capability to quickly change parameters and initiate a test remotely The Hypot III basically operates in a PLC mode by responding to simple switch or relay contact closures The built in memory programs of the instrument are used to accomplish this Three internal memory programs can be accessed by connecting terminals 7 8 and 9 in different combinations 56 e ASSOCIATED RESEARCH INC ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE WARNING REMOTE CONNECTOR SELECTS THE PROGRAM AND STARTS THE TEST WHICH IS PREPROGRAMMED INTO THAT MEMORY DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL CAUTION INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY MEMORY ONE Momentarily connecting terminal 7 to 8 signals the instrument to immediately begin the test program that is stored in memory one MEMORY TWO Momentarily connecting terminal 7 to 9 signals the instrument to immediately begin the test program that is stored in memory two MEMORY THREE Momentarily connecting terminal 7 to terminals 8 and 9 signals the instrument to immediately begin the test program that is stored in memory three Remote Interlo
19. the rear panel with a pen pencil or small screwdriver while powering ON the Hypot III The Hypot III enters calibration mode after the power on sequence is complete The Calibration screens will appear as follows Calibration Calibration gt gt m x GEN y MH i Een IR 1000V select E DC 350 Dun Slat AC 20 00mA IR 999 9MQ AC 3 500mA Exit HH IR 9999MQ Exit More CONT 1 500 9 2 1 Calibration of Parameters From the Calibration screens use the v soft key to scroll the Cursor to the parameter you wish to calibrate Once the cursor is pointing to the parameter you wish to calibrate press the Select soft key A calibration prompt screen will now appear that describes the necessary load and connection information for the parameter being calibrated The following is a list of the calibration parameters and an example of the prompt screen with the details that will be displayed for each parameter screen shown at left Once you press TEST the Calibration data entry screen will appear for the selected parameter screen shown at right Adjust the numeric value of the parameter using the and soft keys and press the Enter soft key to accept the new parameter or press RESET to escape the edit Calibration of AC Hipot Voltage Calibration Calibration Connect the standard Enter standard 5KVAC kilovolt meter Voltage reading from H V to Return
20. up to 10 setups with 3 A real benefit for manufacturers that test different steps per setup Line and Load regulation products Each setup can store up to 3 steps which can be configured to perform any of the safety tests Tests can be linked and run in any order Maintains the output voltage to within 1 of setting even if the load or the line voltage varies This ensures that the test results remain consistent and within safety agency requirements Digitally controlled arc detection Allows the operator to select whether low level arcs system should be detected and provides the operator with the ability to digitally select and program multiple sensitivity levels No load setup of trip current and This provides the operator with an easy and safe way to output voltage TUV amp UL listing Automatic storage of test program All parameters for the setups can be adjusted through a simple menu driven program Tamper proof front panel controls 14 set trip currents and output voltages since parameters are set without the high voltage activated This assures you that this instrument meets or exceeds safety requirements to ensure operator safety Hypot III powers up with the parameters that were used during the last test to avoid operator set up errors The easy to follow setup screens ensure that the operator correctly sets up all test parameters This makes it possible to limit user access to the setup screens so th
21. used to determine if products can be safely operated or handled without posing a shock hazard to the user Line Leakage Testers provide the capability of meeting the line leakage test specified in the following standards UL 544 IEC 950 UL 1950 IEC 601 1 UL 2601 UL 1563 UL 3101 IEC 1010 and others The Line Leakage test is a test which measures the leakage current of a product through a circuit that is designed to simulate the impedance of the human body The simulation circuit is called the Measuring Device MD The instrument has five different MD circuits selectable through the menu which are representative circuits designed to simulate the impedance of the human body under different conditions The impedance of the human body will vary depending upon point of contact the surface area of the contact and the path the current flows For these reasons the specifications of the Measuring Devices are different 12 e ASSOCIATED RESEARCH INC depending upon the type of test being performed as well as the maximum allowable leakage current Leakage current measurements are performed on products under normal conditions and single fault conditions as well as reversed polarity This simulates possible problems which could occur if the product under test is faulted or misused while the product is operating under high line conditions 110 of the highest input voltage rating of the product Line Leakage tests are normally specified as Ty
22. 0 040 uF lt 5KV 0 06 uF lt 3KV 0 015 uF lt 6KV AC Voltage Wave Form Sine Wave Crest Factor 1 3 1 5 lt 2 THD Output Frequency Range 50 or 60 Hz User Selectable 1 of output 5 volts from no load to full load and over input voltage range Dwell Timer Range AC 0 0 3 999 9 sec 0 Constant DC 0 0 4 999 9 sec 0 Constant Resolution 0 1 sec Accuracy 0 1 of reading 0 05 sec Ramp Timer Range Ramp Up 0 1 999 9 sec Ramp Down AC 0 0 999 9 sec DC 1 0 999 9 sec 02OFF Resolution 0 1 sec Accuracy t 0 196 of reading 0 05 sec Ground Continuity DC 0 1 A 0 01A fixed Current Ground Continuity Range 0 00 1 500 Maximum Limit Resolution 0 010 Minimum Limit Accuracy 396 of setting 0 02 Ground Continuity Range 0 00 0 500 Auto Offset Resolution 0 010 Accuracy 3 of setting 0 020 21 e ASSOCIATED RESEARCH INC INSULATION RESISTANCE TEST MODE Voltage Setting Range 30 1000V DC Resolution 1V Accuracy 2 of setting 5 volts Voltage Display Range 0 1000 V Resolution 1V Accuracy 296 of reading 2 counts Resistance Display Range 1 9999 MO 4 Digit Auto Ranging Resolution 500VDC 1000VDC MO MO 0 001 1 000 9 999 0 01 10 00 99 99 0 1 100 0 999 9 1 1000 9999 Accuracy 2 of reading 2 counts at test voltage 500 1000V and 1 999 9 MO t 5 of reading 2 counts at test voltage 500 1000V and 1000 999
23. 50mA range Calibration Connect the 100KQ Load in series with the 7 5mADC standard current meter TEST to Start lt RESET gt to Exit Calibration of DC Current 3 50mA range Calibration Connect the 100KQ Load in series with the 3 5mADC standard current meter lt TEST gt to Start lt RESET gt to Exit Calibration of DC Current 3504A range Calibration Connect the 1MQ Load in series with the 350uADC standard current meter lt TEST gt to Start lt RESET gt to Exit Calibration of IR 999 9MQ and 9999MQ Ranges Calibration Connect the standard 50MOLoad from H V to Return lt TEST gt to Start lt RESET gt to Exit Enter standard Current reading Current XXXXV lt RESET gt to Exit Enter standard Current reading Current z XXXXv RESET to Exit Enter standard Current reading Current XXXXV lt RESET gt to Exit Calibration Automatic calibration processing 65 e ASSOCIATED RESEARCH INC Calibration of Continuity Step 1 Calibration Step 1 Short the and Return Cont Check Leads together TEST to Start RESET to Exit Calibration Automatic calibration processing Calibration of Continuit
24. 6 IN E 7 15 29 30 43 56 58 Programming esmera E E EE 29 Le 16 48 Rear Panel CO EN 25 Eegeregie ees 16 18 23 25 26 55 A lanaxasncaseansneoneshd sensu A E RER 14 21 BUD oeste panes A Ei 6 15 23 25 27 29 30 43 48 50 55 56 57 58 Remote InterloCk 4 oct aeree tae ee Ete Ee vx vere eee LEE eere ee P E Pee eee eee uva 23 27 57 Resistance diia 3 5 6 8 11 12 13 22 37 38 39 40 41 47 48 49 59 Review ie Test E 28 32 37 vor T 2 4 7 8 18 23 26 KEE iij M CHE c a 4 BA PITE RTT REN TT 68 BED THESE EE 68 O E hci tneaneeieab ccs 14 23 32 35 MIDI It APOCO Po O E T 17 30 31 47 63 SErvVice MIT SF EEN 4 E 14 29 30 43 46 47 ee eege Ed eu 22 27 39 40 49 Single E 29 30 43 45 47 Smart GE essen iiae EET E E REE 23 27 29 32 33 43 Specifications E 20 Re ER e TEE 5 7 TD OU ieee ccs caress TER DNS 3 37 38 39 40 41 42 48 49 59 TUV E 14 Uli A A A A E EAE EAA 8 12 14 15 50 PP O E E 17 Vertical da 26 50 51 52 53 54 70 SSOCIATED RESEARCH INC e Warranty 71
25. 9 MQ 8 of reading 2 counts at test voltage 30 500V and 1 1000 MO Maximum Limit Range 0 1 9999 MQ 0 Off Resolution MO Accuracy Same as Resistance display Minimum Limit Range 9999 MO Resolution MO Accuracy Same as Resistance display Short Circuit Current Maximum 9mAp Ramp Timer Range Ramp Up 0 1 999 9 sec Ramp Down 1 0 999 9 sec 0 OFF BEEN Resolution 0 1 sec Accuracy t 0 196 of reading 0 05 sec Delay Timer Range 0 0 5 999 9 sec 0 Constant Resolution 0 1 sec Accuracy 0 1 of reading 0 05 sec Ground Fault Interrupt GFI Trip Current 450uA max HV Shut Down Speed 1ms 22 e ASSOCIATED RESEARCH INC Remote Control And Signal The following input and output signals are provided Output through two 9 pin D type connectors 1 Remote control Test Reset and Remote Interlock 2 Remote recall of memory program 1 2 and 3 3 Outputs Pass Fail Test in Process and Reset Program Memory 10 Memories 3 steps per memory all steps within a memory are linkable Security Key Lock capability to avoid unauthorized access to all test parameters Memory Lock capability to avoid unauthorized access to memory locations Built in Smart GFI circuit Display 128 x 64 dot resolution with front panel contrast setting Alarm Volume Setting Front panel adjustable volume setting with 10 set points Line Cord Detachable 7 ft 2 13m power cable terminated in a three prong gro
26. C 8 Options Introduction This section contains a list and descriptions of available factory installed options at the time of this printing The list of options contains an option code number that can be referenced on the data plate on the rear panel of the unit Option Label On the rear panel of the instrument you will find a label that contains the option code For example your options code would appear as follows Fitted with option Dll pics OPT 01 Fitted with option 01 and 0 OPT 0102 Hypot III Options Option List Description High Resolution IR Limits 5mA Output Current 5Q Continuity PLC Ready Output Description 01 High Resolution IR Limits The High Resolution IR Limits option increases the resolution of the Max and Min trip point limits from 1MQ to 0 1MO in the range of 0 0 to 999 9MQ The Max and Min Lmt set points automatically range while being edited according to the specification table below This is unique only to this feature because this option has multiple ranges INSULATION RESISTANCE TEST MODE Maximum Limit Range 0 0 1 0 999 9 MO 0 Off Resolution 0 1 MO Range 1000 9999 MQ Resolution 1 MO Accuracy Same as Resistance display Minimum Limit Range 1 0 999 9 MQ Resolution 0 1 MO Range 1000 9999 MQ Resolution 1 MO Accuracy Same as Resistance display e ASSOCIATED RESEARCH INC 02 5mA Output The 5mA Output option limits the output current with s
27. EARCH INC TABLE OF CONTENTS Li annie 1 1 1 Warranty E 1 1 2 e S sciebat E E 2 1 2 1 Product Marking Symbols resisti 2 1 2 2 Caution and Warning Symbols rene nene ern nonton nns 2 1 3 Glossary of Terms aa 3 E E EH 4 1 4 1 Service Eu 4 125 2 Test Station ER 5 AS Test O PO E 6 1 4 4 Instrument EE 6 1 4 5 Device Under Tes 6 1 4 6 Key Safety Points to Kombi 7 1 5 Introduction to Product Safety Testing ooooccccnnnocccccononannncnnnnncnnonnanonocccnnn anno 8 1 5 1 Th Importance of Safety Testing 5 j sssesssavsvscersasesdeveneiasasesdacsitedasanes 8 1 6 The Different Types of Safety Testeado 8 1 6 1 Principles and Uses of Dielectric Withstand Testing 8 1 6 2 Insulation Resistance Test oe rancia 11 1 6 3 Ground Bond Vest E 11 104 Tun Testi 12 1 0 5 Line Leakage Td pe er ara ene ACE PEN RR PAR 12 I T Kev Features and B n fitS piete Dus eneM etui rb ae Sab but sius pa BAV pepe pM NEU A SK AS 14 2 Getting A siots ssso soso ssosiosososs ssis sesos 17 2 1 Unpacking and species 17 LANE E 17 2 1 2 Contents OF Carton A sass scnnancecieissueeassassecavresenedeuersnctenvectsstencdeatnredeante 17 2 1 3 Returning the Instrument for Service or Calibration 17 E PEE o O O 18 Ll NOE AA 18 2 2 2 Power REQUIEM iii 18 2 2 3 Basic Conne IOS siiccassonnsiieseoupsveenceiavoceuneavnsseunsansacedecueateandesanegeoeetes 18 2 2 4 Environmental Conditions
28. Hipot Verification Short DUT connection between H V and Return Do not touch during test TEST to Begin RESET to Exit Follow the instructions given in the prompt and then press TEST to begin the verification process At the end of the Verification process a message will appear indicating the outcome of the process Ifthe instrument passes the Verification test failure indicating the fail detectors are working properly the RESET button will illuminate the alarm will sound and the following message will appear DCW 0 0s M1 1 kv gt 7 5mA Verification OK DC Hipot failure detected lt RESET gt to Exit If the instrument fails the Verification test pass indicating the fail detectors are not working properly the following message will appear DCW 1 0s M1 1 0 99kV 0 0uA DC Hipot failure not Detected Check Leads or call 1 800 858 8378 lt TEST gt to Retest lt RESET gt to Exit TIT 53 e ASSOCIATED RESEARCH INC 6 2 4 IR Verification From the Verification screen press the Up or Down soft keys to select IR then press the Select soft key An instructional prompt will now be displayed The prompt will appear as follows IR Verification Short DUT connection between H V and Return Do not touch during test lt TEST gt to Begin lt RESET gt to Exit TIT Follow the instructions given in the prompt and t
29. OPERATION AND SERVICE MANUAL Hypot HI MODEL 3605 AC ONLY HIPOT WITH GROUND CONTINUITY CHECK MODEL 3665 AC DC HIPOT WITH GROUND CONTINUITY CHECK MODEL 3670 AC DC HIPOT WITH IR AND GROUND CONTINUITY SERIAL NUMBER EE EEES O Associated Research Inc 2003 M odel S 13860 West Laurel Drive Lake Forest Illinois 60045 4546 36051366513670 s Item 38302 Ver 1 11 Printed December 5 2003 DECLARATION OF CONFORMITY Manufacturer Associated Research Inc Address 13860 W Laurel Dr Lake Forest IL 60045 USA Product Name Hypot III Dielectric Withstand Voltage Tester Model Number 3605 3665 3670 Conforms to the following Standards Safety IEC 61010 1 1993 A2 EMC EN 61326 1997 Al 1998 Class A EN 61000 4 2 1995 EN 61000 4 3 1996 EN 61000 4 4 1995 EN 61000 4 5 1995 EN 61000 4 6 1996 EN 61000 4 8 1993 EN 61000 4 11 1994 Supplementary Information The product herewith complies with the requirements of the Low Voltage Directive 73 23 EEC as amended by 93 68 EEC and the EMC Directive 89 336 EEC as amended by 92 31 EEC The CE marking has been affixed on the device according to article 10 of the EMC Directive 8 336 EEC The technical file and other documentation are on file with Associated Research Inc Ja Joseph Guerriero Vice President General Manager Associated Research Inc Lake Forest Illinois USA April 3 2002 e ASSOCIATED RES
30. and parameter review screens will appear as follows Test Type ACW Voltage 4360V Max Lmt 20 00mA 4 Min Lmt 9 999mA Ramp UP 999 9s Edit Min Lmt 0 Dwell 999 9s Offset 0 Ramp DN 999 9s Exit Connect ON Exit More Arc Sense Frequency Continuity Max Lmt T From the AC Withstand review screens the following parameters may be selected for editing Voltage Max Limit Min Limit Ramp Up Dwell Time Ramp Down Arc Sense LO Limit Frequency Arc Detect ON OFF Continuity selection On OFF Continuity Max Limit Continuity Min Limit and Continuity Offset Offset When the Continuity is selected ON the Offset function may be used to compensate for lead and test fixture resistance during the continuity test Using the up and down arrow keys scroll the cursor to the Offset parameter and press the Edit softkey You may now manually or automatically set an Offset value To manually set the Offset use the and soft keys to increase and decrease the resistance value Press the Enter soft key to accept the new value or press the Esc soft key to escape from the edit To automatically set an Offset value set the output voltage current and frequency to the values that will be used on the DUT and connect the test cables or test fixture with fixturing to the instrument Next short circuit the ends of the test cables and press the TEST button The instrument will now read the lead res
31. arge the capacitance of the item under test and anything the high voltage may have contacted such as test fixtures before handling it or disconnecting the test leads HOT STICK probes can be used to discharge any capacitance in the device under test as a further safety precaution A hot stick is a non conducting rod about two feet long with a metal probe at the end that is connected to a wire To discharge the device under test two hot sticks are required First connect both probe wires to a good earth ground Then touch one probe tip to the same place that the return lead was connected While holding the first probe in place touch the second probe tip to the same place where the high voltage lead was connected 1 4 6 Key Safety Points to Remember e Keep unqualified and unauthorized personnel away from the test area e Arrange the test station in a safe and orderly manner e Never touch the product or connections during a test e Incase of any problem turn off the high voltage first e Properly discharge any item tested with DC before touching connections e ASSOCIATED RESEARCH INC 1 5 Introduction to Product Safety Testing 1 5 1 The Importance of Safety Testing Product Safety Tests are specified during the design and development stages of a product as well as in the production of the products to insure that it meets basic safety requirements These tests are designed to verify the safety of the electrical products in that they do
32. at only authorized personnel with a security code can change test parameters e ASSOCIATED RESEARCH INC The Graphic display allows monitoring of current down to 1 microamps AC and DC Electronic dwell settings PLC remote inputs and outputs Maximum output current 20 milliamps AC and 7 5 milliamps DC Software calibration control User selectable output voltage frequencies of 50 or 60 hertz Output voltage fine adjustment Built in adjustable Continuity test mode Flashing high voltage indicator This allows the Hypot III to be used even when test requirements only allow a very low level of acceptable leakage current The electronic dwell control helps keep test results consistent by ensuring that the test duration is the same for each product tested The standard 9 pin interfaces provide outputs for Pass Fail Reset and Test in Process Inputs include Test Interlock and Reset Remote recall of memory program 1 2 and 3 This gives the user all the basic remotes required to configure the Hypot III through simple PLC relay control This makes this instrument a true hipot tester with enough output current to test capacitive loads in AC mode and allows the instrument to comply with the UL 120 K ohm requirements Hypot III is calibrated through the front panel keypad All calibration information is stored in non volatile memory This allows Hypot III to be completely calibrated without removing any covers and exposi
33. ave their warranty extended in one year increments to a maximum of 5 years provided they are returned to AR at least annually for calibration and inspection The annual calibration and inspection must be performed annually every year following receipt of instrument Any instrument not calibrated and inspected annually will not be eligible for extended warranty status This extended warranty is non transferable and is offered only to the original purchaser A return material authorization RMA must be obtained from AR before returning this instrument for warranty service Please contact our Customer Support Center at 1 800 858 TEST 8378 to obtain an RMA number It is important that the instrument is packed in its original container for safe transport If the original container in not available please contact our customer support center for proper instructions on packaging Damages sustained as a result of improper packaging will not be honored Transportation costs for the return of the instrument for warranty service must be prepaid by the customer AR will assume the return freight costs when returning the instrument to the customer The return method will be at the discretion of Associated Research 3 Year Program A 3 Year warranty is also available for instruments purchased and used in North America AII costs for this warranty are paid with the initial purchase and include warranty coverage annual calibration and standard ground return frei
34. ck Hypot III is equipped with a featured referred to as Remote Interlock Remote Interlock is a feature that utilizes a set of closed contacts to enable the instruments output In other words if the Interlock contacts open the output of the instrument will be disabled Remote Interlock could also be referred to as a remote system lockout utilizing Fail When Open logic Ifthe Interlock contacts are open and the Test button is pushed a pop up message will be displayed on the screen for two seconds The message will appear as follows Interlock is Open If the Interlock contacts are opened during a test the pop up message will be displayed and the test will abort The hardware and has been configured to provide the interlock connections on pins 4 and 5 of the Remote Interface Signal Input port The instrument can still be used without the external interlock device as long as the Interlock Connector 38075 provided with unit is plugged into the Remote Interface Signal Input port If there is nothing connected to the Remote Interface Signal Input port to provide a connection to the interlock the instrument will not perform tests 57 e ASSOCIATED RESEARCH INC PLC Remote Pop up message If you attempt to start a test from the front panel Test button and the PLC remote function is turned ON a pop up message will be displayed The pop up message will appear as follows PLC Remote ON 58 e ASSOCIATED RESEARCH IN
35. cord test leads and accessories must be returned at least once a year to an Associated Research authorized service center for calibration and inspection of safety related components Associated Research will not be held liable for injuries suffered if the instrument is not properly maintained and safety checked annually User Modifications Unauthorized user modifications will void your warranty Associated Research will not be responsible for any injuries sustained due to unauthorized equipment modifications or use of parts not specified by Associated Research Instruments returned to Associated Research with unsafe modifications will be returned to their original operating condition at the customers expense e ASSOCIATED RESEARCH INC 1 4 2 Test Station Location Select an area away from the main stream of activity which employees do not walk through in performing their normal duties If this is not practical because of production line flow then the area should be roped off and marked for HIGH VOLTAGE TESTING No employees other than the test operators should be allowed inside If benches are placed back to back be especially careful about the use of the bench opposite the test station Signs should be posted DANGER HIGH VOLTAGE TEST IN PROGRESS UNAUTHORIZED PERSONNEL KEEP AWAY Work Area Perform the tests on a non conducting table or workbench if possible If you cannot avoid using a conductive surface be certain that it
36. croll the cursor to the Offset parameter and press the Edit softkey You may now manually or automatically set an Offset value To manually set the Offset use the and soft keys to increase and decrease the resistance value Press the Enter soft key to accept the new value or press the Esc soft key to escape from the edit To automatically set an Offset value set the output voltage current and frequency to the values that will be used on the DUT and connect the test cables or test fixture with fixturing to the instrument Next short circuit the ends of the test cables and press the TEST button The instrument will now read the lead resistance and update Offset parameter automatically Press the Enter soft key to accept the new value or press the Esc soft key to escape from the edit 40 e ASSOCIATED RESEARCH INC 4 3 3 Insulation Resistance Model 3670 only From the Test parameter review screen refer to section 4 2 1 scroll the cursor using the up and down arrow soft keys to the Test Type parameter Press the Edit softkey Select the IR parameter using the and soft keys and press the Enter soft key The default IR parameters will now be loaded into the currently selected memory and step Press the Enter softkey to accept the parameters or press Esc to escape The IR parameter review screen will now be displayed The DC Withstand parameter review screen will appear as follows Test Type IR
37. cy to meet service conditions e Production Line testing Detecting defects in material or workmanship during processing e Acceptance testing Proving minimum insulation requirements of purchased parts e Repair Service testing Determine reliability and safety of equipment repairs The specific technique used to apply the dielectric voltage withstand test to each product is different During a dielectric voltage withstand test an electrical device is exposed to a voltage significantly higher than it normally encounters for a specified duration of time During the test all current flow from the high voltage output to the return is measured If during the time the component is tested the current flow remains within specified limits the device is assumed safe under normal conditions The basic product design and use of the insulating material will protect the user against electrical shock e ASSOCIATED RESEARCH INC The equipment used for this test a dielectric withstand tester is often called a hipot for high potential tester The rule of thumb for testing is to subject the product to twice its normal operating voltage plus 1 000 volts However specific products may be tested at much higher voltages than 2X operating voltages 1 000 volts For example a product designed to operate in the range between 100 to 240 volts can be tested between 1 000 to 4 000 volts or higher Most double insulated products are tested at voltag
38. e disabled 50 e ASSOCIATED RESEARCH INC 6 2 1 Continuity Verification From the Verification screen press the Up or Down soft keys to select Continuity then press Select soft key An instructional prompt will now be displayed The prompt will appear as follows Cont Verification Open DUT connection between Cont and Return Unplug H V from the instrument lt TEST gt to Begin lt RESET gt to Exit TIT Follow the instructions given in the prompt and then press TEST to begin the verification process At the end of the Verification process a message will appear indicating the outcome of the process Ifthe instrument passes the Verification test failure indicating the fail detectors are working properly the RESET button will illuminate the alarm will sound and the following message will appear ACW 0 0s M1 1 kV mA Verification OK Continuity failure detected TIT RESET to Exit If the instrument fails the Verification test pass indicating the fail detectors are not working properly the following message will appear ACW 1 0s M1 1 0 00kV 0 00mA Continuity failure not detected Check Leads or call 1 800 858 8378 lt TEST gt to Retest lt RESET gt to Exit TIT 51 e ASSOCIATED RESEARCH INC 6 2 2 AC Hipot Verification From the Verification screen press the Up or Down soft keys to select AC Hipot then
39. es much higher than the rule of thumb Testing during development and prototype stages is more stringent than production run tests because the basic design of the product is being evaluated Design tests usually are performed on only a few samples of the product Production tests are performed on every item as it comes off the production line The hipot tester must also maintain an output voltage between 100 and 120 of specification The output voltage of the hipot must have a sinusoidal waveform with a frequency between 40 to 70 Hz and has a peak waveform value that is not less than 1 3 and not more than 1 5 times the root mean square value Types of Failures only detectable with a Hipot test e Weak Insulating Materials e Pinholes in Insulation e Inadequate Spacing of Components e Pinched Insulation Dielectric Withstand Test AC verses DC Please check with the Compliance Agency you are working with to see which of the two types of voltages you are authorized to use In some cases a Compliance Agency will allow either AC or DC testing to be done However in other cases the Compliance Agency only allows for an AC test If you are unsure which specification you must comply with please contact our CUSTOMER SUPPORT GROUP at 1 800 858 TEST 8378 Many safety agency specifications allow either AC or DC voltages to be used during the hipot test When this is the case the manufacturer must make the decision on which type of voltage to utili
40. es the connection between pin 5 and pin 6 while the instrument is performing a test The connection is opened at the end ofthe test PASS The relay contact closes the connection between pin 1 and pin 2 after detecting that the item under test passed all tests The connection is opened when the next test is initiated or the reset function is activated FAIL The relay contact closes the connection between pin 3 and pin 4 after detecting that the item under test failed The connection will open when the next test is initiated or the reset function activated RESET OUT The relay contact closes the connection between pin 7 and pin 8 while the reset function is activated This is only a continuous closure dependent on the length of time the reset button is held in an active state 7 2 Signal Inputs of Remote I O and Memory Access The Hypot III remote connector enables remote operation of the TEST RESET and REMOTE INTERLOCK functions and allows the operator to select Memory 1 Memory 2 and Memory 3 When the PLC Remote mode is on the Hypot III will respond to simple switch or relay contacts closures A normally open momentary switch can be wired across pins 3 and 5 to allow remote operation of the TEST function A normally open momentary switch can be wired across pins 2 and 5 to allow remote operation of the RESET function When the PLC remote function is ON the TEST switch on the front panel will be disabled to prevent a
41. essing the EXIT key at any time will return you to the Perform Test screen Press the Menu key Section 4 1 Step 1 M2 2_ ACW PLC Remote ON Settings Memu wm Single Step OFF 4 Alarm 5 Memor v 2000V X E Contrast 5 20 00mA step J Results Last 1 00mA Lock OFF 999 9s Exit em Mem Lock OFF Exit lt More gt Press the Menu key Section 4 1 Step 2 ACW Settings enu A PLC Remote ON 4 M2 2_ 999 95 i M Press the System key SORES SNP ES EL Section 4 1 Step 3 SE v a KM ection 4 1 step Contrast 5 em Results Last Lock OFF i rn RH Mem Lock OFF Exit lt More gt Press the Arrow key Section 4 1 Step 4 Scroll to lt More gt Section 4 1 Step 5 Smart GFI ON M2 2_ ACW Result Cal Alert OFF Settings Cal Date10 16 04 Test Pons eee KE System D la dy11 16 04 ee Ss a od PM 999 9s EXE a ime 49 e ASSOCIATED RESEARCH INC 4 1 1 Setup System Soft keys Directional soft keys gt v The gt A v soft keys are used to scroll the cursor to the different system parameters The and soft key is used to increase or decrease numerical values or toggle settings ON and OFF Exit The Exit soft key is used to return to the Perform Tests screen 4 1 2 System Parameters Directional soft keys v down up a
42. ght for three years However unlike our 5 year program annual calibration and inspection by Associated Research is not required Except as provided herein Associated Research makes no warranties to the purchaser of this instrument and all other warranties express or implied including without limitation merchantability or fitness for a particular purpose are hereby excluded disclaimed and waived Any non authorized modifications tampering or physical damage will void your warranty Elimination of any connections in the earth grounding system or bypassing any safety systems will void this warranty This warranty does not cover batteries or accessories not of Associated Research manufacture Parts used must be parts that are recommended by AR as an acceptable specified part Use of non authorized parts in the repair of this instrument will void the warranty N e ASSOCIATED RESEARCH INC 1 2 Safety Symbols 1 2 1 Product Marking Symbols Product will be marked with this symbol when it is necessary to refer to the operation and service manual in order to prevent injury or equipment damage Product will be marked with this symbol when hazardous voltages may be present gt p Product will be marked with this symbol at connections that require earth grounding 1 2 2 Caution and Warning Symbols WARNING Calls attention to a procedure practice or condition that could possibly cause bodily injury or death Calls attentio
43. he Test button is pressed the next connected step will execute If you press the Reset button before completing all connected steps it will return you to the original starting step Ifa step fails and you wish to continue to the next step do not press Reset 5 4 2 Manual Voltage Adjustment When HYPOT III is performing a test and symbols will appear next to the two bottom soft keys These soft keys may be used to adjust the output voltage while performing a test ACW Dwell M1 4 36 12 89 Use these soft keys to adjust the output voltage while performing a test 47 e ASSOCIATED RESEARCH INC Pressing the soft key will increase the output voltage pressing the soft key will decrease the output voltage Manual voltage adjustment temporarily overrides the voltage setting and only remains in effect until the test is terminated by Pass Fail or Abort ee When the Lock parameter is selected On in the system menu manual voltage adjustment is disabled Therefore you will not see the and symbols next to the bottom soft keys 5 4 3 Description of displayed messages While performing tests a number of messages will be displayed to indicate the test state or test results These messages are displayed in the status area of the screen located on the first line at the top of the LCD These messages also used on other screens where test results are di
44. he instrument This will temporarily start the instrument in an unsecured state The Calibration Alert Warning screen will be displayed and allow you to disable the Calibration alert by selecting No and then pressing the OK soft key This type of security override only affects the Calibration alert screen It is not necessary to restart the instrument to activate the security setting 33 e ASSOCIATED RESEARCH INC 4 2 Setting up Tests Refer to FIG 2 4 2 1 Reviewing Test parameters 1 From the Perform Test screen press the Menu soft key The Main Menu will now be displayed 2 Select the memory and step location you want to review or edit using their corresponding soft keys 3 From the Main Menu screen press the Menu soft key The Results Tests and System selections will now be displayed 4 From this screen press the Test soft key The Test parameter review screen will now be displayed For the example an AC withstand test is displayed You may now review the test parameters by scrolling the cursor with the up and down arrow keys It is important to note that there are two screens of parameters for AC and DC withstand tests FIG 2 ACW Settings M2 2 ACW M2 2 999 95 enu E Sak Phos Result E Press the Menu soft key test IM Section 4 2 1 Step 3 2000V e 20 00mA 1 00mA e 89 ram 999 95 occ j Press the Menu soft key Press the Test soft key
45. he numeric value Once you change the value it is automatically stored Alert Alert Date The Alert date is like an alarm clock that will warn you in advance of the actual calibration due date After a calibration is performed the Alert Date is automatically set 11 months after the calibration date For example if the calibration is performed on 12 15 2002 the Alert Date will automatically be set to 11 15 2003 This parameter defaults to 11 months after the calibration date but may be overwritten to any advanced date desired Within the Alert Date parameter are three separate fields month day and year Use the gt to select the field within the date you want to edit Use the key to change the numeric value Once you change the value it is automatically stored Date Scroll the cursor to the Date parameter using the directional soft keys Within the Set Date parameter are four fields date format mdy dmy month day and year Use the gt key to select the field within the date you want to edit Using the key to change the numeric value Once you change the value it is automatically stored Time Scroll the cursor to the Time parameter using the directional soft keys Within the Set Time parameter are three fields hours minutes and Military or Standard time setting Use the gt key to select the field within the time parameter you want to edit Use the key to change the numeric value Once you change the value it is auto
46. hen press TEST to begin the verification process At the end of the Verification process a message will appear indicating the outcome of the process Ifthe instrument passes the Verification test failure indicating the fail detectors are working properly the RESET button will illuminate the alarm will sound and the following message will appear IR 0 0s M1 1 TV 1Mo Verification OK IR failure detected TIT RESET to Exit If the instrument fails the Verification test pass indicating the fail detectors are not working properly the following message will appear IR 1 0s M1 1 1000V gt 1060 IR failure not Detected Check leads or call 1 800 858 8578 lt TEST gt to Retest lt RESET gt to Exit TIT 54 e ASSOCIATED RESEARCH INC 7 Connection of Remote I O Two 9 pin D type connectors are mounted on the rear panel that provide REMOTE INPUT OUTPUT control and information These connectors mate with standard 9 pin D sub miniature connector provided by the user The output mates to a male plug connector while the input mates to a female receptacle connector For best performance a shielded cable should be used To avoid ground loops the shield should not be grounded at both ends of the cable Suggested AMP part numbers for interconnecting to the Remote I O are shown below 205204 4 PLUG SHELL WITH GROUND INDENTS 205203 3 RECEPTACLE SHELL 745254 7 CRIMP SNAP IN PIN
47. i sio ptem terrea Rear oe pH BEER UR ERI MERE UE 19 3 Specifications and Controls osieseiqesexeni epp ES FOE PE VENE di 20 EM Specifications TO E T 20 3 2 TAS de E 24 3 1 Front Panel Controls nana 24 3 2 2 Rear Panel CONO aaa 25 2 3 UIC KSAT E 26 e ASSOCIATED RESEARCH INC 4 Programming Instructions miii Pd uei ERN eR Un EE QD IRA EVE EN PU PI EUIS 29 no o A ETE 29 ALL Set p System Soft sia sas 30 E 30 E AM NE 36 4 2 1 Reviewing Test E 36 4 2 2 Editing Test Parat etefS ouais deeg ries EX eU rA UE 37 42 3 Reviewing Test Results aa 37 4 3 Test EE 37 4 3 1 AC Withstand TET LU 39 4 3 2 DC Withstand Models 3665 and 2eim0t 40 4 3 3 Insulation Resistance Model 3670 ont 41 4 3 4 Default Test Patamelets cisco en n EEGENEN 42 4 3 5 Memory Step and Default System Parameter Initialization 43 5 Operating Instructor nar 44 5 1 Instrument Connections E 44 5 1 1 Adapter Box Connections s eatis riri rto Eed EE 44 5 2 Perform Tests Main Menu and Results Screens oooooooconoconononononononononononons 44 5 2 1 Connected Step Indicator essen 45 5 2 2 Main Me sil 45 5 2 3 Results Tests and System el etiomg esggreteuterhkdkkgechieRdegEddERENSd e 46 5 2 Perform Tests Metering E 47 SA Performing Testi 47 5 4 1 Manual Current Adjustment oooooccnooccccnnoooncnnnnnnoncnononanononconnoconnonanoss 47 6 Instrument d ulire iat er
48. ired memory location As the Memory softkey is pressed the parameters of the selected memory location are automatically loaded into the instrument 45 e ASSOCIATED RESEARCH INC Step Each of the ten memory locations in Hypot III has three programmable steps that may be Connected together to create multi step testing Press the Step soft key to increment the step number 5 2 3 Results Tests and System Selections From the Main Menu press the Menu soft key M2 2 ACW Settings 2000V 20 00mA 1 00mA 999 9s The Results Tests and System selections will now be displayed From this screen three Software controls may be accessed Results Test and System Pressing the Exit soft key at any time will return you to the Perform Tests screen Results Pressing the Results soft key from this menu will allow you to review the test results of the last test performed An example ofa Results screen is shown below M2 2 ACW Max Fail Settings Results 2000V 1 99KV 15 00mA 15 78mA 1 00mA 1 4s Exit 999 9s Test Pressing the Test soft key from this menu will allow you to access the Parameter Review screen For specific instructions for reviewing and editing test parameters refer to section 4 2 Test Parameters System Pressing the System soft key from this menu will allow you to access the Setup System screen For specific instructions for editing sy
49. is connected to a good earth ground and the high voltage connection is insulated from the grounded surface There should not be any metal in the work area between the operator and the location where products being tested will be positioned Any other metal in the work area should be connected to a good ground never left floating Position the tester so the operator does not have to reach over the product under test to activate or adjust the tester If the product or component being tested is small it may be possible to construct guards or an enclosure around the device to be tested Construct the guards of a non conducting material such as clear acrylic so that the item being tested is within the guards or enclosure during the test If possible the guards or enclosure should also contain safety switches that will not allow the tester to operate unless the guards are in place or the enclosure closed Keep the area clean and uncluttered All test equipment and test leads not necessary for the test should be removed from the test bench and put away It should be apparent to both the operator and to any observers the product that is being tested and the product that is waiting to be tested or has already been tested Do not perform Hipot tests in a combustible atmosphere or in any area where combustible materials are present Power Dielectric Voltage Withstand Test Equipment must be connected to a good ground Be certain that the power wiri
50. istance and update Offset parameter automatically Press the Enter soft key to accept the new value or press the Esc soft key to escape from the edit 39 e ASSOCIATED RESEARCH INC 4 3 2 DC Withstand Models 3665 and 3670 From the Test parameter review screen refer to section 4 2 1 scroll the cursor using the up and down arrow soft keys to the Test Type parameter Press the Edit softkey Select the DC Withstand parameter using the and soft keys and press the Enter soft key The default DC Withstand parameters will now be loaded into the currently selected memory and step Press the Enter softkey to accept the parameters or press Esc to escape The DC Withstand parameter review screens will now be displayed The DC Withstand parameter review screens will appear as follows Test Type DCW Arc Sense 9 Voltage 1200V Continuity ON wm Max Lmt 7500uA Max Lmt 1 500 v Min Lmt 100uA Min Lmt 0 1020 wm Ramp UP 999 9s offset 0 000 Edit n Dwell 999 9s Connect ON Ramp DN 999 9s Exit mm More From the DC Withstand setting screen the following parameters may be controlled Voltage Max Limit Min Limit Ramp Up Dwell Time Ramp Down Arc Sense Ramp HI Arc Detect ON OFF and Continuity ON OFF Offset When the Continuity is selected ON the Offset function may be used to compensate for lead and test fixture resistance during the continuity test Using the up and down arrow keys s
51. it Check to be sure that the correct input line voltage has been selected on the CAUTION rear panel either 115 volts AC or 230 volts AC Connect the power input plug into its socket on the rear panel of the instrument Connect the male end of the plug to the outlet receptacle Please be sure that the safety ground on the power line cord is not defeated and that you are connecting to a grounded power source Turn on the POWER switch located on the lower left hand side of the front panel The initialization screen will appear with a message at the bottom indicating lt TEST gt to verification You now have the option to press the TEST button and activate the Verification Menu Refer to the section Instrument Verification The option to activate the Verification expires approximately 3 seconds after power up If you do not press the TEST button with in the 3 second window the initialization screen will disappear The initialization screen will appear as follows e ASSOC ATED RESEARCH INC H POT Ill MODEL 365 Version HAH amp TEST to verification TIT After the initialization screen disappears the Perform Tests screen will be displayed The Perform Tests screen will appear as follows ACW Settings M2 2_ 999 9s d 35w e BS Menu e ASSOCIATED RESEARCH INC The Hypot III comes with all of the memories and steps loaded with the AC withstand default parameters The i
52. kwise The fuse compartment will be exposed Please replace the fuse with one of the proper rating 3 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 4 INPUT POWER SWITCH Line voltage selection is set by the position of the switch In the left position it is set for 115 volt operation in the right position it is set for 230 volt operation 5 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operation 6 OPTION CONNECTOR Undefined 7 REMOTE SIGNAL OUTPUT 9 Pin D sub miniature female connector for monitoring PASS FAIL and PROCESSING output relay signals 8 REMOTE SIGNAL INPUT 9 Pin D subminiature male connector for remote control of test reset and interlock functions as well as remote program memory selection 9 CALIBRATION BUTTON To put the instrument into the calibration mode push this button and turn on the power switch simultaneously 25 e ASSOCIATED RESEARCH INC 3 3 Quickstart This quick start guide assumes the operator has some familiarity with automated Electrical Safety testing Locate a suitable testing area and be sure you have read all safety instructions WARNING for the operation of the instrument and suggestions on the test area set up in the Safety section Locate a three prong grounded outlet Be sure the outlet has been tested for proper wiring before connecting the instrument to
53. matically stored The Calibration Alert Warning screen appears as follows Cal Alert Model 36XX is due for calibration on 10 16 04 Show screen again OK iili At the Calibration Alert Warning screen there are two options Show screen again Yes or No Show screen again is asking if you would like to continue seeing the Calibration Alert 34 e ASSOCIATED RESEARCH INC Warning screen every time you power up the instrument The question must be answered by toggling between the word Yes and No using its corresponding softkey and then pressing the OK softkey You may turn this screen OFF by toggling to the word No using the soft key next to this parameter and pressing the OK soft key Selecting the Show this screen again parameter No will disable the Calibration Alert function You may leave this screen ON by toggling to the word Yes using the soft key next to this parameter and the pressing the OK soft key Selecting the Show this screen again parameter Yes will exit the Calibration Alert Warning screen and go to the standard introduction screen without disabling the Calibration Alert function If security is enabled you will not see the question Show screen again or the Yes No soft key It is possible to quickly bypass the security of the Calibration Alert by powering up the instrument while depressing the soft key that is second from the top of t
54. mentation must be reviewed for familiarization with safety markings and instructions before operation This product is a Safety Class I instrument provided with a protective earth terminal Before applying power verify that the instrument is set to the correct line voltage 110 or 220 and the correct fuse is installed A Hipot produces voltages and currents that can cause harmful or fatal WARNING electric shock To prevent accidental injury or death these safety procedures must be strictly observed when handling and using the test instrument 1 4 1 Service and Maintenance User Service To prevent electric shock do not remove the instrument cover There are no user serviceable parts inside Routine maintenance or cleaning of internal parts is not necessary Avoid the use of cleaning agents or chemicals on the instrument some chemicals may damage plastic parts or lettering Any external cleaning should be done with a clean dry or slightly damp cloth Schematics when provided are for reference only Any replacement cables and high voltage components should be acquired directly from Associated Research Inc Refer servicing to an Associated Research Inc authorized service center PHONE 1 847 367 4077 ASSOCIATED RESEARCH INC 1 800 858 TEST 8378 13860 WEST LAUREL DRIVE FAX 1 847 367 4080 LAKE FOREST IL 60045 4546 U S A E MAIL info asresearch com www asresearch com Service Interval The instrument its power
55. n resistance tester Typically the IR function provides test voltages from 500 to 1 000 volts DC and resistance ranges from kilohms to gigaohms This function allows manufacturers to comply with special compliance regulations BABT TUV and VDE are agencies that may under certain conditions require an IR test on the product before a Hipot test is performed This typically is not a production line test but a performance design test The insulation resistance test is very similar to the hipot test Instead of the go no go indication that you get with a hipot test the IR test gives you an insulation value usually in Megohms Typically the higher the insulation resistance value the better the condition of the insulation The connections to perform the IR test are the same as the hipot test The measured value represents the equivalent resistance of all the insulation which exists between the two points and any component resistance which might also be connected between the two points Although the IR test can be a predictor of insulation condition it does not replace the need to perform a dielectric withstand test 1 6 3 Ground Bond Test The Ground Bonding test determines whether the safety ground circuit of the product under test can adequately handle fault current if the product should ever become defective A low impedance ground system is critical in ensuring that in case of a product failure a circuit breaker on the input line will act quickly to
56. n to a procedure practice or condition that could possibly cause damage to equipment or permanent loss of data CAUTION e ASSOCIATED RESEARCH INC 1 3 Glossary of Terms As used in this manual Alternating Current AC Current that reverses direction on a regular basis commonly in the U S A 60 per second in other countries 50 times per second Breakdown The failure of insulation to effectively prevent the flow of current sometimes evidenced by arcing If voltage is gradually raised breakdown will begin suddenly at a certain voltage level Current flow is not directly proportional to voltage Once breakdown current has flown especially for a period of time the next gradual application of voltage will often show breakdown beginning at a lower voltage than initially Conductive Having a volume resistivity of no more than 103 ohm cm or a surface resistivity of no more than 10 ohms per square Conductor A solid or liquid material which has the ability to let current pass through it and which has a volume resistivity of no more than 10 ohm cm Current The movement of electrons through a conductor Current is measured in amperes milliamperes microamperes nanoamperes or picoamperes Symbol I Dielectric An insulating material that is positioned between two conductive materials in such a way that a charge or voltage may appear across the two conductive materials Direct Current DC Current that flows in one direction
57. nd gt right are used to navigate the System parameters during reviewing and editing The directional soft keys in the system parameters will change depending on which parameter the cursor is pointing to At the PLC remote parameter only the down arrow key is available PLC Remote Scroll the cursor to the PLC Remote parameter using the directional soft keys When the cursor is pointing to the PLC Remote parameter you may turn the PLC remote function ON and OFF by pressing the soft key Refer to the section 6 Connection of Remote I O for details When the PLC remote is turned ON the front panel Test button is disabled and a test may only be started through the rear panel I O If you attempt to start a test from the front panel Test button when the PLC Remote function is turned ON a pop up message will be displayed The pop up message will appear as follows PLC Remote ON Single Step Scroll the cursor to the Single Step parameter using the directional soft keys When the cursor is pointing to the Single Step parameter you may turn the function ON and OFF by pressing the soft key This function is used to temporarily override the automatic connection feature When the Single Step function is ON the instrument will pause after each step is completed To continue the test sequence press the Test button to execute the next connected step Each time the Test button is pressed the next connected step will execute If yo
58. ng the technician to hazardous voltages Hypot III was designed for the global market This feature makes it simple for the user to select the output frequency in the AC hipot mode so that products can be tested at the same frequency they will be used at To make Hypot III usable in all types of applications the operator can manually bring the voltage up or down in 10 volt increments by simply pressing the up and down arrow keys This makes it very easy to adjust the output voltage even while Hypot III is in the dwell mode so you can analyze test results at different voltages Hypot III meets ground continuity test requirements called out by UL and other safety agencies A flashing LED located directly over the high voltage terminal clearly indicates when high voltage is active to provide maximum operator safety 15 ef ASSOCIATED RESEARCH INC Comes complete with a test box for products terminated in a line cord User selectable input voltage Low current sense Electronic ramping up amp down 16 The standard US style receptacle box allows easy testing of hipot and continuity on line cord terminated products As an additional benefit termination boxes are available for testing products with line cords configured for other countries Hypot III can be switched for either 115 or 230 volt input operation through an easy access rear panel mounted switch to allow it to be used in any country Monitors the minimum level
59. ng to the test bench is properly polarized and that the proper low resistance bonding to ground is in place Power to the test station should be arranged so that it can be shut off by one prominently marked switch located at the entrance to the test area In case of an emergency anyone can cut off the power before entering the test area to offer assistance e ASSOCIATED RESEARCH INC 1 4 3 Test Operator Qualifications This instrument generates voltages and currents that can cause harmful or fatal electric shock and must only be operated by a skilled worker trained in its use The operator should understand the electrical fundamentals of voltage current and resistance They should recognize that the test instrument is a variable high voltage power supply with the return circuit directly connected to earth ground therefore current from the high voltage output will flow through any available ground path Rules Operators should be thoroughly trained to follow all of the aforementioned rules in addition to any other applicable safety rules and procedures Defeating any safety system should be considered a serious offense with severe penalties such as removal from the Hipot testing job Allowing unauthorized personnel in the area during a test should also be dealt with as a serious offense Dress Operators should not wear jewelry that could accidentally complete a circuit Medical Restrictions Personnel with heart ailments or devices
60. nitial test loaded for use is Memory 1 Step 1 Ifthis test is unacceptable for your DUT then refer to the section 4 3 Setting Up a Test for instructions on how to program tests into the instrument If these parameters are acceptable then connect an appropriate set of test leads to the device under test DUT or test fixture Connect the return lead Black to the DUT or test fixture followed by the high voltage output lead Red Make sure the safety ground of this instrument is connected to a known good ground Refer to section 4 1 3 System Parameters Smart GFI for an explanation of DUT grounding configurations DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE TEST HAS WARNING BEEN STARTED Remote Interlock Hypot III is equipped with a featured referred to as Remote Interlock Remote Interlock is a feature that utilizes a set of closed contacts to enable the instruments output In other words if the Interlock contacts open the output of the instrument will be disabled Remote Interlock could also be referred to as a remote system lockout utilizing Fail When Open logic Ifthe Interlock contacts are open and the Test button is pushed a pop up message will be displayed on the screen for two seconds The message will appear as follows Interlock is Open If the Interlock contacts are opened during a test the pop up message will be displayed and the test will abort The hardware has been configured to provide the interlock connec
61. not jeopardize the safety of the people domestic animals and property of anyone who may come in contact with these products In an era of soaring liability costs original manufacturers of electrical and electronic products must make sure every item is as safe as possible All products must be designed and built to prevent electric shock even when users abuse the equipment or by pass built in safety features To meet recognized safety standards one common test is the dielectric voltage withstand test Safety agencies which require compliance safety testing at both the initial product design stage and for routine production line testing include Underwriters Laboratories Inc UL the Canadian Standards Association CSA the International Electrotechnical Commission IEC the British Standards Institution BSI the Association of German Electrical Engineers VDE and TUV the Japanese Standards Association JSI These same agencies may also require that an insulation resistance test and high current ground bond test be performed 1 6 The Different Types of Safety Tests 1 6 1 Dielectric Withstand Test The principle behind a dielectric voltage withstand test is simple If a product will function when exposed to extremely adverse conditions it can be assumed that the product will function in normal operating circumstances Common Applications of the Dielectric Withstand Test e Design performance testing Determining design adequa
62. nstallation 2 2 1 Work Area Locate a suitable testing area and be sure you have read all safety instructions for the operation of the instrument and suggestions on the test area set up in the Safety section Make sure the work area you choose has a three prong grounded outlet Be sure the outlet has been tested for proper wiring before connecting the instrument to it 2 2 2 Power Requirements This instrument requires a power source of either 115 volts AC 15 50 60 Hz single phase or 230 volts AC 15 50 60 Hz single phase Please check the rear panel to be sure the proper switch setting is selected for your line voltage requirements before turning your instrument on For operation at 115 and 230 Volts AC use a 3 15 Amp fast acting 250VAC Do not switch the line voltage selector switch located on the rear panel while CAUTION the instrument is on or operating This may cause internal damage and represents a safety risk to the operator 2 2 3 Basic Connections Power Cable Before connecting power to this instrument the protective ground Earth WARNING terminals of this instrument must be connected to the protective conductor of the line mains power cord The main plug shall only be inserted in a socket outlet receptacle provided with a protective ground earth contact This protective ground earth must not be defeated by the use of an extension cord without a protective conductor grounding The instrument is shipped with
63. nstrument within published specifications End user metrology standards or practices may vary These metrology standards determine the measurement uncertainty ratio of the calibration standards being used Calibration adjustments can only be made in the Calibration mode and calibration checks or verifications can only be made while operating in Test mode 9 1 Warranty Requirements AR offers a standard one year manufacture s warranty This warranty can be extended an additional four years provided that the instrument is returned each year to Associated Research Inc for it s annual calibration In order to be eligible for the extended warranty instruments must be returned to Associated Research Inc for calibration service at least once every twelve months A return material authorization number RMA must be obtained from AR before returning this instrument for calibration To obtain an RMA number or for information regarding our warranty please contact our Customer Support Representatives at 800 858 TEST Required Calibration Equipment e 0 5KV AC DC Metered Voltage Divider e 20 mA AC 10 mA DC Ammeter e 0 30mV AC Millivoltmeter e 1002 0 25 watt resistor 250 volt e 50MO 0 25 watt resistor 1000 volt e 500MQ 0 25 watt resistor 1000 volt e 100KQ 175 watt resistor 4000 volt e IMQ 20 watt resistor 4000 volt 62 e ASSOCIATED RESEARCH INC 9 2 Calibration Initialization Press and hold the calibration key on
64. of current flow thus ensuring that the DUT is properly connected and that the hipot test is being performed Provides a gradual and timed method to increase or decrease output voltage to the DUT minimizing any damage from quick high voltage changes to sensitive DUTs e ASSOCIATED RESEARCH INC 2 Getting Started Introduction This section contains information for the unpacking inspection preparation for use and storage of your Associated Research Inc product 2 1 Unpacking and Inspection 2 1 1 Packaging Your instrument was shipped in a custom foam insulated container that complies with ASTM D4169 92a Assurance Level II Distribution Cycle 13 Performance Test Sequence If the shipping carton is damaged inspect the contents for visible damage such as dents scratches or broken display Ifthe instrument is damaged notify the carrier and Associated Research s customer support department Please save the shipping carton and packing material for the carriers inspection Our customer support department will assist you in the repair or replacement of your instrument Please do not return your product without first notifying us and receiving an RMA return material authorization number To receive an RMA number please contact our customer support department at 1 800 858 8378 e Please retain all of the original packaging materials 2 1 2 Contents of the Carton Inside the carton should be the following
65. oftware control The trip points are adjusted to a maximum of 5mA and the software has been modified so the high speed maximum current shutdown is fixed at 5mA The following specifications have been changed for this option DIELECTRIC WITHSTAND TEST MODE Output Rating 5000V 5 mA AC 6000V 5 mA DC Maximum Limit AC Range 0 00 5 00 mA Minimum Limit AC Range 0 000 0 500 mA DC Range 0 0 50 0 LA 03 502 Continuity The 5Q Continuity option increases the ground continuity maximum limit from 1 5Q to 5Q and increases the ground continuity offset range from 0 0Q 0 50 to 0 00 0 9902 The following specifications have been changed for this option DIELECTRIC WITHSTAND TEST MODE Ground Continuity Range 0 00 5 000 Maximum Limit Resolution 0 010 Minimum Limit Accuracy 3 of setting 0 02Q Ground Continuity Range 0 00 0 990 Auto Offset Resolution 0 01Q Accuracy 3 of setting 0 02Q Calibration The Calibration Procedure varies slightly with this option installed The changes to the calibration procedure are as follows e During Calibration of Continuity the instrument should be calibrated to a standard 5 0Q resistor rather than a 1 0Q resistor This change is reflected on the display during calibration of continuity All other items in the Calibration Procedure remain unchanged Please refer to the Calibration section for details 60 e ASSOCIATED RESEARCH INC 04 PLC Ready O
66. only The source of direct current is said to be polarized and has one terminal that is always at a higher potential than the other Hipot Tester Common term for dielectric withstand test equipment Hypot Registered trademark of Associated Research Inc for its dielectric withstand test equipment Insulation Gas liquid or solid material which has a volume resistivity of at least 1012 ohm cm and is used for the purpose of resisting current flow between conductors Insulation Resistance Tester An instrument or a function of an instrument capable of measuring resistance s in excess of 200 megohms Usually employs a higher voltage power supply than used in ohmmeters measuring up to 200 megohms Leakage AC or DC current flow through insulation and over its surfaces and AC current flow through a capacitance Current flow is directly proportional to voltage The insulation and or capacitance is thought of as a constant impedance unless breakdown occurs Resistance That property of a substance that impedes current and results in the dissipation of power in the form of heat The practical unit of resistance is the ohm Symbol R Trip Point A minimum or maximum parameter set point that will cause an indication of unacceptable performance during a run test Voltage Electrical pressure the force which causes current through an electrical conductor Symbol V e ASSOCIATED RESEARCH INC 1 4 Safety This product and its related docu
67. pe Tests or Design Tests which are performed during the development of the product This helps verify that the design is safe but it does not guarantee the safety of the products being produced on the production line The only way to be sure you are shipping safe products is to test each product at the end of the production line The user may perform a Leakage Current test along with other common safety test such as Dielectric Withstand Insulation Resistance and Ground Bond on the production line with a single connection to the device under test IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION OF YOUR INSTRUMENT CALL 1 800 858 TEST 8378 IN THE U S A 13 e ASSOCIATED RESEARCH INC 1 7 Key Features and Benefits HYPOT III The first manual safety testing instrument with an enhanced graphic LCD display Exclusive SmartGFI function This provides the operator with complete test setup and results in an easy to use interface This eliminates the need to decipher cryptic abbreviations The graphic display makes testing safer easier and more reliable than ever before The SmartGFI patent pending provides maximum operator protection to the user If the circuit detects excessive leakage to ground it shuts down the high voltage in less than 1 millisecond SmartGFI is automatically activated if the DUT is not grounded The operator does not need to make the decision whether to activate the SmartGFI Storage of
68. roll the cursor to the Cal Alert parameter using the directional soft keys When the cursor is pointing to the Cal Alert parameter you may turn the function ON and OFF by pressing the soft key Turning this parameter ON will activate the Cal Alert function and when the date matches the Alert Date the instrument will display the Calibration Alert warning screen upon power up If the Show this screen again function has been turned OFF at the Calibration Alert Warning screen this parameter will automatically be set to OFF Cal Date Calibration Date Calibration Date is a non editable parameter that indicates the Date when calibration was last performed on the instrument This parameter automatically updates after calibrating the instrument Cal Due Calibration Due Date It is recommended that calibration should be performed at least once a year It is recommended that the Calibration Due date not bet set greater than one year from the Calibration Date displayed After a calibration is performed the Calibration Due Date is automatically set 1 year after the calibration date 33 e ASSOCIATED RESEARCH INC This parameter defaults to one year after the calibration date but may be overwritten to any advanced date desired Within the Calibration Due Date parameter are three separate fields month day and year Use the gt key to select the field within the date you want to edit then use the key to change t
69. since AC cannot charge the item under test reactive current is constantly flowing In many cases the reactive component of the current can be much greater than the real component due to actual leakage This can make it very difficult to detect products that have excessively high leakage current Another disadvantage of AC testing is that the hipot has to have the capability of supplying reactive and leakage current continuously This may require a current output that is actually much higher than is really required to monitor leakage current and in most cases is usually much higher than would be needed with DC testing This can present increased safety risks as operators are exposed to higher currents DC testing characteristics During DC hipot testing the item under test is charged The same test item capacitance that causes reactive current in AC testing results in initial charging current which exponentially drops to zero in DC testing DC testing advantages Once the item under test is fully charged the only current flowing is true leakage current This allows a DC hipot tester to clearly display only the true leakage of the product under test Another advantage to DC testing is that the charging current only needs to be applied momentarily This means that the output power requirements of the DC hipot tester can typically be much less than what would be required in an AC tester to test the same product DC testing disadvantages Unless the
70. splayed Messages ACW Xxx xx a enu E M2 2 999 9s Jbw d HD m Dwell This message appears on the display during the AC DC Withstand test in process when the values are being updated in real time Delay This message appears on the display during the Insulation Resistance test in process when the values are being updated in real time Ramp UP This message appears on the display at the beginning of the test when the output voltage is ramping up Ramp DN This message appears on the display at the end of the dwell or delay cycles when the output voltage is ramping down Pass This message appears on the display when the test process is complete and the DUT passed the test Abort This message appears on the display if the test in process is aborted with the RESET button or remote Reset control Max Fail This message appears on the display if the measured reading exceeds the Max Lmt current setting of the AC DC Withstand test or Max Lmt resistance setting of the Insulation Resistance test 48 e ASSOCIATED RESEARCH INC Min Fail This message appears on the display if the measured reading drops below the Min Lmt current setting of the AC DC Withstand test or Min Lmt resistance setting of the Insulation Resistance test Cont Max This message appears on the display if the measured reading exceeds the Max Lmt continuity resistance setting and the Continuity function is set to
71. splayed 2 From the Main Menu screen press the Menu soft key The Results Test and System selections will now be displayed 3 From this screen press the Result soft key The Results screen will now be displayed The Results screen will appear as follows M1 1 GND Max Fail Settings Results TIT 25 00A A 100mO 120mO Omo 0 0s Exit 1 0s For connected tests use the up and down soft keys to scroll through the results 4 3 Test Parameters Description of Test Parameters Voltage The Voltage that is applied to the High Voltage and Return terminals or the Current and Return terminals during a test Max Lmt A maximum current or resistance threshold that when exceeded triggers a failure 37 e ASSOCIATED RESEARCH INC Min Lmt A minimum current or resistance threshold that when not exceeded triggers a failure Ramp Up A length of time that is allowed for the test voltage to climb from 0 to the voltage set point Dwell A length of time that is allowed for the set point voltage to be applied Delay A length of time that the set point voltage is applied but no judgment of the set parameters is made A judgment of the parameters is not made until the end of the delay time Ramp DN A length of time that is allowed for the test voltage to decay from set point to 0 Arc Sense During hipot testing some low current arcing may be allowable Arc sense is a maximum allowable threshold
72. stem parameters refer to section 4 1 Setup System 46 e ASSOCIATED RESEARCH INC 5 3 Perform Tests Metering Each test performed by the Hypot III contains a unique set of parameters and therefore requires specialized metering for each test The following table describes what meters will be displayed for each of the different test types Test Type Current Voltage Time Resistance AC Withstand X X X DC Withstand X X X IR X X X 5 4 Performing a Test 1 From the Main Menu select the memory and step you wish to perform then press the Exit soft key to return you to the Perform Test screen 2 Attach the appropriate load or DUT to the instrument refer to section 5 1 for instrument connections 3 Press the TEST button 4 The instrument will now perform the test or connected sequence of tests Ifthe Test is started from any other step than 01 when you push Reset or Test buttons it will always return to the originally selected step 5 4 1 Single Step Single step is a function that allows you to run one step at a time from a sequence of connected steps To access the Single step function refer to section 4 1 Setup System This function is used to temporarily override the automatic connection feature When the Single Step function is ON the instrument will pause after each step is completed To continue the test sequence press the Test button to execute the next connected step Each time t
73. such as pacemakers should be informed that the voltages and currents generated by the instrument are very dangerous If contacted it may cause heart related problems that a person of good health may not experience Please have the test operator consult their physician for recommendations 1 4 4 Instrument Connections WARNING Never perform a hipot test on energized circuitry or equipment L The instrument is equipped with a safety ground connection be sure that this is connected to a good earth ground Always connect the return lead first regardless of whether the item under test is a sample of insulating material a component tested with the high voltage test lead or a cord connected device with a two or three prong plug The return lead should be connected first for any type of hipot testing Plug in the high voltage test lead only when it is being used Handle its clip only by the insulator never touch the clip directly Be certain that the operator has control over any remote test switches connected to the Hipot Double check the return and high voltage connections from the Hipot and the Line Neutral Ground and Case connections from the Line Leakage tester to be certain that they are proper and secure 1 4 5 Device Under Test 6 e ASSOCIATED RESEARCH INC Never touch the Device Under Test DUT or anything connected to it while WARNING high voltage is being applied by the hipot When testing with DC always disch
74. t is being performed a red lightning bolt indicator located in the lower right side of the front panel will illuminate and flash until the test is finished If the DUT passed the test you will hear a brief beep indicating the DUT passed and that the tests are complete Reviewing results The most direct method for reviewing test results is to press the bottom soft key at the end of the test Pressing the bottom soft key from the Perform Test screen will display the Results screen For more information about reviewing test results refer to section 4 2 3 Reviewing Test Results 28 e ASSOCIATED RESEARCH INC 4 Programming Instructions 4 1 Setup System Refer to FIG 1 1 From the Perform Test screen press the Menu soft key The Main Menu will now be displayed 2 From the Main Menu screen press the Menu soft key The Results Tests and System selections will now be displayed 3 From this screen press the System soft key The Setup System menu will now be displayed 4 At the Setup System menu scrolling from the PLC Remote parameter is restricted to down only Press the down arrow key to access system parameters 5 Scrolling to lt More gt will display the second page of System Parameters From the Setup System screen fourteen different Hardware and Software controls may be accessed PLC Remote Single Step Alarm Contrast Results Lock Mem Lock Smart GFI Cal Alert Cal Date Cal Due Alert Date and Time Pr
75. t switch used to start tests Press the green button to activate the test that is set up in the test buffer shown on the display GRAPHIC LCD 128 X 64 Monographic LCD SOFT KEYS Multifunction parameter selection keys Keys used to select screens and change parameters CONTINUITY OUTPUT JACK Connection for the low current return lead used for continuity testing RETURN OUTPUT JACK Connector used to attach the Return test lead adapter box return lead or test fixture return lead to the instrument This connections provides the return current path for the high voltage and ground bond current POWER SWITCH Rocker style power switch with international ON and OFF 0 markings HIGH VOLTAGE ON INDICATOR This indicator flashes to warn the operator that high voltage is present at the high voltage terminal HIGH VOLTAGE OUTPUT JACK Connector used to attach the High Voltage test lead adapter box high voltage lead or test fixture high voltage lead to the instrument The connector is recessed for safety when not being used e ASSOCIATED RESEARCH INC 3 2 2 Rear Panel Controls 1 REAR PANEL OUTPUT CONNECTORS These connectors are in parallel with the front panel connectors 2 FUSE RECEPTACLE To change the fuse unplug the power mains cord and turn the fuse receptacle counter cloc
76. test or sequence of connected steps The available selections are All P F and Last When All is selected a Results summary screen will be displayed at the end of the test or sequence of connected steps displaying the results of all ofthe steps The Results summary screen will appear as follows ACW Pass 999 9s M2 1 5 00KV 20 00mA DCW Pass 999 9s M2 2 1 20KV 2000uA 3l e ASSOCIATED RESEARCH INC When P F is selected a Pass or Fail screen will be displayed at the end of the test The Pass and Fail screens will appear as follows When P F is selected it is not possible to directly see the test results at the end of the test In order to review the test results refer to section 4 2 3 Reviewing Test Results TIT TIT When Last is selected the results of the last step performed will be displayed on the Perform Tests screen There will not be a change in appearance or special screen displayed in this mode Lock Scroll the cursor to the Lock parameter using the directional soft keys When the cursor is pointing to the Lock parameter you may turn the function ON and OFF by pressing the soft key When the exit soft key is pressed the security settings will take immediate effect Selecting Lock ON restricts access to parameter and system settings The level of security is determined by the Mem Lock function Once the Lock function is activated
77. the RESET button 49 e ASSOCIATED RESEARCH INC 6 Instrument Verification Verification is a process by which an instrument s fail detectors are proven to be functioning properly and thereby Verifying the functionality of the electrical safety tester and connected accessories Verification of failure detect circuitry of the electrical safety tester is required by safety agencies such as CSA UL and TUV 6 1 Verification Initialization Turn on the POWER switch located on the lower left hand side of the front panel The initialization screen will appear with a message at the bottom indicating lt TEST gt to verification You now have the option to press the TEST button and activate the Verification Menu The option to activate the Verification expires approximately 3 seconds after power up The Initialization screen will appear as follows 2 us I ATED RESEARCH INC HYPOT Ill MODEL 35xXX Version X XX ZTEST to verification TT 6 2 Verification Menu From the Initialization screen First start up screen press the TEST button The Verification Menu will now be displayed From the Verification screen four different Verification processes may be accessed Continuity AC Hipot DC Hipot and IR Verification A gt Continuity v AC Hipot DC Hipot Select IR Exit During the Verification process all Remote control output signals except the Fail output ar
78. tions on pins 4 and 5 of the Remote Interface Signal Input port The instrument can still be used without the external interlock device as long as the Interlock Connector 38075 provided with unit is plugged into the Remote Interface Signal Input port If there is nothing connected to the Remote Interface Signal Input port to provide a connection to the interlock the instrument will not perform tests Please check your connections to be sure they are making good contact Clear the area of any debris that may create a hazardous situation and ask any unnecessary personnel to leave the area To initiate the test press the GREEN test button on the front panel This is a momentary button and does not need to be held in the pressed position during the test The instrument will then initiate the test presently loaded in this case Memory 1 Step 1 If the DUT passes the test you will hear a short audible beep Ifa failure occurs you will hear a long audible alarm and the red failure indicator will light up Ifa failure occurs during the test a continuous alarm will sound and the red indicator light in the Reset button will illuminate 27 e ASSOCIATED RESEARCH INC To stop the alarm you must press the illuminated RED button marked RESET This will silence the alarm clear the red fail light and reset the instrument for the next test The RESET button may also be used to quickly ABORT a test and cut off the power to the DUT When a tes
79. ts screen the Main Menu may be accessed by pressing the Menu softkey Menu 44 e ASSOCIATED RESEARCH INC The Perform Tests screen is the main operational screen of instrument From this screen test parameters are monitored while the test is being performed This screen may also be used to debug memories with connected steps with the use of the single step function 5 2 1 Connected Step indicator The connected step indicator is an under score symbol located directly next to the Memory and Step number and only will be displayed when the connect function has been turned On in the Test parameters ACW Settings ee enu i em M2 2 999 95 Ju l e 89 wm Connected Step Indicator 5 2 2 Main Menu From the Perform Tests screen press the Menu soft key M2 2 ACW Settings Nen 2000V Memory 20 00mA Step 1 00mA 999 9s Exit The Main Menu will now be displayed From the Main Menu screen three Software controls may be accessed Menu Memory Step Pressing the Exit soft key at any time will return you to the Perform Tests Menu Pressing the Menu soft key from the Main Menu will display the Results Tests and System selections Please refer to section 5 2 3 Results Test and System Selections Memory The Hypot III has 10 three step programmable memory locations M0 M9 Press the Memory soft key to increment the instrument to the des
80. u press the Reset button before completing all connected steps it will return you to the original starting step Ifa step fails and you wish to continue to the next step do not press Reset 30 e ASSOCIATED RESEARCH INC Alarm Volume Scroll the cursor to the Alarm parameter using the directional soft keys When the cursor is pointing to the Alarm parameter you may use the soft key to increase and decrease the volume of the Alarm The numbers corresponding to the different volume settings are 0 through 9 0 meaning the volume is off and 9 being the loudest setting After the or is pressed a momentary alarm chirp will occur to indicate the volume of the new setting LCD Contrast Scroll the cursor to the Contrast parameter using the directional soft keys When the cursor is pointing to the Contrast parameter you may use the soft key to increase and decrease the contrast of the LCD display The numbers corresponding to the different contrast settings are 0 through 9 0 meaning the lightest color of displayed characters and 9 meaning the darkest color of displayed characters After the is pressed the display will automatically adjust to the new display setting Results Scroll the cursor to the Results parameter using the directional soft keys When the cursor is pointing to the Results parameter you may use the soft key to select what type of results you would preferred displayed at the end of a
81. unding plug Terminations Detachable 5ft 1 52m high voltage and return leads 2 with clips and a standard U S style NEMA 5 15 remote receptacle box for testing items terminated with a line cord International receptacles also available Front and Rear outputs standard Mechanical Tilt up front feet Dimensions W x H x D 215 x 89 x 370 mm Weight 20 96 lbs 9 53Kgs Environmental Operating Temperature 0 40 C pod Relative Humidity 0 to 80 Calibration Traceable to National Institute of Standards and Technology NIST Calibration controlled by software Adjustments are made through front panel keypad in a restricted access calibration mode Calibration information stored in non volatile memory 23 e ASSOCIATED RESEARCH INC 3 2 Instrument Controls 3 2 1 Front Panel Controls 24 e ASSOCIATED RESEARCH INC RESET BUTTON Momentary contact switch used to reset the instrument If a failure condition occurs during a test you will need to reset the system to shut off the alarm and signal the system that you are aware of a failure condition The reset button must be pressed before you can proceed to the next test or change any of the set up parameters This switch also serves as an abort signal to stop any test in progress controlled by the Hypot III TEST BUTTON Momentary contac
82. utput The PLC Ready Output Option creates a signal that acts as an instrument power on indicator The signal is available through the Remote I O output connector which is located on the back of the instrument This option closes the relay contact between pin 1 and pin 2 on the output connector once the instrument is powered on The PLC Ready Output signal replaces the Pass signal that is present on the standard instrument It should be noted that the term Ready in PLC Ready Output only implies that the instrument is powered on To perform a test it should be verified that an interlock device is used or the interlock disable connector that was provided with the instrument is installed and that there are no failure indicators active on the instrument For more information on the Remote I O signals connections and interlock refer to Section 7 Connection of Remote I O 61 e ASSOCIATED RESEARCH INC 9 Calibration Procedure This instrument has been fully calibrated at the factory in accordance to our published specifications It has been calibrated with standards traceable to the National Institute Standards amp Technology NIST You will find in this manual a copy of the Certificate of Calibration It is recommended that you have this instrument re calibrated and a safety check done at least once per year AR recommends you use Calibration Standards that are NIST traceable or traceable to agencies recognized by NIST to keep this i
83. utput and earth ground The GFI s main purpose is to protect the operator from prolonged exposure to High Voltage in the case of an accidental contact with the High Voltage lead and earth ground Ifthe operator accidentally touches the High Voltage lead and earth ground the High Voltage will be shut off immediately and the test aborted If the GFI threshold is exceeded the display will indicate a GFI Fail Smart GFI allows the user to automatically configure the instruments return configuration When the Return lead is earth grounded the GFI circuit is disabled and the instrument operates in a grounded return mode of operation Grounded Return allows the user to perform tests on devices that have their chassis earth grounded by the test fixture or test environment The standard configuration of Hypot III is a floating return connection that is not directly connected to Earth ground The standard configuration allows monitoring of very low level leakage current without internal or external stray earth ground leakage currents being measured and thereby causing errors in the reading Grounding the return will create some amount of leakage current that is proportional to the High Voltage output and can cause small amounts of error depending on the test voltage and physical environment Cal Alert Calibration Alert Calibration Alert is a feature that allows the instrument to give an advanced alert that the calibration for the instrument is coming due Sc
84. y Step 2 Calibration Step 2 Connect the standard 1 00 from Cont Check to Return TEST to Start lt RESET gt to Exit Calibration Automatic calibration processing 66 e ASSOCIATED RESEARCH INC 10 Replacement Parts List ECO 4993 Rev E Number Designator 35099 4 Clack Banana Jacks 37497 1 RestSwich Red 37555 1 PowerSwitch2P 10A250V 375571 1 Earth Connector ss SwitchTest Green RY2 Interlock Comnector TR PAS RENE QUEE FeetKitw oRubberInserts Rubber Insert for Feet Adapter Box CON 3670 Main Control Board o High Voltage Connector w 10cm cable o f High Voltage Connector w 10cm cable 128x64GraphicDisplay oo HighVoltageQutputcable AOL Return cable e For safety tester interconnect cables refer to INSTRUMENT CONNECTIONS section 1 3 Specific Integrated System Connections 67 e ASSOCIATED RESEARCH INC 11 Schematic Index Designator Ea on eng agan sn 68 e ASSOCIATED RESEARCH INC 12 Index AC I IUS talas 27 36 39 42 47 Adapter BOK emere EUM E EE CE ME 17 24 44 Alarm EE deeg 31 Eeer 14 20 38 39 40 42 49 BSCS iia 14 Brak EE 3 49 Calibration Alert PGi Ate ee 33 34 CHE EE 29 33 Cal Date EE 29 33 Sc 29 33 Diada 29 33 34 ht er 29 34 EH E
85. ze In order to do this it is important to understand the advantages and the disadvantages of both AC and DC testing AC testing characteristics Most items that are hipot tested have some amount of distributed capacitance An AC voltage cannot charge this capacitance so it continually reads the reactive current that flows when AC is applied to a capacitive load e ASSOCIATED RESEARCH INC AC testing advantages AC testing is generally much more accepted by safety agencies than DC testing The main reason for this is that most items being hipot tested will operate on AC voltages AC hipot testing offers the advantage of stressing the insulation alternately in both polarities which more closely simulates stresses the product will see in real use Since AC testing cannot charge a capacitive load the current reading remains consistent from initial application of the voltage to the end of the test Therefore there is no need to gradually bring up the voltage since there is no stabilization required to monitor the current reading This means that unless the product is sensitive to a sudden application of voltage the operator can immediately apply full voltage and read current without any wait time Another advantage of AC testing is that since AC voltage cannot charge a load there is no need to discharge the item under test after the test AC testing disadvantages One disadvantage of AC testing surfaces when testing capacitive products Again

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