Associated Research 7620 HypotULTRA III Operation And Service Manual
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Associated Research 7620 HypotULTRA III Operation And Service Manual

Electrical safety compliance analyzer, ac/dc hipot with insulation resistance tester, continuity tester, and usb/rs-232 interface
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AC/DC HIPOT WITH INSULATION RESISTANCE TESTER, CONTINUITY TESTER, AND
AC HIPOT WITH CONTINUITY TESTER AND USB/RS-232 INTERFACE on 7620
Models
7620,7650
Item 38363
OPERATION AND SERVICE MANUAL
MODEL 7620 HypotULTRA
MODEL 7650 HypotULTRA
Electrical Safety Compliance Analyzer
USB/RS-232 INTERFACE on 7650
Ver 3.02
SERIAL NUMBER
®
III
®
III
© Associated Research, Inc. 2012
13860 West Laurel Drive
Lake Forest, Illinois, 60045
U.S.A.
Printed August 21, 2012

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Summary of Contents for Associated Research 7620 HypotULTRA III

  • Page 1 AC/DC HIPOT WITH INSULATION RESISTANCE TESTER, CONTINUITY TESTER, AND USB/RS-232 INTERFACE on 7650 AC HIPOT WITH CONTINUITY TESTER AND USB/RS-232 INTERFACE on 7620 SERIAL NUMBER Models © Associated Research, Inc. 2012 13860 West Laurel Drive 7620,7650 Lake Forest, Illinois, 60045 U.S.A.
  • Page 2 92/31/EEC. The CE marking has been affixed on the device according to article 10 of the EMC Directive 8/336/EEC. The technical file and other documentation are on file with Associated Research, Inc. ______________________________ Joseph Guerriero Vice President / General Manager Associated Research, Inc.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1. INTRODUCTION ...................... 1 1.1. Warranty ...................... 1 1.2. Safety Symbols................... 3 1.2.1. Product Marking Symbols ..............3 1.2.2. Caution and Warning Symbols ............3 1.3. Glossary of Terms ..................3 1.4. Safety ......................5 1.4.1. Service and Maintenance ..............5 1.4.2.
  • Page 4 4.3.3. Selecting a Step................36 4.3.4. Test Parameters ................37 4.3.5. Default Parameters ................. 39 4.3.6. Setting Up a Test ................40 5. OPERATING INSTRUCTIONS ................46 5.1. Instrument Connections ................46 5.1.1. Connecting the Test Leads............. 46 5.1.2. Connecting the Adaptor Box ............46 5.1.3.
  • Page 5 9.2.1. Continuity Verification ..............102 9.2.2. AC Hipot Verification ..............102 9.2.3. DC Hipot Verification ..............103 9.2.4. IR Verification ................. 104 10. CALIBRATION ....................106 10.1. Warranty Requirements ............... 106 10.2. Calibration Initialization ................ 107 10.3. Selecting Specific Calibration Points ..........107 10.4.

  • Page 7: Introduction

    1. INTRODUCTION 1.1. Warranty Policies Associated Research, Inc., certifies that the instrument listed in this manual meets or exceeds published manufacturing specifications. This instrument was calibrated using standards that are traceable to the National Institute of Standards and Technology (NIST).
  • Page 8 Elimination of any connections in the earth grounding system or bypassing any safety systems will void this warranty. This warranty does not cover accessories not of Associated Research, Inc. manufacture. Parts used must be parts that are recommended by Associated Research, Inc. as an acceptable specified part. Use of non-authorized parts in the repair of this instrument will void the warranty.

  • Page 9: Safety Symbols

    1.2. Safety Symbols 1.2.1. Product Marking Symbols Product will be marked with this symbol when it is necessary to refer to the operation and service manual in order to prevent injury or equipment damage. Product will be marked with this symbol when hazardous voltages may be present.
  • Page 10 Direct Current, DC: Current that flows in one direction only. The source of direct current is said to be polarized and has one terminal that is always at a higher potential than the other. Frequency: The number of cycles an AC waveform repeats over time. Usually given in Hertz (Hz). Ground: Refers to the point of low potential in a circuit to which all other voltages are referenced.

  • Page 11: Safety

    LAKE FOREST, IL 60045-4546 U.S.A. FAX: 1 (847) 367-4080 E-MAIL: info@asresearch.com Service Interval Associated Research, Inc. will not be held liable for injuries suffered if the instrument is not properly maintained and safety checked annually. See section 1.1. Warranty Policies for more information. ___________________________________________________________________________________________...

  • Page 12: Test Station

    1.4.2. Test Station Location Select an area away from the mainstream of activity where employees do not walk while 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 test operators should be allowed inside.

  • Page 13: Test Operator

    1.4.3. Test Operator This instrument generates voltages and currents that can cause harmful or fatal electric shock and must only be operated by a skilled worker trained in its use. The operator should understand the electrical fundamentals of voltage, current, and resistance. Rules Operators should be thoroughly trained to follow all national safety standard guidelines for electrical safety testing in the workplace.

  • Page 14: Key Features And Benefits

    1.5. Key Features of the HypotULTRA III Alerts the operator that the machine is due for CAL-ALERT™ calibration in advance of the calibration due date. Two test modes allow for a basic Continuity test to be performed simultaneously with the Hipot test, TWO CONTINUITY TEST or a stand-alone Continuity test to be performed MODES...
  • Page 15 Two standard 9 pin interfaces provide outputs for PASS, FAIL, RESET and TEST IN PROCESS PLC REMOTE INPUTS & signals. Inputs include TEST, INTERLOCK, OUTPUTS RESET and remote recall of MEMORIES 1 - 10. Provides the user with the ability to operate the HypotULTRA III through simple PLC relay control.

  • Page 16: Getting Started

    2. GETTING STARTED Introduction This section contains information for the unpacking, inspection, preparation for use and storage of your Associated Research, Inc., product. 2.1. Unpacking and Inspection 2.1.1. Packaging Your instrument was shipped in a custom foam insulated container. If the shipping carton is damaged, inspect the contents for visible damage such as dents, scratches or a broken display.

  • Page 17: Returning The Instrument For Service Or Calibration

    Please include all accessories and test leads. Mark the container “ FRAGILE” to ensure proper handling. Before shipping, contact an Associated Research, Inc. customer support representative at 1-800-858-TEST (8378) to indicate and explain the reason for service.

  • Page 18: Power Requirements

    Make sure the work area you choose has a three-prong grounded outlet capable of supplying the necessary input current to the power source. Be sure the outlet has been tested for proper wiring before connecting the instrument to it. 2.2.2. Power Requirements This instrument requires a power source of either 115 volts AC ±...
  • Page 19 This instrument may be operated in environments with the following limits: Temperature… ....32° - 104° F (0° - 40°C) Relative humidity… ... 0 – 80% Altitude… ......6560 feet (2,000 meters) NOTE: Keep the ventilation slits uncovered during operation. Failure to do so could cause the instrument to overheat and may damage internal components.

  • Page 20: Specifications And Controls

    3. SPECIFICATIONS AND CONTROLS 3.1. HypotULTRA III Functional Specifications, 7620 and 7650 INPUT 115 / 230 VAC ± 10 %, automatically selected Voltage 50/60 Hz ± 5% Frequency Fuse 4 Amp 250V Slo-Blo DIELECTRIC WITHSTAND TEST MODE Output Rating 5 KV @ 30 mA AC 5 KV @ 10 mA DC for 7650 only Output Adjustment Range:...
  • Page 21 DIELECTRIC WITHSTAND TEST MODE DC (for 7650 only) Range 1: 0.0 – 999.9µA Resolution: 0.1µA Range 2: 1000 – 10000µA Resolution: 1µA ± (2% of setting + 2 counts) Accuracy: Arc Detection Range: 1 – 9 Failure Detector Audible and Visual Voltage Display Range: 0.00 –...

  • Page 22: Ground Continuity

    DIELECTRIC WITHSTAND TEST MODE Maximum Capacitive Load 1uF----< 1KV 0.08uF----< 4KV in DC Mode 0.75uF----< 2KV 0.04uF----< 5KV 0.5uF----< 3KV AC Output Wave Form Sine Wave, Crest Factor = 1.3 – 1.5 Output Frequency Range: 60 or 50 Hz, User Selection ±...
  • Page 23 INSULATION RESISTANCE TEST MODE, MODEL 7650 ONLY Resistance Display Range: 0.05MΩ – 50000 MΩ (5 Digit, Auto Ranging) Resolution: 500VDC 1000VDC MΩ MΩ MΩ 0.001 0.050 – 0.100 – 9.999 9.999 0.01 1.00 – 99.99 1.00 – 99.99 10.0 – 999.9 10.0 –...
  • Page 24 CONTINUITY TEST MODE DC 0.1A ± 0.01A Total Resistance*: 0.00-33.0 Ω Output Current DC 0.01A ± 0.001A Total Resistance*: 31.0-330 Ω DC 0.001A ± 0.0001A Total Resistance*: 310-2000 Ω 0.00 – 19.99 Ω Resistance Display Range 1: Resolution: 0.01 Ω ±...
  • Page 25 GENERAL SPECIFICATIONS PLC Remote Control Input: Test, Reset, Interlock, Recall Memory 1 through Output: Pass, Fail, Test-in-Process, Reset Remote Output Relays 125VAC@1AAC, 30VDC@ 0.5ADC Safety Built-in Smart GFI circuit Memory 50 memories, 30 steps/memory Interface Standard USB/RS-232, Optional GPIB, Ethernet or Printer Port with Date and Time Stamp.

  • Page 26: Instrument Controls

    3.2. Instrument Controls 3.2.1. Front Panel Controls 1. RESET BUTTON: Resets the instrument. If a failure condition occurs during a test, pressing this button will reset the system, shut off the alarm and clear the failure condition. The Reset button must be pressed before performing another test or changing any of the setup parameters.

  • Page 27: Rear Panel Controls

    11. HIGH VOLTAGE INDICATOR: This indicator flashes to warn the operator that high voltage is present at the high voltage output terminal. 12. HIGH VOLTAGE OUTPUT TERMINAL: Connector used to attach the high voltage test lead, adapter box high voltage lead or test fixture high voltage lead to the instrument.
  • Page 28 8. REAR PANEL CONTINUITY OUTPUT TERMINAL: 2 continuity output connector in parallel with the front panel output. 9. FUSE RECEPTACLE: To change the fuse, unplug the power (mains) cord and turn the fuse receptacle counter-clockwise. The fuse compartment will be exposed.

  • Page 29: Programming Instructions

    4. PROGRAMMING INSTRUCTIONS 4.1. Power Up The HypotULTRA III automatically defaults to the Perform Tests screen upon power up. The Perform Tests screen will appear as follows: The Perform Tests screen is the main operational screen of instrument. From this screen all test parameters are monitored while the test is being performed.

  • Page 30: Analog Meters

    feature for that step has been turned ON. 4.1.2. Analog Meters A new feature unique to HypotULTRA III is analog bar graph meters. The bar graphs represent voltage and current and are located directly below their corresponding digital meter. Along with the bar graph displays are arrows that point to the voltage setting in the case of the analog voltmeter and the Min Lmt and Max Lmt settings in the case of the current meter.

  • Page 31: Setup System

    Results At the end of a test sequence or single step test, you may review the measurements of each test by pressing the <more> soft key and then pressing the “ Results” soft key. The Results screen will appear as follow: Using the “...

  • Page 32: System Parameters

    Edit The “ Edit” soft key is used to access the highlighted parameter and activates the Editing Menus. An example of one of the editing menus is as follows: If the selected parameter is a toggle selection, as shown in the example above, the bottom soft key will have the word “...
  • Page 33 PLC Remote Highlight the PLC Remote parameter using the “< , >, ∧, ∨ ” soft keys. When PLC Remote parameter is highlighted, press the “ Edit” soft key. The PLC Remote editing menu will now be displayed. You may turn the PLC remote function ON and OFF by pressing the “...
  • Page 34 ENTER or cancel the edit by pressing EXIT. Fail Stop is a function that will stop a sequence of tests at the step if a failure occurs. If this function is turned off, the sequence of tests will continue to the end of the sequence regardless of whether or not a failure has occurred.
  • Page 35 test or sequence of connected steps displaying the results of all of the steps. The Results summary screen will appear as follows: When P/F is selected, a Pass or Fail screen will be displayed at the end of the test. The Pass and Fail screens will appear as follows: When P/F is selected, it is not possible to directly see the results of the test.
  • Page 36 You may now type in the new password using the numeric keypad, press the ENTER key to accept the new password or press the EXIT key to escape. After you type in your new password you will be required to confirm your new password by typing it again into the “...

  • Page 37: Cal Alert (Calibration Alert)

    “ Change” soft key. Press the ENTER key to accept the new setting or the EXIT key to cancel and return to the original setting. When the ENTER key is pressed, the new security setting will take immediate effect. Selecting Lock ON restricts access to parameter and system settings.
  • Page 38 Turning this parameter ON will activate the Cal Alert function and when the date matches the Alert Date, the instrument will display the Calibration Alert Warning screen upon power up. If the “ Show this screen again?” function has been turned OFF at the Calibration Alert Warning screen, this parameter will automatically be set to OFF.
  • Page 39 Time Scroll the cursor to the Time parameter using the “< , >, ∧, ∨ ” soft keys. Within the Set Time parameter are three fields: hours, minutes, and Military or Standard time setting. Use the “ <” and “ >” soft keys to select the field within the date you want to edit.

  • Page 40: Default System Parameters

    and turning it OFF. If the security is enabled with a password, the Password pop-up screen will appear over the Calibration Alert screen. While in this state the instrument will be virtually unusable until the password is entered. Once the password is entered, the security at the Calibration Alert screen will be bypassed and the “...

  • Page 41: Setup Tests Menu

    Smart GFI Results Last Cal Alert Date The following System parameters will not be affected by the system initialization: Setup Cal Date No change Cal Due No change Alert No change Date No chnage Time No change Security Password No change Security No change 4.3.

  • Page 42: Naming A Memory

    Once you press the ENTER key, the memory location and all of its steps will be loaded into the instruments active memory for use. Once the memory location is loaded, the Perform Test screen will once again be displayed. 4.3.2. Naming a Memory Location At the Memory Recall screen, press the “...

  • Page 43: Test Parameters

    DID YOU KNOW? Ramp Up: The length of time that is allowed for the test voltage to climb from 0 to the programmed test voltage. Associated Research, Inc provides detailed Dwell: The length of time that is allowed for the whitepapers and articles programmed test voltage to be applied.
  • Page 44 Arc Sense: The maximum allowable threshold for arcing. The numbers 0 through 9 correspond to the different arc sensitivity levels, 1 meaning the maximum threshold of allowable arcing, 9 meaning the minimum threshold of allowable arcing, and 0 being OFF. After the “ +” or “ -” soft keys are pressed, the arc sensitivity will automatically adjust to the new setting.

  • Page 45: Default Parameters

    insert a Prompt. To enter a text prompt, use the arrow keys to scroll the highlighted area to the character (or enter a number from the numeric keypad) you wish to use and then press the “ Select” soft key. The letter or symbol will be inserted at the point where the cursor is flashing.

  • Page 46: Setting Up A Test

    TEST TYPE PARAMETER VALUE Arc Sense Continuity Scanner OOOOOOOO Prompt Voltage 500V (7650 only) Max Lmt 0.00MΩ Min Lmt 0.05MΩ Ramp UP 0.1s Delay 1.0s Ramp DN 0.0s Connect Charge-LO 0.000uA Scanner OOOOOOOO Prompt CONT Max-Lmt 10.00Ω Min-Lmt 0.00Ω Dwell 1.0s Offset 0.00Ω...
  • Page 47 the edit and return to the original number. When you are done modifying test parameters, press the EXIT key twice to return to the Perform Test screen. The instrument is now ready to perform tests with the modified parameters. AC Withstand From the Test Parameter Review screen, scroll the highlighted area to the Test Type and press the “...
  • Page 48 From the AC Withstand Setting screen the following parameters may be selected for editing: Voltage, Max-Lmt T, Min-Lmt T, Max-Lmt R, Min-Lmt R, Display Total/Real, Connect, Ramp Up, Dwell Time, Ramp Down, Frequency, Arc Detect (ON/OFF), Arc Sense, Continuity selection (DC continuity or OFF), Prompt and Scanner Channel selections (if there is a scanner installed).
  • Page 49 The Scanner selections will only appear if there is a scanner installed or an external Scanner connected to the instrument (this is an auto-detect feature in hardware). From the DC Withstand Parameter Review screen the following parameters may be selected for editing: Voltage, Max-Lmt, Min-Lmt, Ramp Up, Dwell Time, Ramp Down, Connect, Ramp-HI, Charge LO, Arc Detect (ON/OFF), Arc Sense, Continuity selection (DC continuity or OFF), Scanner Channel selections if installed, and Prompt.

  • Page 50: Insulation Resistance

    Insulation Resistance (Model 7650 only) From the Test Parameter Review screen, scroll the highlighted area to the Test Type and press the “ Edit” soft key. The Test Parameter Edit screen will now be displayed. Now press the “ Change” soft key until the letters IR appear in the parameter field.
  • Page 51 From the Continuity Parameter Setting screen, the following parameters may be controlled: Max-Lmt, Min-Lmt, Dwell, Offset, Connect, Scanner Channel Output Select if installed, and Prompt. Offset This function allows the instrument to compensate for lead and test fixture resistance during a Continuity test. Using the “ ^ , v” soft keys or the ENTER key, scroll the highlighted area to the Offset parameter.

  • Page 52: Operating Instructions

    5. OPERATING INSTRUCTIONS 5.1. Instrument Connections The test leads and the adaptor box may be connected to the receptacle located on the front or back of HypotULTRA III. These receptacles are wired in parallel and may be used depending upon the application 5.1.1.

  • Page 53: Performing A Test

    port located on the back of the tester. 5.2. Performing a Test 1. As instructed in section 4.2. System Setup, select a memory and step that is suitable for the test you would like to perform. 2. Attach the appropriate DUT to the instrument (refer to section 5.1. Instrument Connections).

  • Page 54: Perform Tests Metering

    When the Lock parameter is selected ON in the System Menu, manual voltage adjustment is disabled. Therefore, you will not see the “ +” and “ -” soft keys. 5.3. Perform Tests Metering Each test performed by the HypotULTRA III contains a unique set of parameters and therefore requires specialized metering for each test.

  • Page 55: Error Messages

    Method 1, Hot key Pressing the bottom soft key at the Perform Tests screen will display the Results screen. Method 2, Menu Selection 1. From the Perform Tests screen, press the “ Menu” soft key. The Main Menu will now be displayed. 2.
  • Page 56 Max-Lmt: This message appears on the display if the DUT measurement exceeds the Max-Lmt setting of any parameter. Min-Lmt: This message appears on the display if the DUT measurement drops below the Min-Lmt. CONT-Fail: This message appears on the display if the DUT fails the basic continuity check performed during an AC/DC Withstand test (if Continuity is selected “...
  • Page 57 All of the buttons and keys are not active in this situation. You should contact Associated Research, Inc to receive further instruction. Fatal Error identification number will represent type of the failure that occurs. Error number of 9002 will appears on the display, if the instrument’ s System data or Model/Option/Serial Number data are corrupted and does not match the setting.

  • Page 58: Connection Of Remote I/O

    6. CONNECTION OF REMOTE I/O Two 9-pin “ D” type connectors mounted on the rear panel provide REMOTE-INPUT- OUTPUT control and information. These connectors mate with a standard 9 pin D- sub-miniature connector provided by the user. The output mates to a male (plug) connector while the input mates to a female (receptacle) connector.

  • Page 59: Remote Signal Inputs And Memory Access

    Pins 1 and 2 provide the PASS signal. Pins 3 and 4 provide the FAIL signal. Pins 5 and 6 provide the PROCESSING signal. Pins 7 and 8 provide the RESET signal. The following describes how the relays operate for each test condition: PROCESSING –...
  • Page 60 The Remote File Select function gives the user the capability to quickly change parameters and initiate a test remotely. Ten pre-programmed test files can be accessed by connecting pins 1,6,8, and 9 to the common pin 7, in different combinations. The memory select bits should be set simultaneously and remain set for a minimum of 20ms to guarantee that the correct memory will be selected.
  • Page 61 If the Remote Interlock contacts are opened during a test, the pop-up message will be displayed and the test will abort. The hardware and has been configured to provide the interlock connections on pins 4 and 5 of the Remote Interface, Signal Input port. The instrument can still be used without the external interlock device as long as the Interlock Disable Key (38075 provided with unit) is plugged into the Remote Interface, Signal Input port.

  • Page 62: Bus Remote Interface Gpib / Rs-232

    7. BUS REMOTE INTERFACE GPIB/USB/RS-232 This section provides information on the proper use and configuration of the bus remote interface. The USB/RS-232 remote interface is standard on the HypotULTRA III but the GPIB (IEEE-488) interface option can be substituted for the USB/RS-232 interface.

  • Page 63: Sending And Receiving Commands

    No parity This interface does not support XON/XOFF protocol or any hardware handshaking. The controller should be configured to ignore the handshaking lines DTR (pin 4), DSR (pin 6) CTS (pin 8) and RTS (pin 7). If the port cannot be configured through software to ignore these lines the handshake lines should be jumpered together in two different sets.

  • Page 64: Gpib Address

    A maximum total cable length of 20 m. No more than 15 device loads connected to each bus, with no less than two-thirds powered on. For example 1 GPIB controller and a maximum of 14 GPIB instruments. NOTE: A bus extender, which is available from numerous manufacturers, is available to overcome these limitations.

  • Page 65: Gpib / Rs-232 Interface Command List

    7.4. USB/RS-232 / GPIB Interface Command List Echo and Response Considerations USB/RS-232 Responses The USB/RS-232 bus will automatically send any response back to the controller's input buffer. GPIB Queries and Responses The HypotULTRA III GPIB bus will not send any data to the controller without being queried.

  • Page 66: File Editing Commands

    Set the offset for the Continuity test. The cables and any test fixture should be connected before executing the command. This command will perform an actual test and all safety precautions should be observed when using this command. SACG Set the Charge-LO parameter for the DCW or IR test. The cables and any test fixture should be connected before executing the command.
  • Page 67 FN < file name> Creates a new file name for the active memory loaded into RAM. SS <step number> Selects the active selected step to load into RAM. The step must first be selected before any specific parameters can be edited. SAA, SAD, SAI, SAC These commands add the appropriate test type within the memory at the step location that has been selected.

  • Page 68: Test Parameter Editing Commands And Companion Queries

    CONT Voltage Voltage Voltage Max-Limit Max-Lmt Total Max-Lmt Max-Lmt Min-Lmt Min-Limit Total Min-Limit Min-Limit Dwell Ramp Up Ramp Up Ramp Up Offset Dwell Time Dwell Time Delay Time Connect (ON/OFF) Ramp Down Ramp Down Ramp Down Internal Scanner (opt) Arc Sense Charge-LO Charge-LO External...
  • Page 69 used a different possible set of values. COMMAND NAME TEST VALUE TYPES ECC {1|0} Edit Connect 1= On, 0=Off ECC? ED {1|0} Edit Current Meter 1 = Real, 0 = Total Display EV <value> Edit Voltage 0 - 5000V 0 - 5000V 50 - 1000V ECG <...

  • Page 70: System Parameter Editing Commands And Companion Queries64

    COMMAND NAME TEST VALUE TYPES EL < value > Edit Min-Lmt 0.0 - 10000uA 0.05 - 50000MΩ 0.0 - 2000 Ω CONT EF {1|0} Edit Frequency 1=60Hz, 0=50Hz EIS <scanner Edit Internal scanner string = 1-16 string> Scanner element ASCII string EIS? consisting of H, L, or O.

  • Page 71: Query Commands

    COMMAND NAME VALUE SCDA < value > Cal Date mm,dd,yy or yy,mm,dd or SCDA? dd,mm,yy according to SDF setting SCDU < value > Cal Due mm,dd,yy or yy,mm,dd or SCDU? dd,mm,yy according to SDF setting SA < value > Alert Date mm,dd,yy or yy,mm,dd or dd,mm,yy according to SDF setting...
  • Page 72 COMMAND NAME VALUE List Testing Data Test In Process RD <step number>? List Results Data step number = 1-30 Read Remote Reset 1=Open, 0=Closed Read Remote Interlock 1=Open, 0=Closed Read Scanner Status 0 = None, 1 = Internal 2 = External, 3 = Both List File Name Active selected memory LFN?

  • Page 73: Ieee 488.2 Common Commands

    *IDN? command which can be used to retrieve the instrument identification information, and the four status reporting commands *ESR?, *ESE, *ESE? and *STB? COMMAND NAME DESCRIPTION *IDN? Identification Query Associated Research Inc., Model Number, Serial Number, Firmware ___________________________________________________________________________________________...
  • Page 74 Service Request Enable Query 0 - 255 *IDN? Read the instrument identification string. Company = Associated Research Inc. *RST Reset the instrument to original power on configuration. Does not clear Enable register for Standard Summary Status or Standard Event Registers. Does not clear the output queue.

  • Page 75: Status Reporting

    Enable registers. *OPC Sets the operation complete bit (bit 0) in the Standard Event register after a command is completed successfully. *OPC? Returns an ASCII "1" after the command is executed. *WAI After the command is executed, it prevents the instrument from executing any further query or commands until the no-operation-pending flag is TRUE.

  • Page 76: Gpib Service Request

    The status reporting system is configured using two types of registers. An Event register and a Summary register. The Summary register is known as the Status Byte register and records high-level summary information acquired by the Event registers. An Event register report defines conditions or messages at each bit. The bits are latched and remain at an active state until the register is either Read or Cleared.

  • Page 77: Example Of Communicating Over The Gpib Bus

    After the serial poll (SPOLL) is executed the RQS bit will be cleared to 0, and the remaining bits will remain unchanged. The Status Byte will not change value until the event register is read and cleared for the corresponding Status Byte bit. For example after the All Pass SRQ has been enabled, when the test(s) have finished with pass indications the instrument will set the hardware SRQ line and output the Status Byte of 41 hex.

  • Page 78: Options

    8. OPTIONS Introduction This section contains a list and descriptions of available factory installed options at the time of this printing. The list of options contains an option code number that can be referenced on the data plate on the rear panel of the unit. Option Label On the rear panel of the instrument, you will find a label that contains the option code.
  • Page 79 >, ∧, ∨” soft keys. 2. Press the “ Edit” soft key. The Scanner Channel Edit screen will now be displayed. 3. Use the “ < , >” soft keys to select which Scanner channel you want to edit then press the change key to select H, L, O. The three different selectable Scanner states are L (Scanner channel set to the return point), H (Scanner set to the high voltage point or continuity output) and O (OFF).
  • Page 80 02 4 Channel Scanner with Continuity This option is the same as Option 01, 8 Channel Scanner with Continuity, with the exception that the numbers of channels are limited to 4. The Scanner functions the same as the 8-channel option but the Scanner status display will only indicate the status of channels 1-4, even though all 8 channel indicators are displayed.

  • Page 81: Test Screen

    The Printer Port is a USB interface and should be compatible with most USB printers. The printer port output uses simple ASCII characters and control codes. Simply connect the printer to the HypotULTRA III and configure the printer output using the Setup Systems menu. At the System Setup screen, scroll the highlighted area to <more>.
  • Page 82 Device ID The Device ID number is a counter that increments once every time a test is performed. The number can be set to match the exact serial number or some portion of the actual serial number of the item under test, or just used as an identifier or tracking number.
  • Page 83 DIELECTRIC WITHSTAND TEST MODE DC Range 1: 0.0 – 999.9µA for 7650 only Resolution: 0.1µA Range 2: 1000 – 10000µA for 7650 only Resolution: 1µA ± (2% of setting + 2 counts) Accuracy: Current Display Auto Range AC Total Range 1: 0.000mA –...
  • Page 84 DIELECTRIC WITHSTAND TEST MODE AC Real Range 1: 0.000 – 5.000mA Resolution: 0.001mA ± (3% of setting + 0.05mA) All Ranges Accuracy: PF > 0.1 V > 250VAC Range 1: 0.0 – 999.9µA for 7650 only Resolution: 0.1µA Range 2: 1000 –...
  • Page 85 The port labeled “ Barcode” is a PS/2-type connector that is used for the connection of a barcode scanner. The Ethernet port is for use with a standard CAT-5 Ethernet cable and may be connected to any compatible PC. The 9-pin D- type subminiature connector labeled “...
  • Page 86 Associated Research, Inc. Ethernet Card Communications Information (To be completed by Network Administrator) Ethernet Card Address: ______:______:______:______:______ Device Name: _____________________ Device IP Address: _______._______._______._______ Gateway IP Address: _______._______._______._______ Subnet Mask: _______._______._______._______...
  • Page 87 Saving New Settings Any time the user edits one of the Ethernet Card parameters and exits the Ethernet Card Settings menu, the following message will be displayed: The Ethernet Card will attempt to re-establish a connection with the server anytime the user modifies a parameter and exits the Ethernet Card Parameters Menu or uses the command set at the end of this option description.
  • Page 88 If the HypotULTRA III fails to receive an IP Address after approximately 20 seconds, the following pop-up message will be displayed: Press the EXIT key to remove the pop-up message and return to the HypotULTRA III’ s Perform Tests screen. Ethernet Card Menu When the Ethernet Card option is installed, the “...
  • Page 89 IP Setup Highlight the IP Setup parameter using the “∧, ∨ ” soft keys. When the IP Setup parameter is highlighted, press the “ Edit” soft key. IP Setup is used to determine how the HypotULTRA III will request an IP address from the server to which it is connected.
  • Page 90 Press the EXIT key to save the new settings. If the IP Setup parameter is set to AUTO, you do not need to enter an IP Address manually. Gateway IP Highlight the Gateway IP parameter using the “∧, ∨ ” soft keys. When the Gateway IP parameter is highlighted, press the “...
  • Page 91 The Device Name screen will appear as follows: From this screen you may enter a Device Name for the HypotULTRA III. The Device Name is used to identify the HypotULTRA III on your server and may be used in place of a dedicated IP Address.
  • Page 92 After the barcodes are scanned, press TEST to initiate the test sequence. Pressing RESET will abort the TEST sequence. The Ethernet Card permits re-scanning of barcodes if the previously scanned barcode was incorrect. Re-scanning is only available in the SERIAL#, PRODUCT# and SER/PROD modes.
  • Page 93 Using the RUN FILE feature will enable the instrument’ s output once the barcode is scanned. Do not touch the DUT at any time when using this feature in order to avoid potential shock or serious injury. When using a barcode scanner, the HypotULTRA III’ s responses to the TD? and RD x? commands will differ slightly from an OMNIA with the standard RS-232 interface.
  • Page 94 HypotULTRA III. Next, scan the product number. From this point, HypotULTRA III will operate the same as when the Barcode I/P setting is set to PRODUCT#. The Autostart feature will not work with the SERIAL# setting. WARNING The Autostart feature will enable the instrument’ s output once the product number barcode is scanned a second time when in the PRODUCT# and SER/PROD modes.
  • Page 95 times necessary after one of the commands in the table is sent. In addition, the current socket connection between the user’ s terminal and the Ethernet Card is no longer valid, and the user will need to close their current connection and establish a new one.
  • Page 96 To navigate to the Data Card Settings menu, select the <more> soft key from the Perform Tests screen. Then select the “ DCard” soft key. A brief description of the settings follows: Results Limit Highlight the Results Limit parameter using the “∧, ∨ ” soft keys. When the Results Limit parameter is highlighted, press the “...
  • Page 97 Time Limit Highlight the Time Limit parameter using the “∧, ∨ ” soft keys. When the Time Limit parameter is highlighted, press the “ Edit” soft key. The Time Limit allows the user to receive an alert message on the display of the HypotULTRA III when any of the results saved on the Data Storage Card’...
  • Page 98 parameter is highlighted, press the “ Edit” soft key. Use the “ Change” soft key to select the Serial Port setting. Press the ENTER key to accept the new setting or the EXIT key to cancel and return to the original setting. The serial port can be set to RS232, RS485, or OFF.
  • Page 99 X <RS485 Address>;<Command><line feed> NOTE: When communicating with the HypotULTRA III using the RS485/RS232 port, results are not saved to the Data Storage Card. Barcode I/P Highlight the Barcode I/P parameter using the “∧, ∨ ” soft keys. When the Barcode I/P parameter is highlighted, press the “...
  • Page 100 PRODUCT# and SER/PROD modes. Anytime before a test is initiated, the user can re-scan a barcode. If the user decides to re-scan barcodes when the Barcode I/P setting is set to SER/PROD, the Data Storage Card will first replace the data in the Serial Number field, and if the user re-scans another barcode, the Data Storage Card will replace the data in the Product Number field.
  • Page 101 Operation The Data Storage Card Results Menu can be viewed by pressing the “ Results” soft key while in the Perform Tests screen. After doing so the following menu will be shown: Pressing the “ Instrument” soft key will display the detailed results from the previously executed test.
  • Page 102 Pressing ENTER will verify that the user wants to delete all of the results on the Data Storage Card, and pressing EXIT will cancel deleting the results. The following message will appear if the “ Delete ALL” soft key is pressed: The following menu will appear if the “...
  • Page 103 each transfer, the Data Storage Card will copy all results in the internal Flash memory regardless if some or all of the results have been transferred before. During each transfer, the Data Storage Card will create a .txt file that will contain the information for all of the results.
  • Page 104 CONT Test Voltage Test Test Voltage Voltage Resistance Test Dwell Leakage Leakage Resistance Time Current (T) Current Test Dwell Test Delay Leakage Time Time Current (R) Test Dwell Time NOTE: If barcoding is used, the barcoding information will be the final entries in the results file with Serial Number being first and Product Number being second.
  • Page 105 The above message occurs when the user tries to transfer results from the Data Storage Card without the USB Flash memory drive connected. To transfer results, the user needs to have the Flash memory drive connected to the Data Storage Card. The above message appears when the user attempts to give a name to a results file that already exists on the Data Storage Card.
  • Page 106 The above message appears when the USB Flash memory drive is write-protected. There are two ways to configure the memory drive as write-protected. One is to set the switch on the side of the memory drive up (towards the drive’ s connector). The other is to configure it through the drive’...

  • Page 107: Instrument Verification

    9. VERIFICATION Verification is the process by which an instrument’ s failure detectors are proven to be functioning properly. Verifying the failure detection circuitry of the electrical safety tester is required by safety agencies such as CSA, UL, and TÜV. NOTE: Verification should be performed at the beginning of each day or each shift, before testing has begun.

  • Page 108: Continuity Verification

    9.2.1. Continuity Verification From the Verification screen, press the “ ∧” and “ ∨” soft keys to select “ Continuity.” Then press the “ Select” soft key. An instructional prompt will now be displayed. The prompt will appear as follows: Follow the instructions given in the prompt and then press TEST to begin the verification process.

  • Page 109: Dc Hipot Verification

    Follow the instructions given in the prompt and then press TEST to begin the verification process. At the end of the verification process a message will appear indicating the outcome of the process. If the instrument passes the verification (test failure, indicating the fail detectors are working properly) the RESET button will illuminate, the alarm will sound and the following message will appear: If the instrument fails the verification (test pass, indicating the fail detectors are not...

  • Page 110: Ir Verification

    Follow the instructions given in the prompt and then press TEST to begin the verification process. At the end of the verification process a message will appear indicating the outcome of the process. If the instrument passes the verification (test failure, indicating the fail detectors are working properly) the RESET button will illuminate, the alarm will sound and the following message will appear: If the instrument fails the verification (test pass, indicating the fail detectors are not...
  • Page 111 Follow the instructions given in the prompt and then press TEST to begin the verification process. At the end of the verification process a message will appear indicating the outcome of the process. If the instrument passes the verification (test failure, indicating the fail detectors are working properly) the RESET button will illuminate, the alarm will sound and the following message will appear: If the instrument fails the verification (test pass, indicating the fail detectors are not...

  • Page 112: Calibration

    Associated Research, Inc. offers a standard one-year manufacturer’ s warranty. This warranty can be extended an additional four years provided that the instrument is returned each year to Associated Research, Inc. for its annual recertification. In order to be eligible for the extended warranty instruments must be returned to Associated Research, Inc.

  • Page 113: Calibration Initialization

    10.2. Calibration Initialization Press and hold the calibration key on the rear panel with a pen, pencil, or small screwdriver while powering ON the HypotULTRA III. The HypotULTRA III enters calibration mode after the power on sequence is complete. The Initial Calibration screens will appear as follows: 10.3.

  • Page 114: Calibration Of Ac Hipot Voltage

    10.4.1. Calibration of AC Hipot Voltage 10.4.2. Calibration of DC Hipot Voltage...

  • Page 115: Calibration Of Ir Dc Voltage

    10.4.3. Calibration of IR DC Voltage 10.4.4. Calibration of 30mA AC Total Current Range ___________________________________________________________________________________________...

  • Page 116: Calibration Of 3.5Ma Ac Total Current Range

    10.4.5. Calibration of 3.5mA AC Total Current Range 10.4.6. Calibration of 200W/30mA AC Real Current Range...

  • Page 117: Calibration Of 20W/30Ma Ac Real Current Range

    10.4.7. Calibration of 20W/30mA AC Real Current Range 10.4.8. Calibration of 20W/3.5mA AC Real Current Range ___________________________________________________________________________________________...

  • Page 118: Calibration Of 3.5Ma Ac Total Current Range

    10.4.9. Calibration of 2W/3.500mA AC Real Current Range 10.4.10. Calibration of 10mA DC Current Range...

  • Page 119: Calibration Of 3.500Ma Dc Current Range

    10.4.11. Calibration of 3.500mA DC Current Range 10.4.12. Calibration of 350uA DC Current Range ___________________________________________________________________________________________...

  • Page 120: Calibration Of 999.99Mω Ir Range

    10.4.13. Calibration of 999.99MΩ IR Range 10.4.14. Calibration of 9999.9MΩ IR Range...

  • Page 121: Calibration Of 50000Mω Ir Range

    10.4.15. Calibration of 50000MΩ IR Range 10.4.16. Calibration of DC Continuity 20Ω This screen will appear after both steps 1 and 2. ___________________________________________________________________________________________...

  • Page 122: Calibration Of Continuity 200Ω

    10.4.17. Calibration of DC Continuity 200Ω This screen will appear after both steps 1 and 2.

  • Page 123: Calibration Of Continuity 2000Ω

    10.4.18. Calibration of DC Continuity 2000Ω This screen will appear after both steps 1 and 2. ___________________________________________________________________________________________...

  • Page 124: Replacement Parts List

    11. REPLACEMENT PARTS Rev: J 8-21-2012 ECO 5548 Part Qty. Ref. Designator Description Number Supplied Accessories 38794 2U Rack Mount Handle 38793 2U Rack Mount Bracket 38549 Screw for Rack Mount Handle/Bracket 38388 Fuse 4A 250V Slow Blow 20mm 04040A-08 High Voltage Cable 02100A-13 Cable Assembly Return...
  • Page 125 Part Qty. Ref. Designator Description Number Internal Components 38235 IC 27 IC 29C020 EEPROM DIP 38424 IC 31 IC BQ3287 Real-Time Clock 38298 IC 40 IC ATF16V8B 20pin PLCC 38427 IC 41 IC 29C020 EEPROM PLCC 38428 IC 51 IC XA-G30 Microcontroller 38391 Input Transformer 38393...

  • Page 126: Schematic Index

    12. SCHEMATIC INDEX DRAWING DESCRIPTION REFERENCE PAGES NUMBER DESIGNATOR S07650 Wiring Diagram S38394 Main Control Board CON7650 S38194 Real Current Board REA7500 S38478 HV Control Board HV7650 S38390 Amplifier Board AMP7650 S38392 Connector Transfer Board CNR7650 S38396 Keypad Board KEYU3 S38401 Scanner Control Board CSU7650...
  • Page 127 Index AC Withstand ..................39, 41, 43, 44, 45, 46, 50 Adapter Box....................10, 20, 21, 48, 120 Alarm Parameter ......................... 29 Arc ...................3, 8, 15, 40, 41, 42, 44, 45, 52, 64, 65 Breakdown ........................3, 4, 52 Calibration . 11, 19, 21, 30, 31, 32, 33, 35, 36, 53, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119 Calibration Alert ........................
  • Page 128 Medical Restrictions ......................7 Memory 19, 23, 24, 32, 37, 38, 40, 44, 49, 50, 52, 56, 60, 61, 62, 63, 66, 68, 69, 70, 71, 73, 75, 91, 92, 93, 97, 99, 100, 101, 102 Menu ... 8, 23, 25, 27, 28, 29, 30, 35, 37, 42, 43, 50, 51, 76, 77, 83, 84, 91, 92, 97, 98, 100, 101, Min Lmt ......................
  • Page 129 File ..........................62, 67 Ground Continuity ......................46 Insulation Resistance ...................... 45 Scanner ......................... 40, 74, 76 Setup System......................84, 92 System ..........................77 Test ..........................37, 38 Short......................16, 29, 40, 47, 52 Single Step ..............25, 28, 29, 36, 37, 66, 85, 86, 87, 89, 92 Smart GFI ....................19, 25, 32, 36, 37, 66 Specifications ........................

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