Associated Research 3500D Series Hypot II Operation & Calibration
Contents
1. 20 THERMAL FAN To cool the instrument INPUT POWER SWITCH Line voltage selection is set by the position of the switch In the down position it is set for 115 volt operation in the up position it 1s set for 230 volt operation REMOTE INPUT OUTPUT 9 pin D subminiature male connector for remote control of test and reset funtions as well as for monitoring PASS FAIL and PROCESSING output relay signals CHASSIS GROUND EARTH TERMINAL This safety terminal should be connected to a good earth ground before operation INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord FUSE RECEPTACLE To change the fuse unplug the power mains cord and turn the fuse cap counter clockwise to remove the fuse CALIBRATION ENABLE KEY To enter the calibration mode press this key while the instrument is being powered ON INSTALLATION Introduction This section contains information for the unpacking inspection preparation for use and storage of your Associated Research Inc product Unpacking and Inspection 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 meters If the instrument is damaged notify the carrier and the Associated Research customer s2. 14 To set the Low Resistance Limit on model 3570D only Please press the SET key until the display shows I Low XXXX MQ Use the Up Down Arrow keys to enter the resistance low limit setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The unit of measure is in megohms with 1 1000 MQ range of setting A measured value below the Low Limit setting will result in a failure condition at the end of the Delay time setting 15 To set the Delay Time on model 3570D only Please press the SET key until the display shows I Delay XXX X s Use the Up Down Arrow keys to enter the delay time setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key If the delay time is set to 0 the instrument will operate in a continuous ON mode when the test button is pressed and released The test will stop only when the manual reset button is pressed to abort the Test The minimum delay time setting is 0 5 seconds with 0 1 second resolution Note The Delay timer in the IR mode differs from the Dwell timer in the Hipot mode A judgment is not made until the Delay time has elapsed In the Hipot mode a Pass Fail judgment is made a soon as the leakage limits are exceeded Therefore when the Delay time is set to zero Pass and Fail judgment or indications will not be made 32 C OPERATING PROCEDURES 1 If the instruments defaults are acceptable then
3. FAIL RESE ee TES o PROCESSING X O O 3 PASS 7 p N FAIL REMOTE 1 0 and PROCESSING conditions These signals are provided by three normally open internal relays that switch on to indicate the current condition of the tester These are normally open free contacts and will not provide any voltage or current The ratings of the contacts are 1A 250 VAC 0 5 ADC 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 Pins 6 and 7 provide the PASS signal Pins 8 and 9 provide the FAIL signal Pins 1 and 4 provide the PROCESSING signal 39 The following describes how the relays operate for each test condition PROCESSING The relay contact closes the connection between pin 1 and pin 4 while the instrument is performing a test The connection is opened at the end of the test PASS The relay contact closes the connection between pin 6 and pin 7 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 8 and pin 9 after detecting that the item under test failed any test The connection is opened when the next test is initiated or the res
4. Check to be sure the correct input line voltage has been selected on the 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 d Turn on the POWER switch located on the lower left hand side of the front panel Upon powering the instrument up a POWER ON SELF TEST POST will automatically be performed This test will check for the condition of the ram chips led indicators pcb s and other critical components All of the front panel led s will light temporarily then go out In addition you will see the Associated Research name and Model Number briefly appear on the LCD readout and then clear itself ARI HYPOT II 3500D VER E Current software version displayed here SET You should then see the default l parameters on the LCD meter as 124KVAC follows for models 3500D SET Or these defaults for models 3505D and 3565D 1 24KVAC Or these defaults for models 3570D W SET The underbar character after the memory location indicates that an 1 24KVAC Insulation Resistance test will execute after the Dielectric Withstand test is completed successfully 25 These abbreviated parameters stand for the following SET This is the parameter settings revie
5. Fast Acting 5x20mm_ 37781 tT Fuse Holder 20mm 37554 1 LCD Display 16 x 2 Characters 137555 1 PowerSwitch2P10A 250V__ 376733 1 Test Switch Green 37497 1 Reset Switch Red 33189 1 Input Power Cable 10A 7Ft 04040A 08 1 High Voltage Output cable 02100A 13 2 Retumecable 49 SCHEMATIC INDEX Drawing Number S03500D Wiring Diagram S37917 Main Control Board ra S37961 Ground Continuity Check Board EM S37903 Ground Continuity Check Board w IR test 50
6. MX XXX Xs W Test MX xXXX Xs X XXKVAC XX XX mA X XXKVAC XX XX mA The instrument will continue to output the desired voltage for the duration of the selected dwell time for model 3500D or selected Ramp and Dwell times on model 3505D 3565D and 3570D 34 5 If there is a short circuit in the DUT during the test the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show models 3500D models 3505D and 3565D HI FAIL XXX Xs HI FAIL MX XXX Xs X XXKVAC OFL mA X XXKVAC OFL mA model 3570D W High MX XXX Xs X XXKVAC OFL mA 6 If a flash over occurs in the DUT during the test which results in an OFL condition due to the current exceeding the maximum metering range Breakdown will be indicated as follows The red indicator light will illuminate on the RESET switch and an alarm will sound The display will show models 3500D models 3505D and 3565D HI FAIL XXX Xs HI FAIL MX XXX Xs X XXKVAC OFL mA X XXKVAC OFL mA model 3570D W High MX XXX Xs X XXKVAC OFL mA 7 If the leakage current exceeds the metering range and neither a short circuit nor flash over occurred the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show models 3500D models 3505D and 3565D HI FAIL XXX Xs HI FAIL MX XXX Xs X XXKVAC OFL mA X XXKVAC OFL mA model 3570D W High MX XXX Xs X XXKVAC OFL mA 35 8 If the leakage
7. not allow return to the calibration menu 47 a ASSOCIATED 3 Calibration of Insulation Resistance Current model 3570D only Equipment needed STANDARD DC MILLIAMMETER with a range of 2000uA and a fixed Resistor 500K Ohms 50 watts Please connect a 500KQ resistor in series with the standard DC microammeter and connect these across the output leads of the instrument Press the EXIT key The instrument will provide around 500VDC on the output and the display will show Current __ uA Please use the Up Down Arrow keys to enter the reading of the standard DC microammeter into the instrument Then press the SET key to store the current setting Press the EXIT or RESET key to return to the calibration menu without changing the calibration setting The instrument will output two short beeps when attempting to save a missing or bad parameter and will not allow return to the calibration menu 4 Save Calibration After the calibration the instrument has to be turned off to save the calibration parameters The power must be turned off and on again to switch from the calibration mode to the run mode 48 o ASSOCIATED Replacement Parts List HYPOT IT Model 3500D 3505D 3565D and 3570D Rev I ECO 4671 Designator 37903 37590 37593 37515 37017 1 CW720 Main Control Board SOS 37571 DEA a EE 359 4 Black BananaJacks 37478 2 HighVoltageComector 3759 1 eetkit o 37880 1 Fuse 3 15A 250V
8. second resolution 8 To set the Dwell Time Please press the SET key until the display shows Models 3500D 3505D and 3565D Model 3570D Timer XXX X s or W Dwell XXX X s 29 Use the Up Down Arrow keys to enter the dwell time setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key If the dwell time is set to 0 the instrument will operate in a continuous ON mode when the test button is depressed and released It will stop when the DUT Device Under Test goes into failure or the manual reset button is pressed The minimum dwell time setting is 0 2 seconds with 0 1 second resolution 9 To setup the Ground Continuity Check Please press the SET key until the display shows Models 3500D 3505D and 3565D Continuity ON or Continuity OFF Model 3570D W Continuity ON or W Continuity OFF Press the Up Down Arrow key to select the ON or OFF function of the Ground Continuity Check mode the display will show the set status immediately Press the EXIT key to exit to the test mode or toggle to another setting using the SET key If the Continuity Function is set to ON the Ground Continuity cable has to be connected between the Cont Check connector on the instrument panel and the chassis of the DUT The instrument will test the ground connection of the DUT automatically If continuity is present a green indicator will be illuminated on the TEST switc
9. that the test duration is the same for each product tested PLC remote inputs and outputs The standard 9 pin interfaces provide outputs for Pass Fail and Test in Process Inputs include Test and Reset This gives the user all the basic remotes required to configure the Hypot II through simple PLC relay control Front panel LCD displays test parameters and results A front panel LCD allows the operator to monitor the test The display holds the results after a test item failure so that the operator can easily review the test results Indications of high fail and continuity failure are clearly displayed Maximum output current 12 milliamps AC and 5 milliamps DC 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 15 11 12 13 14 15 16 17 18 19 2 ASSOCIATED Software calibration control Hypot II is calibrated through the front panel keypad All calibration information is stored in non volatile memory This allows Hypot II to be completely calibrated without removing any covers and exposing the technician to hazardous voltages User selectable output voltage frequencies of 50 or 60 hertz Hypot II 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 sam
10. E OUTPUT JACK For the connection of the detachable 5 foot 1 52 m red high voltage test lead The silicone rubber insulation is flexible for easy handling and is rated at 30K VDC The jack is recessed for safety when this lead is not being used HIGH VOLTAGE ARROW LED INDICATOR This indicator flashes to warn the operator that high voltage is present at the high voltage output terminal RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black return test lead This lead is always used when performing a test 19 Y GND F2A 250V A caution A WARNING PLEASE OPERATE THIS INSTRUMENT ACCORDING RISK OF ELECTRICAL SHOCK II ar O D 1 Do not touch the output terminals the DO NOT REMOVE COVER product under test while o lest Is behg REFER SERVICE TO MANU rind c gt c gt FACTURER S SERVICE CENTER 2 If there is ony abnormal condition or a 115 de FOR CONTINUED PROTECTION malfunction tum off the Input power switch y gt HA RESET 1 AGAINST FIRE REPLACE ONLY Puello eee eee c gt gt Pa Peces e input wolloge se WTH 250V FUSH OF THD sich polcian the re logs the Tabo a SPECIFIED CURRENT RATING ment wil be connected to c 5 g 5 5 4 Pleose refer to the instruction manual for O 98 132 192 264VAC detailed operating instructions before using yA gt 2A MAX 50 60HZ this instrument C gt O REMOTE 1 0
11. OPERATION AND SERVICE MANUAL Hypot II MODEL 3500D AC ONLY HIPOT WITH GROUND CONTINUITY CHECK MODEL 3505D ENHANCED AC ONLY HIPOT WITH GROUND CONTINUITY CHECK MODEL 3565D ENHANCED AC DC HIPOT WITH GROUND CONTINUITY CHECK MODEL 3570D ENHANCED AC DC HIPOT WITH IR AND GROUND CONTINUITY SERIAL NUMBER A A E M O d e S Associated Research Inc 2000 13860 West Laurel Drive 3 5 0 0 D 3 gt 0 gt D Lake Forest e 60045 4546 3565D 3570D U S A Item 37589 Ver 3 18 Printed Nov 6 2000 5 YEAR WARRANTY POLICY 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 Options and accessories that are external to the instrument are warranted for a period of 90 days from date of shipment You must return the Owners Registration Card provided within 15 days from receipt of your instrument AR recommends that your instrument be calibrated on a twelve month cycle Instruments purchased and used in North America only may have 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
12. OUS VOLTAGES MAY BE PRESENT CHASSIS GROUND SYMBOL CALLS ATTENTION TO A PROCEDURE PRACTICE OR WARNING CONDITION THAT COULD POSSIBLY CAUSE BODILY INJURY OR DEATH CAUTION CALLS ATTENTION TO A PROCEDURE PRACTICE OR CONDITION THAT COULD POSSIBLY CAUSE DAMAGE TO EQUIPMENT OR PERMANENT LOSS OF DATA io A Hipot produces voltages and currents which can cause harmful or fatal electric shock To prevent accidental injury or death these safety procedures must be strictly observed when handling and using the test instrument 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 Any external cleaning should be done with a clean dry or slightly damp cloth Avoid the use of cleaning agents or chemicals to prevent any foreign liquid from entering the cabinet through ventilation holes or damaging controls and switches also some chemicals may damage plastic parts or lettering 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 asresearc
13. Since a DC hipot does charge the item under test it becomes necessary to discharge the item after the test 3 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 a key reason that some safety agencies do not accept DC testing as an alternative to AC 4 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 The Ground Continuity Test The Ground Continuity test is checking to verify that there is low impedance path between the chassis and the safety ground wire of the line cord A low impedance ground system is critical in ensuring that in the event of a product failure a circuit breaker on the input line will act quickly to 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 A low current test merely indicates that there is a safety ground con
14. T BE DEFEATED BY THE USE OF AN EXTENSION CORD POWER CABLE WITHOUT A PROTECTIVE CONDUCTOR GROUNDING This instrument is shipped with a three wire power cable When this cable is connected to an appropriate AC power source this cable connects the chassis to earth ground The type of power cable shipped with each instruments depends on the country of destination Operating Environment This equipment is intended for indoor use only The equipment has been evaluated according to Installation Category Il and Pollution Degree 2 as specified in IEC 664 This instrument may be operated within the following environmental conditions Temperatures from 32 113 F 0 45 C Relative humidity of 0 to 95 Altitude up to 15 000 feet 4 600 meters STORAGE AND SHIPMENT Environment This instument may be stored or shipped in environments with the following limits Temperature 40 to 75 C Altitude 7 620 meters 25 000 feet The instrument should also be protected against temperature extremes which may cause condensation within the instrument Packaging Original Packaging Please retain all original packaging materials if you do not have an alternate method of repackaging If you are returning your instrument to us for servicing please repackage the instrument in its original container or use an alternate packaging solution Please do not reuse the original packing material if there appears to be damage or missing packing mater
15. TPUT JACK For the connection of the detachable 5 foot 1 52 m red high voltage test lead The silicone rubber insulation is flexible for easy handling and is rated at 30KVDC The jack is recessed for safety when this lead is not being used 2 RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black return test lead This lead is always used when performing a test 3 CONTINUITY CHECK OUTPUT JACK For the connection of the detachable 5 foot 1 52 m return test lead This lead is always used when performing a continuity test 03 Remote Interlock Option 03 is a Remote Interlock feature that inverts the present reset logic on the instrument from normally opened must close contacts to activate the reset to normally closed must open contacts to activate the reset Hardware and software have been reconfigured to provide the interlock connections on pins 2 and 5 of the Remote Interface Signal Input port This reset scheme is designed for use with an external safety interlock device that utilizes a Fail When Open configuration on its output interface The instrument can still be used without the external reset device as long as the Interlock Connector 38037 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 reset then the instrument will not function Please refer to page 38 for furthe
16. When the HYPOT II tests the ground conductor of the line cord if the resistance of the ground conductor exceeds 10 the hipot will signal a continuity failure If continuity is present high voltage is applied to both conductors of the line cord to insure that all current carrying conductors in the primary circuit are tested When testing products with two prong plugs do not activate the continuity circuit 41 MODEL 3500D 3505D 3565D and 3570D 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 which can be referenced on the model option label on the rear panel of the unit when options are present Model 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 01 OPT 01 fitted with option 01 and 03 OPT 0103 3500D 3505D 3565D and 3570D Options Option List Remote Interlock Description 01 Rear Outputs The Rear Outputs option gives the user the capability to access the High Voltage Return and Continuity outputs from the rear panel for use in automated systems The configuration and descriptions are as follows 42 OPTIONAL REAR PANEL CONTROLS 1 2 kann A CAUTION HN END FZA 250V CAUTION A HIGH YOLTAGE FN N 3 1 HIGH VOLTAGE OU
17. a where combustible materials are present TEST OPERATOR Qualifications This instrument generates voltages and currents which 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 Safety Procedures Operators should be thoroughly trained to follow these and all other applicable safety rules and procedures before they begin a test Defeating any safety system should be treated as a serious offense and should result in 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 which could accidentally complete a circuit Medical Restrictions This instrument should not be operated by personnel with heart ailments or devices such as pacemakers TEST PROCEDURES NEVER PERFORM A HIPOT TEST ON ENERGIZED CIRCUITRY OR EQUIPMENT If the instrument has an external safety ground connection be sure that this is connected Then Connect the return lead first for any test regardless of whether the item under test is a sample of insulating material tested with electrodes a component tested with the high voltage test lead or a cord connected device with a two or three prong plug Plug in the high voltage test lead only when it is being used Handl
18. afety of equipment repairs The specific technique varies with each product but basically during a dielectric voltage withstand test an electrical devise is exposed to a voltage significantly higher than it normally encounters The high voltage is continued for a given period of time If during the time the component is tested stray current flow remains within specified limits the device is assumed to be safe under normal conditions The basic product design and use of the insulating material will protect the user against electrical shock 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 2 ASSOCIATED gt gt INTRODUCTION 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 voltages 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 each and every item as 1t comes off the producti
19. ain reason for this is that most items being hipot tested will operate at AC voltages and 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 2 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 1 A key disadvantage of AC testing surfaces when testing capacitive products Again 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 mu
20. be sure to connect the appropriate test leads to the device under test DUT or test fixture Be sure to connect the safety ground on the rear panel to a suitable known good ground before energizing this instrument Then connect the return lead first to the test fixture or the DUT followed by the high voltage lead Check your connections to be sure they are making good contact and that the test station or area is clear of debris or other personnel DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE TEST HAS BEEN STARTED WARNING 2 Please follow the setup procedures to set the parameters The display will show the Dwell or Delay Timer value the Test Voltage value and the High Limit Setting On model 3505D 3565D and 3570D the memory location will also be displayed models 3500D models 3505D and 3565D Set XXX Xs Set MX XXX Xs X XXKVAC XX XX mA X XXKVAC XX XXmA On model 3570D the display will show either the Dielectric Withstand test stettings or the Insulation Resistance test settings depending on what has been selected as follows model 3570D W Set MX XXX Xs or I Set MX XXX Xs X XXKVAC XX X X mA X XX KV DC XXX X MO On model 3570D the underbar character may be displayed after the memory number i e M5_ this indicates that there is another configured test that will execute after the displayed setup has completed successfully To view the second test setup press the down arrow key Return to the first test by pressing the
21. calibration and inspection must be performed annually each and 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 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 watranty Elimination of any connections in the earth gr
22. ch 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 1 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 The other advantage to DC testing is that since the charging current only needs to be applied momentarily 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 l Unless the 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 which will indicate failure almost immediately if the total current reaches the leakage threshold during the initial charging of the product under test 2 ASSOCIATED gt gt INTRODUCTION 2
23. current exceeds the high limit setting but does not exceed the metering range the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show models 3500D models 3505D and 3565D HI FAIL XXX XS HI FAIL MX XXX Xs X XXKVAC XX XX mA X XXKVAC XX XX mA model 3570D W High MX XXX Xs X XXKVAC XX XX mA 9 If the leakage current does not exceed the low limit setting on model 3505D 3565D and 3570D the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show models 3505D and 3565D model 3570D LO LMT MX XXX Xs W Low MX XXX Xs X XXKVAC XX XX mA X XXKVAC XX XX mA 10 To stop the alarm please press the RESET switch once The alarm will stop and the display will retain the failure information If the RESET switch is pressed again the data on the display screen will be cleared and the display will indicate the setting data from the last test The instrument is now ready for the next test 11 If the DUT passed the test the instrument will output a short audible beep tone to indicate the DUT has passed the test The display will show models 3500D models 3505D and 3565D Pass XXX Xs Pass MX XXX Xs X XXKVAC XX XX mA X XXKVAC XX XX mA model 3570D W Pass MX XXX Xs X XXKVAC XX XX mA The instrument is now ready to perform another test 36 12 If the operator elects to abort a test in process this can be accomplis
24. default settings on the instrument The default settings shown will remain in memory unless you choose to override them with your own test program The default settings will appear in memories 1 through 5 for models 3505D 3565D and 3570D The instrument default settings are as follows DEFAULTS Input Voltage Lock Test Dielectric Withstand Test Mode Voltage Output High Current Trip Low Current Trip Ramp Timer Dwell Timer Voltage Type AC Output Frequency Continuity 115 or 230 volts AC country specific rear panel switch selectable OFF W 1 3570D only 1 240 volts AC HI LMT 10 mA LO LMT 0mA_ 3505D and 3565D only 0 second 3505D 3565D 3570D only 1 second AC 60Hz OFF Insulation Resistance Mode model 3570D only 24 Voltage Output High Resistance Trip Low Resistance Trip Delay Timer 1 000 volts DC I High 0 MQ I Low 1 MQ 2 seconds Qne a Unpack this instrument from its special shipping container Be sure to save all packaging materials in case you need to return it to the factory for service WARNING 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 of this manual Locate a three prong grounded outlet Be sure the outlet has been tested for proper wiring before connecting the instrument to it QUICK START CAUTION c
25. del 3505D 3565D and 3570D SETTING 0 and 0 2 999 9 seconds 0 1 second step 0 ramp setting 0 1 seconds fixed ramp Model 3500D and 3505D Ramp 0 1 seconds fixed FAILURE SETTINGS AC mode High limit 0 10 12 00 mA 0 01 mA step Low limit 0 00 0 10 12 00 mA 0 01 mA step 0 OFF 3505D 3565D and 3570D only Accuracy 2 of setting 0 02 mA DC mode High limit 0 02 5 00 mA 0 01 mA step Low limit 0 00 0 02 5 00 mA 0 01 mA step 0 OFF 3505D 3565D and 3570D only Accuracy 2 of setting 0 02 mA 2 ASSOCIATED Specifications METERING Voltmeter 4 digits Range AC 0 00 5 00 KV DC 0 00 6 00 KV Resolution 01 KV Accuracy 2 of reading 10 V Ammeter 4 digits Range AC 0 10 12 00 mA DC 0 02 5 00 mA Resolution 0 01 mA Accuracy 2 of reading 0 02mA TIMER DISPLAY Range 0 0 999 9 seconds Resolution 0 1 second Accuracy 0 1 of reading 0 05 seconds DISCHARGE TIME lt 300 ms The maximum capacitive load vs output voltage 0 20 uF lt IKV 0 050 uF lt 4KV 0 10 uF lt 2KV 0 040 uF lt SKV 0 06 uF lt 3KV 0 015 uF lt 6KV Current DC 0 1 A 0 01A fixed CONTINUITY CHECK Max ground resistance 1 Q 0 10 fixed Output Voltage Range 100 1000 Volts DC Resolution 10 volt step Accuracy 2 of reading 5 volts Voltage Display Range 0 1000 V Resolution 10 volt step Accuracy 2 of reading 2 co
26. e frequency they will be used at Output voltage fine adjustment To make Hypot IT 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 II is in the dwell mode so you can analyze test results at different voltages Built in Continuity test mode Hypot II meets ground continuity test requirements called out by UL and other safety agencies Flashing high voltage indicator A flashing LED located directly over the high voltage terminal clearly indicates when high voltage is active to provide maximum operator safety Comes complete with a test box for products terminated in a line cord 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 User selectable input voltage Hypot II 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 Low current sense Monitors the minimum level of current flow thus ensuring that the DUT is properly connected and that the hipot test is being performed Electronic ramping Provides a gradual and timed method to increase output voltage to the DUT minimizi
27. e 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 to be certain that they are proper and secure NEVER TOUCH THE ITEM UNDER TEST OR ANYTHING CONNECTED TO IT WHILE HIGH VOLTAGE IS PRESENT DURING THE HIPOT TEST When testing with DC always discharge the capacitance of the item WARNING 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 item under test as a further safety precaution A hot stick is a nonconducting rod about two feet long with a metal probe at the end which 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 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 KEY SAFETY POINTS TO REMEMBER Keep unqualified and unauthorized personnel away from the test area Arrange the test station in a safe and orderly manner Never touch the product or connections during a test In case of any problem turn off the high voltage first Properly discharge any item tested with DC before touching conn
28. eakage Current Limit Please press the SET key until the display shows Models 3500D 3505D and 3565D Model 3570D HI LMT XXXX mA or W High XX XX mA Use the Up Down Arrow keys to enter the leakage current high limit setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The unit of measure is in milliamperes with 0 10 AC and 0 02 DC milliamperes as the minimum setting 6 To set the Low Leakage Current Limit on models 3505D 3565D and 3570D only Please press the SET key until the display shows Models 3505D 3565D Model 3570D LO LMT XX XX mA or W Low XX XX mA Use the Up Down Arrow keys to enter the leakage current low limit setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The unit of measure is in milliamperes with 0 00 milliamperes AC and DC as the minimum setting 7 To set the Ramp Time on models 3505D 3565D and 3570D only Please press the SET key until the display shows Models 3505D 3565D Model 3570D Ramp T XXX Xs or W Ramp XXX Xs Use the Up Down Arrow keys to enter the ramp time setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key If the ramp time is set to 0 the instrument will raise the voltage up to the test voltage in a fixed ramp time of 0 1 seconds AC and DC and then begin the dwell cycle The minimum ramp time setting is 0 2 seconds with 0 1
29. ections 2 ASSOCIATED gt gt INTRODUCTION GLOSSARY OF TERMS as used in this manual Alternating Current AC Current which reverses direction on a regular basis commonly in the U S A 60 times per second in other countries 50 times per second Breakdown The failure of insulation to effectively prevent the flow of current sometimes evident 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 a repeated 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 105 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 103 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 which 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 which flows in one direction only The source of direct current is said to be polarized and has one terminal which is always at a higher pot
30. ential 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 which 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 The minimum current flow required to cause an indication of unacceptable performance during a dielectric voltage withstand test Voltage Electrical pressure the force which causes current through an electrical conductor Symbol V INTRODUCTION The importance of testing User safety In an era of soaring liability costs original manufacturers of electrical and electronic products must make sure ever
31. et function activated 2 SIGNAL INPUTS OF REMOTE I O The Hypot II remote connector enables remote operation of the TEST and RESET functions A normally open momentary switch can then be wired across pins 3 and 5 to allow remote operation of the TEST function A normally open momentary switch can also be wired across pins 2 and 5 which allows remote operation of the RESET function 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 DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY 40 E ADAPTER BOX CONNECTION The following diagram shows how to connect the adapter box to the HYPOT II and to the device under test WARNING Never connect the adapter box to the hipot while the high voltage outputs are energized 3500D 3505D 3565D and 3570D 36544 38202 Test Connections The adapter box allows you an easy way to connect an item which is terminated in a two or three prong line cord If you are testing a product which is terminated in a three prong plug you are also required to perform a continuity or ground bond test on the ground conductor of the DUT to the chassis or dead metal of the product With the HYPOT IL you can perform both the hipot and continuity tests at the same time by activating the continuity function on the instrument
32. g 5000V AC Please connect a standard ac voltmeter with 5000V minimum full scale range to the high voltage and return connectors Then press the SET key on the front panel The instrument will provide around 5000V AC on the output connectors and the display will show Voltage _ V Please use the Up Down Arrow keys to enter the reading off the AC Voltmeter into the instrument Then press the SET key to store the voltage setting Press the EXIT or RESET key to return to the calibration menu without changing the calibration setting The instrument will output two short beeps when attempting to save a missing or bad parameter and will not allow return to the calibration menu 2 Calibration of Dielectric Withstand Current Equipment needed STANDARD AC MILLIAMMETER with a range of 25mA and a fixed Resistor 500K Ohms 50 watts Please connect a 500KQ resistor in series with the standard ac milliammeter and connect these across the output leads of the instrument Press the Down Arrow key The instrument will provide around 5000V AC on the output and the display will show Please use the Up Down Arrow keys to enter the reading of the standard AC milliammeter into the instrument Then press the SET key to store the current setting Press the EXIT or RESET key to return to the calibration menu without changing the calibration setting The instrument will output two short beeps when attempting to save a missing or bad parameter and will
33. h and the operator may proceed with the hipot test The Hypot II will continue to test the ground connection of the DUT during other tests If no continuity is present while the operator tries to initiate a test the instrument will signal a continuity failure 10 To set the Frequency 50 60 Hz Please press the SET key until the display shows Models 3500D 3505D and 3565D Freq 50 HZ or Freq 60 HZ Model 3570D W Freq 50 HZ or W Freq 60 HZ Press the Up or Down Arrow keys to toggle the frequency selection 50 or 60 hertz then press the EXIT key to exit to the test mode or toggle to another setting using the SET key 11 To Set Key Lock or Memory Lock The Hypot Il is equipped with two different lockout selections The first selection is Key Lock Within this selection you can lockout all front panel control functions except TEST and RESET The second selection is Memory Lock and is used in conjunction with the Key Lock Within this selection you can lockout all front panel control functions except TEST RESET and memory select You can toggle this selection only from a power OFF state Please turn the POWER switch to the off position then press and hold the SET key then turn the power ON Momentarily you will see one of the following screens to indicate if the keys are locked or unlocked Key Lock ON or Key Lock OFF To toggle the Key Lock function on and off use the Up or Down Arrow keys then press EXIT to selec
34. h com www asresearch com Service Interval The instrument and its power 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 returned for its annual safety check and maintained properly 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 your expense 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 Power Dielectric Voltage Withstand Test Equipment must be connected to a good ground Be certain that
35. hed by pressing the RESET switch at anytime The instrument will stop the test process immediately and the display will show models 3500D models 3505D and 3565D Abort MX XXX Xs X XXKVAC XX XX mA Abort XXX Xs X XXKVAC XX XX mA model 3570D W ABRT MX XXX Xs X XXKVAC XX XX mA Please press the TEST switch to initiate another test Insulation Resistance Test Mode model 3570D only 13 To initiate a test press the TEST switch on the front panel The red High Voltage Arrow indicator will flash and the display will immediately show I Test MX XXX Xs X XXKVDC XXX X MO 14 If the DUT passed the test the instrument will output a short audible beep tone to indicate the DUT has passed the test The display will show I Pass MX XXX Xs X XXKVDC XXX X MQ 15 If the operator elects to abort a test in process this can be accomplished by pressing the RESET switch at anytime The instrument will stop the test process immediately and the display will show I ABRT MX XXX Xs X XXKVDC XXX X MO 37 16 If the insulation resistance exceeds the high limit setting but does not exceed the metering range the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show I High MX XXX Xs X XXKVDC XXX X MQ 17 If the insulation resistance exceeds the high limit setting and exceeds the metering range the red indicator light will illuminate on the RESET
36. ial Contact our customer support department 1 800 858 8378 for an RGA return goods authorization number Please enclose the instrument with all options 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 22 o ASSOCIATED Other Packaging If you do not have the original packaging materials please follow these guidelines 1 2 3 4 5 6 7 Wrap the instrument in a bubble pack or similar foam Enclose the same information as above Use a strong double wall container that is made for shipping instrumentation 350 lb test material is adequate 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 Seal the container securely Mark the container FRAGILE to insure proper handling Please ship models 3500D 3505D 3565D and 3570D via Federal Express or UPS air Please refer in all correspondence to your AR service number Field Installation Of Options There are no field installable options on the model 3500D 3505D 3565D or 3570D 23 Qne QUICK START QUICK START This quick start guide assumes the operator has some familiarity with automated hipot testing and desires to use the
37. instrument executes only the test selected When W I is selected first the Dielectric Withstand test will execute and then the Insulation Resistance test will execute selecting LW executes the two tests in the reverse order To change the Test type on model 3570D only please press the SET key until the display shows Press the Up or Down Arrow keys to toggle the test selection then press the EXIT key to exit to the test mode or toggle to another setting using the SET key or Note The Test mode type will effect the number of items displayed in the menu The menu will display only the items that are relative to the Test mode that has been selected 3 To set the AC DC mode for models 3565D and 3570D only Press the SET key until the display shows Models 3565D Mode AC or Mode DC Model 3570D W Mode AC or W Mode DC Press the Up or Down Arrow keys to toggle the output function AC or DC then press the EXIT key to exit to the test mode or toggle to another setting using the SET key 4 To set the Output Test Voltage Please press the SET key until the display shows Models 3500D 3505D 3565D Model 3570D Voltage XXX KV or W Volt XXX KV Please use the Up Down Arrow keys to enter the desired test voltage then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The maximum voltage which may be entered is 5000 volts AC or 6000 volts DC 28 5 To set the High L
38. is manual a copy of the Certificate of Calibration It is recommended that you have this instrument recalibrated 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 instrument 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 Equipment Required The following equipment will be needed to properly calibrate your instrument 1 Digital Multimeter with the minimum ranges AC Voltage 5 000 volts AC Current 25mA range DC Current 2000uA range 2 500KQ 50Watt resistor CALIBRATION PROCEDURE Model 3500D 3505D and 3565D To enter the calibration mode the instrument must be in the OFF position Using a pen or small screw driver press and hold the recessed calibration key on the rear panel then turn on the Input Power Switch For model 3500D 3505D and 3565D the display will show Press the SET key for kilovolts calibration Down Arrow key v for milliamps For model 3570D the display will show CAL Mode EXIT IR SET V V A Press the SET key for kilovolts calibration Down Arrow key v for milliamps and the EXIT key for insulation resistance calibration 46 1 Calibration of Voltage Equipment needed STANDARD AC VOLTMETER capable of measurin
39. nection it does not completely test the integrity of that connection that would be accomplished when using much higher currents in the range from 10 to 30amps The high current test is know as a Ground Bond test The Ground Continuity test verifies that the ground circuit between the Continuity and Return panel jacks on the Hypot H is below lohm while test at a current of 100mA This function can be enabled or disabled through software when a ground circuit is not provided on the device under test or test requirement are not needed The Insulation Resistance Test Some dielectric analyzers today come with a built in insulation 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 10 Qne the insulation The connections to perform the IR test are the same as the hipot test The measured value rep
40. ng any damage from quickly over applying high voltage to sensitive DUTs 20 Test setup memories The operator can store and recall test setups thus eliminating the need to re enter setup information Qne 21 Insulation Resistance Test Mode This allows the operator to perform an Insulation Resistance test independently or in sequence with the Dielectric Withstand Hipot test thus eliminating the need for a separate piece of test equipment when IR testing is required SPECIFICATIONS 22 Insulation Resistance Adjustable Output The Insulation Resistance test mode provides an adjustable output range of 100 1000 volts DC This gives the user the ability to meet most IR test requirements Only available on model 3505D 3565D and 3570D Only available on model 3570D 17 FRONT PANEL CONTROLS 1 2 3 4 CAUTION HIGH VOLTAGE 5 OKVAC MAX 6 0KVDC MAX RETURN QRR 5 6 T7 8 9 10 11 12 RESET SWITCH This is a momentary contact switch If an out of range reading is detected during a hipot test or an IR test or if continuity failure occurs the red failure lamp within the switch will light To reset the system for the next test press and release this switch This switch may also be used to abort a test in progress TEST SWITCH This is a momentary contact switch Press the green switch to turn on the high voltage output when in test m
41. ode The indicator lamp within the switch will light when continuity is good if continuity mode is enabled LCD DISPLAY The Liquid Crystal Display is the main readout for the operator and programmer of the test settings and test results CONTINUITY CHECK OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black return test lead or three prong receptacle adapter box This jack is always used when performing a continuity test Please refer to page 41 for details on connecting the adapter box between Hypot II and the device under test POWER SWITCH Rocker style switch with international ON and OFF 0 markings SET KEY Use this key to advance forward through the setup menus DOWN ARROW v Use this key to decrement numeric values in the setup mode This key also used to toggle ON OFF functions Also may be used to decrease output voltage during a test in 10 volt increments 10 11 12 FRONT PANEL CONTROLS 1 2 3 4 CAUTION RESET HIGH VOLTAGE S OKVAC MAX 6 0KVDC MAX RETURN AC DC WITHSTAND VOLTAGE TESTER 5 6 T 8 9 10 11 12 UP ARROW A Use this key to increment numeric values in the setup mode This key also used to toggle ON OFF functions Also may be used to increase output voltage during a test in 10 volt increments EXIT KEY Use this key when you desire to enter the Run Mode to initiate a test HIGH VOLTAG
42. omated test sequence using the defaults If a failure occurs you will HEAR an audible alarm go off To stop the alarm you must depress the RED button marked RESET This will silence the alarm and reset the instrument to begin another test This RESET button may also be used as a safety button to quickly ABORT a test and cut off the HIGH VOLTAGE When HIGH VOLTAGE is present a RED flashing indicator located above the HV receptacle will remain flashing until the HIGH VOLTAGE is OFF If the device under test PASSED the test then no audible alarm will sound You will hear a brief BEEP to let you know the item was successfully tested and it PASSED In the case of a FAIL condition the instrument will provide a memory of the test condition results on the LCD display that will remain until the next test is initiated Depressing the reset button will reset the instrument alarm while keeping the last test results on the display Depressing the reset button a second time will clear the display 26 OPERATION INSTRUCTIONS FOR Hypot Il Model 3500D 3505D 3565D and 3570D A POWER UP Check to be sure the correct input line voltage has been selected on the 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 g
43. on 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 Advantages and Disadvantages of AC Testing and DC Testing Please check with the Compliance Agency you are working with to see which of the two type 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 utilize 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 AC testing advantages 1 AC testing is generally much more accepted by safety agencies than DC testing The m
44. ounding system or by passing 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 TABLE OF CONTENTS SECTION I OPERATORS MANUAL cccssssssssscsscssssssssssessssncssessessessesssssssssssessoses 1 SAFETY enop a a 2 INTRODUCTION 2 e T a a a 6 SPECIFICA TION Sicario ias e de 12 CONTRO ES iaa 18 INSTALLATION orie a na oats a Geass Ses A A a aa a 21 QUICK STAR Domene eat saul pidas 24 OPERATION 0000 A E A EA A AA AAA Ed 21 OPTIONS egudnin mnnn ana Ra A A R An 42 SECTION II SERVICE MANUAL cosita 45 CALIBRATION caida idad 46 PARTS LISTS 49 SCHEMATICS a 50 lil SECTION 1 OPERATORS MANUAL SAFETY PRECAUTIONS REQUIRED FOR HIGH VOLTAGE TESTING GENERAL This product and its related documentation 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 115 or 230 and the correct fuse is installed INSTRUCTION MANUAL SYMBOL PLEASE REFER TO THE INSTRUCTION MANUAL FOR SPECIFIC WARNING OR CAUTION INFORMATION TO AVOID PERSONAL INJURY OR DAMAGE TO THE PRODUCT INDICATES HAZARD
45. r information about the remote interface 43 04 Arc Detection This option provides the user with the capability of detecting low level arcing The arc detection circuit has nine preset sensitivity levels The specifications for the Arc Detection option are as follows FAILURE SETTINGS Arc for AC and DC mode Option 04 only Sensitivity range 1 9 Arc detection minimum duration lt 10us SETUP PROCEDURE 1 To activate Arc Detection and set the sensitivity level Please press the SET key until the display shows Use the Up Down Arrow keys to select the arc sensitivity level The arc sensitivity level may be set between the values of 1 and 9 1 being the least sensitive 9 being the most sensitive To deactivate the Arc Detection set the arc sensitivity to 0 Press the EXIT key to exit to the test mode or toggle to another setting using the SET key OPERATION PROCEDURE 1 If there is an arcing condition over the Arc sensitivity limit the red indicator light will illuminate on the reset switch and an alarm sound The display will show models 3500D models 3505D and 3565D Arc Fail XXX Xs Arc MX XXX Xs X XXKVAC XX XX mA X XXKVAC XX XX mA model 3570D Arc MX XXX Xs X XXKVAC XX XX mA SECTION 2 SERVICE MANUAL CALIBRATION PROCEDURES This instrument has been fully calibrated at the factory in accordance to our published specifications It has been calibrated with standards traceable to NIST You will find in th
46. resents 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 INTRODUCTION Although the IR test can be a predictor of insulation condition it does not replace the need to perform a Dielectric Withstand test TYPES OF FAILURES DETECTABLE ONLY WITH A HIPOT TEST Weak Insulating Materials Pinholes in Insulation Inadequate Spacing of Components Pinched Insulation IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION OF YOUR INSTRUMENT CALL 1 800 858 TEST 8378 IN THE U S A 11 2 ASSOCIATED Model 3500D 3505D 3565D and 3570D Functional Specifications Unless otherwise stated accuracy s are relative to a laboratory standard measurement DIELECTRIC WITHSTAND TEST MODE Specifications INPUT VOLTAGE 115 230V selectable 15 variation 47 63 Hz FUSE 115 VAC 230VAC 3 15A fast acting 250V AC OUTPUT Rating AC 0 5000V 2V step 12mA DC 0 6000V 2V step 5mA DC mode on 3565D and 3570D only Regulation 1 of output 5V VOLTAGE SETTING OV Max output rating 10 volts step Accuracy 2 of Setting 5V relative to displayed output Can be adjusted during operation via UP and DOWN arrow keys OUTPUT 3500D 3505D 50 60 Hz selectable 3565D and 3570D DC and 50 60 Hz selectable 0 and 0 2 999 9 seconds 0 1 second step SETTING 0 for continuous running RAMP TIME Mo
47. rounded power source Also connect the rear panel chassis ground for additional safety Turn on the POWER switch located on the lower left hand side of the front panel Upon powering the instrument up a POWER ON SELF TEST POST will be automatically performed This test will check for the condition of the ram chips pcb s and other critical components In addition the display will show the following message with the actual model number displayed in place of model below ARI HYPOT II model VER X X The instrument will recall the last setup which was active and the display will show the parameters which were programmed into the unit The instrument is now ready for operation B SETUP PROCEDURE 1 To select the Memory location on models 3505D 3565D and 3570D only Please press the SET key until the display shows Use the Up Down arrow keys to select memory locations 1 through 5 After selecting the memory press the SET key to view the settings that have been recalled from memory or to make any changes to these settings To store any changes to the settings press the Exit key The parameters are automatically updated into the memory location that was selected when exiting to the test mode 27 2 To set the test type and sequence for model 3570D only On model 3570D only the Insulation Resistance I and Dielectric Withstand W test can be run independently or as a sequence of tests When W or I is selected the
48. s are made through front panel keypad in a restricted access calibration mode Calibration information stored in non volatile memory 2 ASSOCIATED KEY FEATURES amp BENEFITS OF Hypot I 10 No load setup of trip current and output voltage This provides the operator with an easy and safe way to set trip currents and output voltages since parameters are set without the high voltage activated Automatic storage of test program Hypot II powers up with the parameters that were used during the last test to avoid operator set up errors All parameters for the setups can be adjusted through a simple menu driven program The easy to follow setup screens ensure that the operator correctly sets up all test parameters Tamper proof front panel controls This makes it possible to limit user access to the setup screens so that only authorized personnel with a security code can change test parameters Line and load regulation This system maintains the output voltage to within 1 from no load to full load and over the line voltage range to ensure that test results remain consistent and within safety agency requirements The LCD display allows monitoring of current down to 100 microamps AC and 20 microamps DC This allows the Hypot II to be used even when test requirements only allow a very low level of acceptable leakage current Electronic dwell settings The electronic dwell control helps keep test results consistent by ensuring
49. switch and an alarm will sound The display will show I High MX XXX Xs X XXKVDC gt 1000MQ 18 If the leakage current does not exceed the low limit setting and is within the metering range the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show I Low MX XXX XS X XXKVDC XXX X MO 19 If the leakage current does not exceed the low limit setting and is not within the metering range the red indicator light will illuminate on the RESET switch and an alarm will sound The display will show I Low MX X XXKVDC 38 Qne D CONNECTION OF REMOTE I O A 9 pin D type connector is mounted on INPUT OUTPUT control and information OPERATION the rear panel which provides REMOTE This connector mates with standard 9 pin D subminiature connector provided by the user The Remote I O 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 205203 3 RECEPTACLE SHELL 745253 7 CRIMP SNAP IN SOCKET CONTACT for receptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 741184 3 JACKSCREW SET 2 REMOTE INTERFACE REAR PANEL 1 SIGNAL OUTPUTS ON REMOTE I O The rear panel connector provides outp ut signals to remotely monitor PASS
50. t or press the SET key again to reach the Memory Lock screens The memory lock screens appear as follows Memory Lock ON or Memory Lock OFF To toggle the Memory Lock function on and off use the Up or Down Arrow keys then press EXIT to select or press the SET key again to reach the Key Lock screens Use the following chart to set the Key Lock and Memory Lock for your application Key Lock Memory Lock Accessible keys Off Off All Off On All On Off TEST RESET and Up Down Arrows for memory selection On On TEST and RESET 12 To set the IR output Test Voltage on model 3570D only Please press the SET key until the display shows I Volt XXX KV Please use the Up Down Arrow keys to enter the desired test voltage then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The maximum voltage which may be entered is 1 00 kilovolts DC 31 13 To set the High Resistance Limit on model 3570D only Please press the SET key until the display shows I High XXXX MO Use the Up Down Arrow keys to enter the resistance high limit setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The unit of measure is in megohms with 0 1000 MQ range of setting A setting of O MQ disables the high limit setting A measured value above the High Limit setting will result in a failure condition at the end of the Delay time setting
51. the power wiring 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 the event of an emergency anyone can cut off the power before entering the test area to offer assistance Work Area Perform the tests on a nonconducting table or workbench if possible There should not be any metal in the work area between the operator and the location where products being tested will be positioned 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 made of a non conducting material such as clear acrylic such that the item being tested is within the guards or enclosure during the test and fit them with switches so that the tester will not operate unless the guards are in place or the enclosure closed Keep the area clean and uncluttered All test equipment and test leads not absolutely necessary for the test should be removed from the test bench and put away It should be clear to both the operator and to any observers which product is being tested and which ones are waiting to be tested or have already been tested Do not perform Hipot tests in a combustible atmosphere or in any are
52. unts Resistance Display Range 1 1000 MQ 4 Digit Auto Ranging Resolution 500VDC 1000VDC MQ MQ MQ 0 01 1 00 40 00 1 00 80 00 0 1 35 0 999 9 75 0 999 9 Accuracy 3 of reading 2 counts at test voltage gt 500V 7 of reading 2 counts at test voltage lt 500V 2 ASSOCIATED High Resistance Limit Range 0 1000 MQ 0 Off Delay Timer Range 0 0 5 999 9 sec 0 Constant Resolution 0 1 sec step Accuracy 0 1 0 05 sec GENERAL REMOTE CONTROL The following input and output signals are provided through AND SIGNAL the 9 pin D type connector OUTPUT 1 Remote control test and reset 2 Outputs pass fail and test in process PROGRAM MEMORY 5 Sets 3505D 3565D and 3570D only SECURITY Key Lock capability to avoid unauthorized access to all test parameters Memory Lock capability to avoid unauthorized access to memory locations prong grounding plug TERMINATIONS 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 MECHANICAL Tilt up front feet Dimensions W x H x D 11 x 3 5 x 14 56 in 280 x 89 x 370 mm Weight 20 lbs 9 Kgs Operating Temperature 32 113 F 0 45 C Relative Humidity 0 to 95 CALIBRATION Traceable to National Institute of Standards and Technology NIST Calibration controlled by software Adjustment
53. up arrow key If a second test is not configured an audible beep will be heard when the arrow keys are pressed Dielectric Withstand Test Mode 3 If you are performing a Ground Continuity Check the Ground Continuity must be set to the ON Enabled position The ground check cable has to be connected properly to the chassis of the DUT and the green indicator on the TEST switch should be illuminated before activating the Test switch Otherwise the instrument will signal a continuity failure when the test switch is activated Please refer to page 41 for the proper test connections using the adapter box to test items terminated in a three prong plug 33 Qane The display will show OPERATION models 3500D models 3505D and 3565D CONT Fail KVAC model 3570D If you are not performing a Ground Continuity Check the Ground Continuity must be set to the OFF Disabled position Itis not necessary to connect the Cont Check cable since this test will not be performed if the circuit is disabled The instrument will proceed with the Hipot Test when the Test switch is activated 4 To initiate a test press the TEST switch on the front panel The red High Voltage Arrow indicator will flash and the display will immediately show models 3500D Testing XXX Xs X XXKVAC XX XX mA models 3505D and 3565D Ramp MX XXX Xs Dwell MX XXX Xs X XXKVAC XX XXmA X XXKVAC XX XX mA model 3570D W Ramp
54. upport department immediately 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 materials authorization number Preparation for Use Power Requirements and Line Voltage Selection This instrument requires a power source of either 115 volts AC CAUTION 15 47 63 Hz single phase or 230 volts AC 15 47 63 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 In addition please be sure the correct fuse is selected and installed while the instrument is in the off position Do not switch the line voltage selector switch located on the rear panel while the instrument is on or operating This may cause internal damage and represents a safety risk to the operator NOTE For operation at 115 Volts AC and 230 Volts AC use a 3 15A fast acting fuse 21 o ASSOCIATED Power Cable WARNING BEFORE CONNECTING POWER TO THIS INSTRUMENT THE PROTECTIVE GROUND EARTH TERMINALES 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 NO
55. w screen W SET This is the parameter settings review screen for Dielectric Withstand test mode M1 Indicates the memory location of the current settings Mi Indicates that an Insulation Resistance test will execute after the Dielectric Withstand test is completed successfully 3570D only 1 0 S The dwell timer is set to a test duration of 1 second 1 24KVAC The test voltage is set to 1 240 volts AC 10 00 mA The high leakage current trip point is set to 10 milliamps If you wish to not use any one of these parameters you must change your parameters Please refer to the Operation Instructions section in this manual for further details e If the instrument defaults are acceptable then be sure to connect the appropriate test leads to the device under test DUT or test fixture Be sure to connect this safety ground to a suitable known good ground before energizing this instrument Then connect the return lead first black to the test fixture or item followed by the high voltage output lead red WARNING Please check your connections to be sure they are making good contact and that the test station or area is clear of debris and other personnel DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE TEST HAS BEEN STARTED 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 cycle ON and begin the aut
56. y 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 BSD the Association of German Electrical Engineers VDE the Japanese Standards Association JSI These same agencies may also require that an insulation resistance test and high current ground bond test be performed The Dielectric Withstand Hipot 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 The most common applications of the dielectric withstand test are e Design performance Testing determining design adequacy 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 s
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