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Associated Research HypotULTRA II 7500DT, Operation And Service Manual

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Associated Research HypotULTRA II 7500DT Operation And Service Manual Download Page 8

SAFETY

4

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 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.  If you cannot avoid
using a conductive surface, be certain that it is securely grounded to a good earth ground
and insulate the high voltage connection 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, 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 area 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

Summary of Contents for HypotULTRA II 7500DT

Page 1: ...T WITH INSULATION RESISTANCE TESTER including 500VA OUTPUT CAPACITY IEEE 488 GPIB or RS 232 INTERFACE and GROUND BOND TESTER on 7504SA or CONTINUITY TESTER on 7500DT SERIAL NUMBER Models 7504SA 7500DT Associated Research Inc 2005 13860 West Laurel Drive Lake Forest Illinois 60045 4546 U S A Item 37988 Ver 1 14 Printed January 13 2005 ...

Page 2: ... 1984 EN 60555 2 1987 IEC 801 4 1988 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 Asso...

Page 3: ...ts 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 th...

Page 4: ...SECTION I OPERATORS MANUAL 1 SAFETY 2 INTRODUCTION 7 SPECIFICATIONS 13 WHAT S NEW 20 CONTROLS 23 INSTALLATION 28 QUICK START 31 OPERATION 34 OPTIONS 79 SECTION II SERVICE MANUAL 88 CALIBRATION 89 PARTS LIST 97 SCHEMATICS 98 ...

Page 5: ...SECTION 1 OPERATORS MANUAL ...

Page 6: ... instrument is set to the correct line voltage SAFETY SYMBOLS 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 HAZARDOUS VOLTAGES MAY BE PRESENT CHASSIS GROUND SYMBOL CALLS ATTENTION TO A PROCEDURE PRACTICE OR CONDITION THAT COULD POSSIBLY CAUSE BODILY INJURY OR DEATH CALLS ATTEN...

Page 7: ... IL 60045 4546 U S A PHONE 1 847 367 4077 1 800 858 TEST 8378 FAX 1 847 367 4080 E MAIL info asresearch 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 f...

Page 8: ...ned 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 made of a non conducting material such as clear acrylic such that the item being ...

Page 9: ... 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 Handle its clip only by the insulator never touch the clip directly Be certain t...

Page 10: ...arth 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 connection...

Page 11: ...rials 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 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 whic...

Page 12: ...ll 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 Design performance Testing determining design adequacy to meet service conditions Production Line Testing detecting defects in material or workmanship during processing Acceptance Testing provin...

Page 13: ...orized 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...

Page 14: ...quired 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 expone...

Page 15: ...ilt 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 TÜV 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 produ...

Page 16: ...t 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 The 7504SA provides up to 30 amps output current at any voltage between 3 and 8 volts through the safety ground of the product under test Simultaneously the instrument measures the induced voltage across the safet...

Page 17: ...f setting 5 volts Ramp HI 12mA peak maximum ON OFF selectable Charge LO Range 0 0 350 0mA DC or Auto set HI Limit AC Range 0 00 99 00 mA Resolution 0 01 mA step DC Range 0 9999mA Resolution 1mA step Accuracy AC or DC 2 of setting 2 counts LO Limit AC Range 0 000 9 999 mA Resolution 0 001 mA step DC Range 0 0 999 9 mA Resolution 0 1 mA step Accuracy AC or DC 2 of setting 2 counts Arc Detection Rang...

Page 18: ...C Output Ripple 4 Ripple RMS at 6 KV DC 3 5 mA Resistive Load AC Output Wave Form Sine Wave Crest Factor 1 3 1 5 Output Frequency Range 60 or 50 Hz User Selection Accuracy 1 Output Regulation 1 of setting 5 volts from no load to full load Dwell Timer Range 0 0 3 999 9 sec 0 Constant Resolution 0 1 sec increments Accuracy 0 1 0 05 sec Ramp Timer Range AC 0 1 999 9 sec DC 0 4 999 9 sec Resolution 0 ...

Page 19: ...1 000 5 388 1 000 9 999 0 01 1 40 53 88 2 80 99 99 0 1 14 0 538 8 28 0 999 9 1 104 9999 280 9999 Accuracy 2 of reading 2 counts at test voltage 500 1000V and 1 1000 MW 8 of reading 2 counts at test voltage 500 1000V and 1000 9999 MW 8 of reading 2 counts at test voltage 100 500V and 0 1000 MW Charge LO Range 0 000 3 500mA or Auto Set HI Limit Range 0 9999 MW 0 Off LO Limit Range 1 9999 MW Delay Ti...

Page 20: ...play Range 0 00 30 00 Amps Resolution 0 01 Amp step Accuracy 3 of Reading 0 03 A Resistance Display Range 0 600 mW Resolution 1 mW step Accuracy 2 of Reading 2 mW HI Limit Range 0 600 mW for 3 10 A 0 150 mW for 3 30 A Resolution 1 mW step Accuracy 2 of Setting 2 mW LO Limit Range 0 600 mW for 3 10 A 0 150 mW for 3 30 A Resolution 1 mW step Accuracy 2 of Setting 2 mW Dwell Timer Range 0 0 5 999 9 s...

Page 21: ...apability to avoid unauthorized access to test set up program LCD Contrast Setting 9 ranges set by the numeric keys on the front panel Buzzer Volume Setting 10 ranges set by the numeric key on the front panel Calibration Software and adjustments are made through front panel Mechanical Bench or rack mount with tilt up front feet Dimension 7500DT and 7504SA W x H x D 17 x 5 8 x 16 5 in 432 x 147 x 4...

Page 22: ...or high current Ground Bond testing for use with the QUADCHEK II A single 2 x 20 LCD display provides a clear indication of all test results and setup parameters This single easy to view and simple to interpret LCD display allows the operator to monitor all test activity All setup parameters can be adjusted through a simple menu driven program with hot keys to quickly access all functions by using...

Page 23: ... and set up completely through simple PLC control Up to 100mA of current is available in AC Hipot mode and 3500 µA in DC Hipot mode with resolutions of 10 microamps in AC and 1 microamp in DC This makes these instruments true hipot testers with enough output current to test even highly capacitive loads while allowing them to be versatile enough to monitor leakage current of items with very low lea...

Page 24: ...out multiple displays and hard to understand abbreviations Quick access user interface To make access to each function of the instrument easier we have now configured the instruments with dedicated hot keys that quickly allow the user to step through each mode of the instrument without having to scroll through the entire menu Enhanced storage capability The total number of setup memories have been...

Page 25: ...arameters Lighter weight and reduced size Both instruments are now enclosed in a smaller 3U rack mount cabinet to minimize their rack space needs The lowest weight 500VA instruments in the industry High resolution current metering Resolution in AC hipot mode is now 1 microamp and 0 1 microamp in DC hipot mode High resolution timers The ramp and dwell time resolution has been improved to 0 1 second...

Page 26: ...sts were passed In addition the GPIB controller can retrieve stored test results from up to 8 different tests that have been stored in the instruments memory as well as polling the instrument for real time data acquisition Real Current Option The Real Current option allows the user to monitor only the real portion of the leakage current and ignore any reactive components due to capacitance in the ...

Page 27: ...ment is able to send and receive signals across the GPIB IEEE 488 or RS 232 bus 4 LCD DISPLAY The 2x20 character display indicates test function memory and step location test parameter and failure type as well as test measurements during a test 5 POWER SWITCH Rocker style switch with international ON and OFF 0 markings 6 RESET BUTTON This is a momentary contact switch If an out of range leakage cu...

Page 28: ...f the instrument to the Local mode 12 FUNCTION KEYS Use these keys to select the test function that will be performed for the memory and step indicated The four selections are AC W AC Withstand Test DC W DC Withstand Test INSULATION Insulation Resistance Test G BOND Ground Bond Test 13 EXIT PARAMETER KEY Use this key to exit any menu or to clear an unwanted entry in a parameter field 14 SETUP PARA...

Page 29: ...0KVDC The jack is recessed for safety when this lead is not being used 19 HIGH VOLTAGE ON INDICATOR This indicator flashes to warn the operator that high voltage is present at the high voltage output terminal 20 RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m return test lead This lead is always used when performing a test On model 7504SA this jack will carry high current for...

Page 30: ...ent 6 HIGH VOLTAGE OUTPUT JACK For the connection of the detachable 5 foot 1 52 m 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 7 RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m return test lead This lead is always used when performing a test On model ...

Page 31: ...tion are 115V and 230V input For 115V input place the left switch in the up position and the right switch in the down position For 230V input place both switches in the up position 10 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord 11 CHASSIS GROUND EARTH TERMINAL This terminal should be connected to a good earth ground before operati...

Page 32: ...irst notifying us and receiving an RMA return material authorization number Preparation for Use Power Requirements and Line Voltage Selection This instrument requires a power source of either 100 115 200 or 230 volts AC 10 47 63 Hz Please check the rear panel to be sure the proper switch setting is selected for your line voltage requirements before turning your instrument on Do not switch the line...

Page 33: ...ging Original Packaging Please retain all original packaging materials that you originally received If you are returning your instrument to us for servicing please repackage the instrument in its original container Contact our customer support department 1 800 858 8378 for a RMA return material authorization number Please enclose the instrument with all options accessories and test leads Indicate ...

Page 34: ... sides of the instrument Protect the control panel with cardboard 4 Seal the container securely 5 Mark the container FRAGILE to insure proper handling 6 Please refer in all correspondence to your AR service number Field Installation Of Options There are no field installable options on this instrument ...

Page 35: ...re as follows DEFAULTS Function Parameter Value ACW Voltage 1240VAC HI Limit 10 00mA LO Limit 0 000mA Ramp Time 1 0s Dwell Time 1 0s Frequency 60Hz Arc Sense 5 Arc Fail OFF Scanner OOOOOOOOOOOOOOOO Connect OFF Continuity 7500DT only OFF DCW Voltage 1500VDC HI Limit 3500mA LO Limit 0 0mA Ramp Time 1 0s Dwell Time 1 0s Ramp HI OFF Charge LO 0 0mA Arc Sense 5 Arc Fail OFF Scanner OOOOOOOOOOOOOOOO Con...

Page 36: ...ng before connecting the instrument to it c Check to be sure the correct input line voltage has been selected on the rear panel 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...

Page 37: ...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 arrow indicator located in th...

Page 38: ...elect the Key Lock mode then press the EXIT key The program will switch the Key Lock function from LOCK to UNLOCK or UNLOCK to LOCK mode and advance the program to the Operation mode automatically If the Key Lock function is in the Lock mode the LOCK indicator on the front panel will light If the Memory Lock function MR Lock is selected to ON the Memory selection Menu will be disabled when in the ...

Page 39: ... ENTER key The program will recall the test parameters stored in this location and return to the operation mode automatically 1 4 Step Selection Press the STEP key the display will show the test parameters of the functions selected for that step i e the parameters of AC Withstand Voltage DC Withstand Voltage Insulation Resistance or Ground Bond test Pressing the step key again will advance to the ...

Page 40: ...ell Time Frequency Arc Sense Arc Fail Scanner Set Offset Connect 2 1 1 AC Output Voltage setting Advance the menu to the Voltage parameter The display will show Voltage XXXX V Range 0 5000 Use the Numeric keys to enter the voltage setting then press the ENTER key The program will store the voltage setting and advance to the High Limit parameter automatically The unit is volt and 1 volt per step Pr...

Page 41: ...p Time setting and advance to the Dwell Time setting automatically The unit is second and 0 1 second per step Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set 2 1 5 Dwell Time setting Advance the menu to the Dwell Time parameter The display will show Dwell Time XXX X s Range 0 3 999 9 0 Constant Use the Numeric keys to enter the Dwell Time sett...

Page 42: ...c Fail O N ENTER to Select or Arc Fail O F F ENTER to Select Use the ENTER key to select the Arc Fail mode then press the Ù or Ú key to advance the program to another test parameter or press the EXIT key to exit from the setting mode to the operation mode If the Arc Fail mode is set to ON the program will indicate an arc failure when the arc current is over the setting The program will shut down t...

Page 43: ...onnection setting Advance the menu to the Connection parameter The display will show Connect O N ENTER to Select or Connect O F F ENTER to Select Use the ENTER key to select the Step Connection mode then press Ù or Ú key to advance the program to another test parameter or press the EXIT key to exit from the setting mode to the operation mode If Connect is set to ON the next step in the sequence wi...

Page 44: ...ting Advance the menu to the HI Limit parameter The display will show HI Limit XXXX mA Range 0 9999 Use the Numeric keys to enter the HI Limit setting then press the ENTER key The program will store the HI Limit setting and advance to the Low Limit parameter automatically The unit is mA and 1mA per step Press the EXIT key to exit from the setting mode to the operation mode if all parameters have b...

Page 45: ...ing mode to the operation mode if all parameters have been set If the Dwell Time is set to the timer will continue to count to the maximum test time then reset to 0 and start over automatically The test will continue until a reset is executed or a failure occurs 2 2 6 Charge LO Advance the menu to the Charge LO parameter The display will show Charge LO XXX X mA TEST to Auto Set The Charge LO funct...

Page 46: ...ey to advance the program to another test parameter or press the EXIT key to exit from the setting mode to the operation mode 2 2 7 Ramp HI Advance the menu to the Ramp High parameter The display will show Ramp HI ON ENTER to Select or Ramp HI OFF ENTER to Select Use the ENTER key to select the Ramp HI mode then press the Ù or Ú key to advance the program to another test parameter or press the EXI...

Page 47: ... 2 2 9 Scanner Channel setting Advance the menu to the Scanner Set parameter The display will show Scanner Set CH 1 16 XXXXXXXXXXXXXXXX Note X H O or L Use the Numeric keys to enter the status of High Open or Low for each scanner channel then press the ENTER key The program will store the scanner channel status and advance to the Connection setting automatically The following table is the cross re...

Page 48: ... s MXX X XXXX V XXXXX MW Note X the numeric IR Set Insulation Resistance test setting screen XXX X s Delay Time setting MXX Memory Program number X Test Step number XXXX V DC Output Voltage XXXX MW Low Limit of Insulation Resistance Use the Ù or Ú arrow keys to progress through the test parameters menu The Ú key will advance forward and Ù key will advance backward The sequential forward menu items...

Page 49: ...parameter of Output Voltage has been set to the values that will be used for the final test and connect the test cables and or test fixture between the instrument and DUT If the scanner is to be used then the scanner channel must also be set Then press the TEST button The instrument will apply the voltage that has been entered for this memory step selection Please be aware that the program will ac...

Page 50: ... the menu to the Delay Time parameter The display will show Delay Time XXX X s Range 0 5 999 9 0 Constant Use the Numeric keys to enter the Delay Time setting then press the ENTER key The program will store the Delay Time setting and advance to the Scanner Channel parameter automatically The unit is second and 0 1 second per step Press the EXIT key to exit from the setting mode to the operation mo...

Page 51: ...t any unassigned channel s to OPEN automatically after pressing the ENTER key Therefore it is necessary to set only the channels that are required for the test If the external Scanner is not connected this setting is not necessary 2 3 7 Step Connection setting Advance the menu to the Connection parameter The display will show Connect ON ENTER to Select or Connect OFF ENTER to Select Use the ENTER ...

Page 52: ...ng and advance to the Output Voltage parameter automatically The unit is amps and 0 01A per step Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set 2 4 2 Output Voltage setting Advance the menu to the Voltage parameter The display will show Voltage X XX V Range 3 00 8 00 Use the Numeric keys to enter the voltage setting then press the ENTER key T...

Page 53: ... have been set If the LO Limit is set to the LO Limit is disabled 2 4 5 Dwell Time setting Advance the menu to the Dwell Time parameter The display will show Dwell Time XXX X s Range 0 5 999 9 0 Constant Use the Numeric keys to enter the Dwell Time setting then press the ENTER key The program will store the Dwell Time setting and advance to the Frequency selection parameter automatically The unit ...

Page 54: ...lled the Scanner Channel must be set to to receive accurate readings 2 4 8 Offset setting Advance the menu to the Offset parameter The display will show Offset XXX mW TEST to Auto Set This instrument can set the mW offset value by two different methods One is the Manual Offset and the other is Auto Offset For Manual Offset use the Numeric keys to enter the mW Offset value and then press the ENTER ...

Page 55: ... set to ON the next step in the sequence will be executed If Connect is set to OFF the test sequence will stop at this step If Step 8 is set to ON the test process will be connected to the first step of the next Memory 3 System Parameter Settings Use the SETUP key to progress through the menu of System Parameters Successive key presses will advance the menu forward The sequential forward menu item...

Page 56: ...ess setting If the GPIB interface card is not installed on this instrument this setup program will not appear on the setup menu Press the Setup key to advance the menu to the address parameter The display will show Address XX Range 0 30 Use the Numeric keys to enter the GPIB Address number then press the ENTER key and the display will show the current address immediately Press the SETUP key to adv...

Page 57: ...tically 3 5 Fail to Stop Continue selection Press the Setup key to advance the menu to the Fail Stop parameter The display will show Fail Stop ON ENTER to Select or Fail Stop OFF ENTER to Select Use the ENTER key to select the mode of Fail Stop After the selection of Fail Stop mode press the SETUP key to advance to the beginning of the menu PLC Remote or press the EXIT key to exit from the Fail St...

Page 58: ...xture 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 ONC...

Page 59: ...tting Screens before any test has been executed If the first step selected is an AC Withstand test the display will show ACW Set XXX X s M25 1 X XX KV XX XX mA ACW Set AC Withstand Voltage test setting screen XXX X s Dwell Time setting MXX Memory Program number X Test Step number X XX KV AC Output Voltage setting XX XX mA AC High Limit current setting If the first step selected is a DC Withstand t...

Page 60: ...Ready XXX X s M25 1 X XX KV XX XX mA If you are not performing a Ground Continuity Check the Ground Continuity must be set to the OFF Disabled position It is 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 button is activated Press the TEST button to activate the test proces...

Page 61: ...nd can cause small amounts of error depending on the test voltage and physical environment 4 6 Reviewing Test Results The test results from the first 8 test that are executed can be reviewed by pressing the Enter Review key Successive key presses will continue advancing to the next result The results of the last step in the process will be followed by the first step when scrolling through the resu...

Page 62: ...ond test and the ground continuity resistance is beyond the metering range the display will show GND HI Limit XXX X s MXX X 0 00 A 600 mW If the DUT resistance falls below the LO Limit of the Ground Bond test the display will show GND LO Limit XXX X s MXX X XX XX A XXX mW When the DUT passed the Ground Bond test when the test process is complete the display will show GND Pass XXX X s MXX X XX XX A...

Page 63: ...g the AC Withstand Voltage test when the values are being updated in real time during the dwell cycle the display will show ACW Dwell XXX X s MXX X X XX KV XX XX mA If the ramp time is very short and the program has not read the meter readings the display will show ACW Dwell XXX X s MXX X KV mA If the DUT current exceeds the HI Limit of AC Withstand Voltage test and the leakage current is within t...

Page 64: ...f the DUT current is within the metering range of the AC Withstand Voltage test and an Arcing current exceeds the Arc Sense limit and the Arc function is set to ON then an Arc failure has occurred and the display will show ACW Arc Fail XXX X s MXX X X XX KV XX XX mA If the GFI threshold is exceeded during of the AC Withstand Voltage test the display will show ACW GND Fault XXX X s MXX X X XX KV XX...

Page 65: ... cycle the display will show DCW Ramp XXX X s MXX X X XX KV XXXX mA During the DC Withstand Voltage test when the values are being updated in real time during the Dwell cycle the display will show DCW Dwell XXX X s MXX X X XX KV XX XX mA If the Ramp time is very short and the program has not read the meter readings the display will show DCW Dwell XXX X s MXX X KV mA If the Ramp HI function is enab...

Page 66: ...e DUT current is well beyond the metering range of DC Withstand Voltage test and an Arcing condition beyond the Arc Sense limit is indicated the display will show DCW Breakdown XXX X s MXX X X XX KV 9999 mA If the DUT current falls below the LO Limit of DC Withstand Voltage test and the leakage current is within the metering range the display will show DCW LO Limit XXX X s MXX X X XX KV XXX X mA I...

Page 67: ...rt XXX X s MXX X V MW or IR Abort XXX X s MXX X XXXX V MW At the beginning of Insulation Resistance test when the voltage begins to ramp but before the meter readings are taken the display will show IR Delay XXX X s MXX X V MW During the Insulation Resistance test when the values are being updated in real time during the Delay cycle the display will show IR Delay XXX X s MXX X XXXX V XXXX MW If th...

Page 68: ...he display will show IR LO Limit XXX X s MXX X XXXX V XXXX MW If the DUT current falls below the LO Limit of Insulation Resistance test and the resistance is below the metering range the display will show IR LO Limit XXX X s MXX X XXXX V 1MW If the GFI threshold is exceeded during of the Insulation Resistance test the display will show IR GND Fault XXX X s MXX X XXXX V XXXX MW When the DUT passed ...

Page 69: ...G SHELL WITH GROUND INDENTS 205203 3 RECEPTACLE SHELL 745254 7 CRIMP SNAP IN PIN 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 6 1 Signal Outputs on Remote I O The rear panel connector provides output signals to remotely monitor PASS FAIL and PROCESSING condition...

Page 70: ... the TEST and RESET functions or allows the operator to select one of three pre programmed tests When the remote function is ON the TEST switch on the front panel will be disabled to prevent a test from being activated through the test switch 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 al...

Page 71: ... how to connect the adapter box to the HypotULTRA II or QUADCHEK II and to the device under test The adapter box provides 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 dea...

Page 72: ...ry circuit are tested When testing products with two prong plugs do not activate the continuity circuit When the Ground Bond test is selected on the QUADCHEK II the High Current will be applied through the Current lead to the Adapter box and flow back through the Return lead The resistance is measured and compared to the HI and LO Limit trip points stored in memory ...

Page 73: ...her interconnected GPIB devices Interface messages often called commands or command messages and Device dependent messages often called data or data messages Data Messages contain information such as programming instructions or measurement results Command Messages perform functions such as initializing the bus and addressing and unaddressing devices 8 3 Functions A GPIB device can be a Listener Ta...

Page 74: ...d to place devices in remote or local program mode SRQ service request The SRQ line can be driven by any device to asynchronously request service from the Controller EOI end or identify This line has two purposes the Talker uses this line to mark the end of a message string and the Controller uses it to tell devices to identify their response in a parallel poll 8 5 GPIB Connector Connection is usu...

Page 75: ... clear capability No device trigger capability No controller capability 3 state driver CONTROLLABLE ITEMS Test Reset control Setting of test status parameters for test Display Reading Results Reading DATA CODES ASCII DELIMITER CR LF EOI 8 7 GPIB Address Each device on the GPIB IEEE 488 interface must have a unique address You can set the address of the 7504SA or 7500DT to any value between 0 and 3...

Page 76: ... and 8 jumpered together at the controller end of the cable When sending command over the RS232 bus the instrument will echo a response string identical to the string that was sent if the transfer was recognized and accepted by the instrument This allows for software handshaking to monitor and control data flow If there is an error with the command string that is sent the instrument will respond w...

Page 77: ...W Function Select FE IR Function Select FF GND Function Select 7504SA only FG ACW DCW Continuity On 7500DT Only x FH ACW DCW Continuity Off 7500DT Only x FI ACW 60Hz x FJ ACW 50Hz x FK ACW Arc Fail On x FL ACW Arc Fail Off x FM DCW Arc Fail On x FN DCW Arc Fail Off x FO GND 60hz 7504SA only x FP GND 50hz 7504SA only x FQ Connect On FR Connect Off FS Fail Stop On FT Fail Stop Off FU GND Auto Offset...

Page 78: ...t 0 000 9 999 mA SD Ramp Time 0 1 999 9 S SE Dwell Time 0 0 3 999 9 S SF Arc Sense 1 9 SG Scanner H Hi L Low O Open up to 16 channels DCW Command Parameter Value Unit SI Voltage 0 6000 V SJ HI Limit 0 3500 mA SK LO Limit 0 0 999 9 mA SL Ramp Time 0 4 999 9 S SM Dwell Time 0 0 3 999 9 S SO Charge LO 0 0 350 0 mA SP Arc Sense 1 9 SQ Scanner H Hi L Low O Open up to 16 channels IR Command Parameter Va...

Page 79: ...fset 0 200 mW General Operation Command Function Value Unit S5 Memory Select 1 50 Integer S6 Step Select 1 8 1 8 Integer When the Controller sends a correct or command the instrument will echo back the identical command string if a GPIB read command is sent after the command string If an error occurs when the command is sent the instrument will send an ASCII code 15h after the read command is sent...

Page 80: ...Buffer 7 40 Read the 2 x 20 display results of the seventh test executed 8 Step Buffer 8 40 Read the 2 x 20 display results of the eighth test executed A Ground Bond Offset 5 Read the Ground Offset Setting G Bond mode must be active B DCW Charge LO 5 Read the DCW Charge LO Setting DCW mode must be active C IR Charge LO 5 Read the IR Charge LO Setting IR mode must be active D Remote Reset Status 1 ...

Page 81: ...t the ACW mode by sending the string FC then send the string SA 1240 This tells the instrument to set the AC voltage at 1240 volts A string is a list of ASCII characters octal or hex bytes or special symbols enclosed in double quotes If the Test Function has already been selected to ACW mode and you wish to set the ramp time of the ACW test across the IEEE bus at 10 seconds send the string SD 10 0...

Page 82: ...fect the life of the internal non volatile memory chip FOR MORE INFORMATION ON IEEE GPIB PLEASE CONTACT The Institute of Electrical and Electronic Engineers Inc 345 East 47th Street New York NY 10017 1 212 705 7018 Communications Society of IEEE Internet www ieee org ...

Page 83: ...ll be an option label on the rear panel of the unit The option label contains an option s code that may be cross referenced to the Options List For example your options code would appear as follows fitted with option 03 OPT 03 fitted with option 03 and 05 OPT 0305 7500DT 7504SA Options Option List Code Description 03 High Resolution IR megohm meter 50KW 05 RS232 Interface 06 Dual Remote Test Switc...

Page 84: ...1000VDC MW MW MW 0 0001 0 0500 0 1200 0 1000 0 2500 0 001 0 100 1 200 0 200 2 500 0 01 1 00 99 99 2 00 99 99 Accuracy 2 of reading 2 counts at test voltage 100 500V and 0 050 9 999 MW 2 of reading 2 counts at test voltage 501 1000V and 0 100 9 999 MW 8 of reading 2 counts at test voltage 499 1000V and 10 00 99 99 MW Charge LO Range 000 0 350 0mA or Auto Set HI Limit Range 0 0 05 99 99 MW 0 Off LO ...

Page 85: ...software handshaking to monitor and control data flow If there is an error with the command string that is sent the instrument will respond with 15h or the NAK ASCII control code When requesting data from the instrument it automatically send the data to the controller input buffer The controller input buffer will accumulate data being sent from the instrument including the echo response string unt...

Page 86: ... AC ramp down feature allows the AC voltage applied to the DUT to be reduced linearly over a specified period at the end of a hipot test There are three set up screens associated with this feature that will allow control of Ramp Up Dwell and Ramp Down The setup screens will appear as follows Ramp Up XXX X s Range 0 1 999 9 Use the Numeric keys to enter the Ramp Up time setting then press the ENTER...

Page 87: ...me is very short and the program has not read the meter readings the display will show ACW Dwell XXX X s MXX X KV mA At the end of the dwell cycle when the voltage begins to ramp down the display will show the values being updated in real time as follows ACW Ramp down XXX X s MXX X X XX KV XX XX mA NOTE In order to view the ACW values measured during the dwell cycle the review key must be pressed ...

Page 88: ...amp Down Time setting and advance to the Frequency parameter automatically The unit is second and 0 1 second per step Press the EXIT key to exit from the setting mode to the operation mode if all parameters have been set Displayed messages for Enhanced DC Ramping At the beginning of DC Withstand Voltage test when the voltage begins to ramp but before the meter readings are taken the display will s...

Page 89: ...1 999 9 Use the Numeric keys to enter the Ramp Up time setting then press the ENTER key The program will store the Ramp Up Time setting and advance to the Dwell Time parameter automatically The unit is second and 0 1 second per step Delay Time XXX X s Range 0 5 999 9 0 Constant Use the Numeric keys to enter the Dwell time setting then press the ENTER key The program will store the Dwell Time setti...

Page 90: ... X XXXX V XXXX MW At the end of the delay cycle when the voltage begins to ramp down the display will show the last value measured during the delay cycle and the actual voltage value as the voltage is ramping down IR Ramp down XXX X s MXX X XXXX V XXXX MW NOTE In order to see the IR values measured during the delay cycle the review key must be pressed GPIB Commands The following chart is a list of...

Page 91: ...OPTIONS 87 This page is intentionally left blank ...

Page 92: ...SECTION 2 SERVICE MANUAL ...

Page 93: ...nge 0 9 9 9 9 or Password X X X X Range 0 9 9 9 9 The Password can be any four 4 digit number If the Password is set to the keyboard lock out will be selected by the LOCK key on the front panel without a Password The Password default is preset to at the factory 2 Memory Lock selection Press the Ú key the program will advance to the Memory Lock selection mode The display will show MR Lock O N ENTER...

Page 94: ...rd value of AC hipot voltage for calibration and display will show ACW Voltage 5000V OK T E S T t o C a l i b r a t e 4 DC Hipot Voltage Press the Ú key the program will advance to the DC Voltage calibration of the hipot test The display will show DCW Voltage 6000V TEST to Calibrate Connect a DC standard voltage meter which can measure up to 6000V to the output connectors and then press the TEST b...

Page 95: ...play will show IR Voltage 1000V OK T E S T t o C a l i b r a t e 6 AC Hipot 100mA current range Press the Ú key the program will advance to the AC 100mA range calibration of the hipot test The display will show AC 100mA 10KW T E S T t o C a l i b r a t e Connect a resistor about 10KW 100W in series with a AC standard Ammeter which can measure up to 100mA to the output leads The Ammeter should be c...

Page 96: ...ange for calibration and the display will show DC 10mA 100KW OK T E S T t o C a l i b r a t e 8 AC Hipot 3 5mA current range Press the Ú key the program will advance to the AC 3 5mA range calibration of the hipot test The display will show AC 3 5mA 100KW T E S T t o C a l i b r a t e Connect a resistor about 100KW 10W in series with a AC standard Ammeter which can measure up to 3mA to the output l...

Page 97: ...C 3500mA range of hipot test and the display will show DC 3500mA 100KW OK T E S T t o C a l i b r a t e 10 DC Hipot 350mA current range Press the Ú key the program will advance to the setting and reading of DC 320mA range calibration of the hipot test The display will show DC 350mA 1MW T E S T t o C a l i b r a t e Connect a resistor about 1MW 0 25W in series with a DC standard Ammeter which can m...

Page 98: ... a l i b r a t e Connect a 50MW 0 25W 1000VDC standard resistor to the output connectors then press the TEST button the program will automatically calibrate the XXXX MW range of IR test and the display will show XXXXMW STD 50MW OK T E S T t o C a l i b r a t e 13 Ground Bond AC Voltage Model 7504SA only Press the Ú key the program will advance to the AC Voltage calibration of the Ground bond test ...

Page 99: ...tandard I out Use the Numeric keys to enter the standard value of current unit A and then press the ENTER key to store the standard value of AC Ground Bond current and display will show Ground A 30A OK T E S T t o C a l i b r a t e 15 Real Current This menu item will be shown only when the Real Current option is installed Press the Ú key the program will advance to the Real Current calibration of ...

Page 100: ... Use the Numeric keys to enter the standard value of current unit mA and then press the ENTER key to store the standard value of AC Real current and display will show AC 5mAR 500K OK T E S T t o C a l i b r a t e ...

Page 101: ... shield 37982 1 T2 Output High Voltage Transformer 37999 1 Fuse 15A 250V Fast Blow 20mm 37571 1 Earth Connector 37800 2 3U Rack Mount Bracket 37801 2 3U Rack Mount Handle 38071 1 Input Power Cable 15A 6Ft 38101 1 Feet Kit w o Rubber Inserts 38102 4 Rubber Insert 37478 2 High Voltage Connector 04040A 08 1 High Voltage Output Cable 37697 1 IC12 IC Microcontroller 8 bit 20Mhz 89C52 Model 7500DT only ...

Page 102: ...trol Board CHV 06 1 S37998 Power Amplifier Board AMP H500 1 S37995 Rectifier Board REC H15 1 S37742 Keypad Board CKB 03 1 S37994 Input Protection Board CSW 05 1 S37744 Display LED Board DSP 06 1 S37745 GPIB Interface Board CGP 03 1 S37778 Ground Continuity Check Board 7500DT only CGC 02 1 S37814 RS232 Interface Board RS232 1 S37940 Printer Board CPR 01 1 S07500X 37 Real Current Board 37881 1 ...

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