Associated Research hypot III 3605, hypot III 3665, hypot III 3670 Operation And Service Manual
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Form 080/01
OPERATION AND SERVICE MANUAL
HypotIII
MODEL 3605 (AC ONLY HIPOT WITH GROUND CONTINUITY CHECK )
MODEL 3665 (AC/DC HIPOT WITH GROUND CONTINUITY CHECK)
MODEL 3670 (AC/DC HIPOT WITH IR AND GROUND CONTINUITY)
SERIAL NUMBER
Models
3605/3665/3670
Item 38302 Ver 1.19
© Associated Research, Inc., 2007
13860 West Laurel Drive
Lake Forest, Illinois, 60045-4546
U.S.A.
Printed January 15, 2007
DECLARATION OF CONFORMITY
Manufacturer: Associated Research, Inc.
Address: 13860 W. Laurel Dr.
Lake Forest, IL 60045
USA
Product Name: Hypot® III Dielectric Withstand
Voltage Tester
Model Number: 3605/3665/3670
Conforms to the following Standards:
Safety: IEC 61010-1: 1993 + A2
EMC: EN 61326: 1997 + A1: 1998 Class A
EN 61000-4-2: 1995, EN 61000-4-3: 1996,
EN 61000-4-4: 1995, EN 61000-4-5: 1995,
EN 61000-4-6: 1996, EN 61000-4-8: 1993,
EN 61000-4-11: 1994.
Supplementary Information
The product herewith complies with the requirements of the Low
Voltage Directive 73/23/EEC as amended by 93/68/EEC and the EMC
Directive 89/336/EEC as amended by 92/31/EEC.
The CE marking has been affixed on the devic e according to article 10
of the EMC Di rective 8/336/EEC.
The technical file and other documentation are on file with
Associa ted Research, Inc.
_______ __________________ __ ___
Joseph Gu erriero
Vice Pres ident / General Manager
Associa ted Research, Inc.
Lake Forest, Il linois U SA
April 3, 2002
TABLE OF CONTENTS
1. Introduction...............................................................................................................1
1.1. Warranty Policies..........................................................................................1
1.2. Safety Symbols.............................................................................................2
1.2.1. Product Marking Symbols ..................................................................2
1.2.2. Caution and Warning Symbols ...........................................................2
1.3. Glossary of Terms.........................................................................................3
1.4. Safety ...........................................................................................................4
1.4.1. Service and Maintenance....................................................................4
1.4.2. Test Station........................................................................................5
1.4.3. Test Operator......................................................................................6
1.4.4. Instrument Connections......................................................................6
1.4.5. Device Under Test..............................................................................7
1.4.6. Key Safety Points to Remember.........................................................7
1.5. Introduction to Product Safety Testing..........................................................8
1.5.1. The Importance of Safety Testing.......................................................8
1.6. The Different Types of Safety Tests..............................................................8
1.6.1. Principles and Uses of Dielectric Withstand Testing...........................8
1.6.2. Insulation Resistance Test ................................................................11
1.6.3. Ground Bond Test............................................................................11
1.6.4. Run Test ...........................................................................................12
1.6.5. Line Leakage Test............................................................................12
1.7. Key Features and Benefits...........................................................................14
2. Getting Started........................................................................................................17
2.1. Unpacking and Inspection...........................................................................17
2.1.1. Packaging.........................................................................................17
2.1.2. Contents of Carton............................................................................17
2.1.3. Returning the Instrument for Service or Calibration..........................17
2.2. Installation..................................................................................................18
2.2.1. Work Area........................................................................................18
2.2.2. Power Requirements.........................................................................18
2.2.3. Basic Connections............................................................................18
2.2.4. Environmental Conditions................................................................19
3. Specifications and Controls.....................................................................................20
3.1. Specifications..............................................................................................20
3.2. Instrument Controls ....................................................................................24
3.2.1. Front Panel Controls.........................................................................24
3.2.2. Rear Panel Controls..........................................................................25
3.3. Quickstart ...................................................................................................26
i
4. Programming Instructions......................................................................................29
4.1. Setup System..............................................................................................29
4.1.1. Setup System Soft keys....................................................................30
4.1.2. System Parameters ...........................................................................30
4.2. Setting up Tests...........................................................................................36
4.2.1. Reviewing Test parameters...............................................................36
4.2.2. Editing Test Parameters....................................................................37
4.2.3. Reviewing Test Results....................................................................37
4.3. Test Parameters...........................................................................................37
4.3.1. AC Withstand...................................................................................39
4.3.2. DC Withstand (Models 3665 and 3670)............................................40
4.3.3. Insulation Resistance (Model 3670 only)..........................................41
4.3.4. Default Test Parameters....................................................................42
4.3.5. Memory, Step, and Default System Parameter Initialization .............43
5. Operating Instructions............................................................................................44
5.1. Instrument Connections ..............................................................................44
5.1.1. Adapter Box Connections.................................................................44
5.2. Perform Tests, Main Menu, and Results Screens.........................................44
5.2.1. Connected Step Indicator..................................................................45
5.2.2. Main Menu.......................................................................................45
5.2.3. Results, Tests and System Selections................................................46
5.3. Perform Tests Metering...............................................................................47
5.4. Performing a Test........................................................................................47
5.4.1. Manual Current Adjustment .............................................................47
6. Instrument Verification...........................................................................................50
6.1. Verification Initialization............................................................................50
6.2. Verification Menu.......................................................................................50
6.2.1. Continuity Verification.....................................................................51
6.2.2. AC Hipot Verification......................................................................52
6.2.3. DC Hipot Verification......................................................................53
6.2.4. IR Verification .................................................................................54
7. Remote Control .......................................................................................................55
7.1. Signal Outputs on Remote I/O.....................................................................55
7.2. Signal Inputs of Remote I/O and Memory Access.......................................56
8. Options.....................................................................................................................59
9. Calibration Procedure.............................................................................................62
9.1. Warranty Requirements ..............................................................................62
9.2. Calibration Initialization.............................................................................63
9.2.1. Calibration of Parameters .................................................................63
10. Replacement Parts List .........................................................................................67
11. Schematic Index.....................................................................................................68
ii
Index is located at the back of the manual
iii
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 Nat ional Inst itute of Standards and Technology (NIST).
Your new instrument is warranted to be free from defects in workmanship and material for a
period of (1) year from date of shipment. You must complete the on-line registration at
www.asresearch.com/register
5-Year Program
AR recommends that your instr ument be calibrated on a twelve-month cycle. Instruments
purchased and used in North America only, may have their warrant y extended in one year
increments to a maximum of (5) years provided they are returned to AR at least annually for
calibration and inspection. The annual calibration and inspection must be performed annually
every year following receipt of instrument. Any instrument not calibrated and inspected
annually will not be elig ible for e xtend ed wa rra nty status. T h is ext ende d w arr a nty is nontransferable 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 t he custo mer. The ret urn method will be at the discretion of Associated
Research.
or call 1-800-858-TEST ext. 210 to register over the phone
3-Year Program
A 3-Year warranty is also available for instruments purchased and used in North America. All
costs for this warranty are paid with the initial purchase and include warranty coverage, annual
calibration and standard ground return freight for three years. However, unlike our 5-year
program annual calibration and inspection by Associated Research is not required.
Except as provided herein, Associated Research makes no warranties to the purchaser of this
instrument and all other warranties, express or implied (including, without limitation,
merchantability or fitness for a particular purpose) are hereby excluded, disclaimed and
waived.
Any non-authorized modifications, tampering or physical damage will void your warranty.
Elimination of any connections in the earth grounding system or bypassing any safety systems
will void this warranty. This warranty does not cover batteries or accessories not of Associated
Research manufacture. Parts used must be parts that are recommended by AR as an acceptable
specified part. Use of non-authorized parts in the repair of this instrument will void the
warranty.
1
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.
Product will be marked with this symbol at connections that require earth grounding.
1.2.2. Caution and Warning Symbols
WARNING
CAUTION
Calls attention to a procedure, practice, or condition that could possibly cause
bod ily inju ry or d ea th.
Calls attention to a procedure, practice, or condition that could possibly
cause damage to equipment or permanent loss of data
2
1.3. Glossary of Terms
(As used in th is manua l)
Alternating Current, AC: Current that reverses direction on a regular basis, commonly in the U.S.A. 60
per second, in other countries 50 times per second.
Breakdown: The failure of insulation t o effectively prev ent th e flow of current sometimes eviden ced by
arcing. If voltage is gradually raised, breakdown will begin suddenly at a certain voltage level. Current flow is
not directly proportional to voltage. Once breakdown current has flown, especially for a period of time, the next
gradual application of voltage will often show breakdown beginning at a lower voltage than initially.
Conductive: Having a volume resistivity of no more than 10
105ohms per square.
3
ohm-cm or a surface resistivity of no more than
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 103ohm-cm.
Current: The movement of electrons through a conductor. Current is measured in amperes, milliamperes,
microamperes, nanoamperes, or picoamperes. Symbol = I
Dielectric: An insulating material that is positioned between two conductive materials in such a way that a
charge or voltage may appear across the two con ducti ve mater ials.
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.
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 10
for the purpos e of resist ing cu rren t flow b etween condu ctor s .
12
ohm-cm and is used
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
mea suring up to 2 00 megohm s.
Leakage: AC or DC curren t flow through insu lation and over it s surfaces, an d AC cur ren t flow through a
capacitance. Curren t flow is directl y proportional t o voltage. The insul ation and/or capacitan ce is thought of as a
constant imp edance, unless breakdown occurs.
Resistance: That property of a substance that impedes current and results in the dissipation of power, in the
form of heat. The practical unit of resistance is the ohm. Symbol = R
Trip Point: A minimum or maximum parameter set point that will cause an indication of unacceptable
performan ce during a run test.
Voltage: Electrical pressure, the force which causes current through an electrical conductor.
Symbol = V
3
1.4. Safety
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 (110 or 220)
and the correct fuse is installed.
A Hipot produces voltages and currents that can cause harmful or fatal
WARNING
1.4.1. Service and Maintenance
User Service
To prevent electric shock do not remove the instrument cover. There are no user serviceable
parts inside. Routine maintenance or cleaning of internal parts is not necessary. Avoid the use
of cleaning agents or chemicals on the instrument, some chemicals may damage plastic parts or
lettering. Any external cleaning should be done with a clean dry or slightly damp cloth.
Schematics, when provided, are for reference only. Any replacement cables and high voltage
components should be acquired directly from Associated Research, Inc. Refer servicing to an
Associated Research, I nc. authorized service center.
electric shock. To prevent accidental injury or death, these safety procedures
must be strictly observed when handling and us ing the test instrument.
(PHONE: 1 (847) 367-4077
ASS OCI ATE D RE SEARCH, IN C.
13860 WEST LAUREL DRIVE
LAKE FOREST, IL 60045-4546 U.S.A.
1 (800) 858-TEST (8378)
FAX: 1 (847) 367-4080
E-MAIL : info@asresearc h.co m
www.asresearch.com
Service Interval
The instrument, its po wer cord , test leads, and accesso ries must be returned at least once a year
to an Associated Research authorized service center for calibration and inspection of safety
related components. Associated Research will not be held liable for injuries suffered if the
instrument is not properly maintained and safety checked annually.
User Modifications
Unauthorized user modifications will void your warranty. Associated Research will not be
responsible for any injuries sustained due to unauthorized equipment modifications or use of
parts not specified by Associated Research. Instruments returned to Associated Research with
unsafe modifications will be returned to their original op erating condition at the customers
expense.
4
1.4.2. Test Station
Location
Select an area away from the main stream of activity which employees do not walk through in
performing their normal duties. If this is not practical because of production line flow, then the
area should be roped off and marked for HIGH VOLTAGE TESTING. No employees other
than the test operators should be allowed inside.
If benches are placed back-to-back, be especially care ful about the use of the bench opposite
the test station. Signs should be posted:“DANGER – HIGH VOLTAGE TEST IN
PROGRESS – UNAUTHORIZED PERSONNEL KEEP AWAY.”
Work Area
Perform the tests on a non-conducting table or workbench, if possible. If you cannot avoid
using a conductive surface, be certain that it is connected to a good earth ground and the high
voltage connection is insulated from the grounded surface.
There should not be any metal in the work area between the operator and the location where
products being tested will be positioned. Any other metal in the work area should be
connected to a good ground, never left “floating”.
Position the t ester so the operator does not have to reach over the product under test to activate
or adjust the tester. If the product or component being tested is small, it may be possible to
construct guards or an enclosure around the device to be tested. Construct the guards of a nonconducting material such as clear acrylic, so that the item being tested is within the guards or
enclosure during the test. If possible, the guards or enclosure should also contain safety
switches that will not allow the tester to operate unless the guards are in place or the enclosure
closed.
Keep the area clean and uncluttered. All test equipment and test leads not necessary for the
test should be removed from the test bench and put away. It should be apparent to both the
operator and to any observers, the product that is being tested and the product that is waiting to
be tested, or has already been tested.
Do not perform Hipot tests in a combustible atmosphere or in any area where combustible
materials are present.
Power
Dielectric Voltage-Withstand Test Equipment must be connected to a good ground. Be certain
that the power wiring to the test bench is properly polarized and that the proper low resistance
bonding to ground is in place.
Power to the test stat ion should be arranged so that it can be shut off by one prominently
marked switch located at the entrance to the test area. I n case o f an emergency, anyo ne ca n cut
off the power before entering the test area to offer assistance.
5
1.4.3. Test Operator
Qualifications
This instrument generates voltages and currents that can cause harmful or fatal electric shock
and must only be operated by a skilled worker trained in its use.
The operator should understand the electrical fundamentals of voltage, current, and resistance.
They should recognize that the test instrument is a variable high-voltage power supply with the
return circuit d irectly connected to eart h gro und, therefore, current from the high-voltage
output will flow through any available ground path.
Rules
Operators should be thoroughly trained to follow all of the aforementioned rules, in addition to
any other applicable safety rules and procedures. Defeating any safety system should be
considered a serious offense with severe penalties such as removal from the Hipot testing job.
Allowing unauthorized personnel in the area during a test should also be dealt with as a serious
offense.
Dress
Operators should not wear jewelry that could accidentally complete a circuit.
Medical Restrictions
Personnel with heart ailments or devices such as pacemakers should be informed that the
voltages and currents generated by the instrument are very dangero us. If cont acted it may
cause heart-r elated problems that a person of good health may not experience. Please have the
test operator consult their physician for recommendations.
1.4.4. Instrument Connections
WARNING
The instrument is equipped with a safety ground connection, be sure that this is
connected to a good earth ground.
Always connect the return lead first, regardless of whether the item under test is a sample of
insulating material, a component tested with the high voltage test lead, or a cord-connected
device with a two or three prong plug. The return lead should be connected first for any type
of hipot testing.
Plug in the high voltage test lead only when it is being used. Handle its clip only by the
insulator---never touch the clip directly. Be certa in that the operator has control over an y
remote test switches connected to the Hipot. Double check the return and high voltage
connections from the Hipot and the Line, Neutral, Ground and Case connections from the Line
Leakage tester to be certain that they are proper and secure.
Never perform a hipot test on energized circuitry or equipment.
6
1.4.5. Device Under Test
WARNING
When testing with DC, always discharge the capacitance of the item under test and anything
the high voltage may have contacted–such as test fixt ures–before handling it or disconnecting
the test leads.
HOT STICK probes can be used to discharge any capacitance in the device under test as a
further safety precaution. A hot stick is a non-conducting rod about two feet long with a metal
probe at the end that is connected to a wire. To discharge the device under test, two hot sticks
are required. First, connect both probe wires to a good earth ground. Then touch one probe tip
to the same place that the return lead was connected. While holding the first probe in place,
touch the second pro be t ip to the same place where the high voltage lead was co nnected.
1.4.6. 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 conne ctions during a test.
Never touch the Device Under Test (DUT) or anything connected to it while
high voltage is being applied by the hipot.
• In case of any problem, turn off the high voltage first.
• Properly discharge any item tested with DC before touching connections.
7
1.5. Introducti on t o Pr oduc t Saf ety Testi ng
1.5.1. The Importance of Safety Testing
Product Safety Tests are specified during the design and develo pment stages of a product as
well as in the production of the products to insure that it meets basic safety requirements.
These tests are designed to verify the safety of the electrical products in that they do not
jeopardize the safety of the people, domestic animals, and property of anyone who may come
in contact with these products. In an era of soaring liability cost s, original manufacturers of
electrical and electronic products must make sure every item is as safe as possible. All
products must be designed and built to prevent electric shock, even when users abuse the
equipment or by-pass built in safety features.
To meet recognized safety standards, one common test is the “dielectric voltage-withstand
test”. Safety agencies which require compliance safety testing at both the initial product
design stage and for routine production line testing include: Underwriters Laboratories, Inc.
(UL), the Canadian Standards Association (CSA), t he International Electrot echnical
Commission (IEC), the British Standards Institution (BSI), the Association of German
Electrical E ngineers (VDE) and (TÜV), the Japanese Standards Association (JSI). These same
agencies may also require that an insulation resistance test and high current ground bond test
be performed.
1.6. The Different Types of Safety Tests
1.6.1. Dielectric Withstand Test
The principle behind a dielectric voltage – withstand test is simple. If a product will function
when exposed to extremely adverse conditions, it can be assumed that the product will funct ion
in normal operating circumstances.
Common Applications of the Dielectric Withstand Test:
• Design (performance) testing: Determining design adequacy to meet service conditions.
• Production Line testing: Det ecting defects in material or workmanship during processing.
• Acceptance testing: Proving minimum insulation requirements of purchased parts.
• Repair Service testing: Determine reliability and safety of equipment repairs.
The specific technique used to apply the dielectric voltage – withstand test to each product is
different. During a dielectric voltage – withstand test, an electrical device is exposed to a
voltage significantly higher than it normally encounters, for a specified durat ion of t ime.
During the test, all current flow from the high voltage output to the return is measured. If,
during the time the component is tested, the current flow remains within specified limits, the
device is assumed safe under normal conditions. The basic product design and use of the
insulating material will protect the user against electrical shock.
8
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 volt s.
However, specific products may be tested at much higher voltages than 2X oper ating 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 hig her. Most “double insulated” products
are tested at voltages much higher than the “rule of thumb”.
Testing during develo pment and prototype stages is more stringent than production run tests
because the basic design of the product is being evaluated. Design tests usually are performed
on only a few samples of the product. Production tests are performed on every item as it
comes off the production line.
The hipot tester must also maintain an output voltage between 100% and 120% of
specification. The output voltage of the hipot must have a sinusoidal waveform with a
frequency between 40 to 70 Hz and has a peak waveform value that is not less than 1.3 and not
more than 1.5 times the root-mean-square value.
Types of Failures only detectable with a Hipot test
• Weak Insulating Materials
• Pin holes in I nsula tio n
• Inadequate Spacing of Components
• Pinched Insulation
Dielectric Withstand Test; AC verses DC
Please check with the Compliance Agency you are working with to see which of the two types
of voltages you are authorized to use. In some cases, a Compliance Agency will allow either
AC or DC testing to be done. However, in other cases the Compliance Agency only allows for
an AC test. If you are unsure which specification you must comply with please contact our
CUSTOMER SUPPORT GROUP at 1-800-858-TEST (8378).
Many safety agency specificatio ns 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 capacita nce so it continually reads the reactive current that flows when AC
is applied to a capacitive load.
9
AC testing advantages
AC testing is generally much more accepted by safety agencies than DC testing. The main
reason for this is that most items being hipot tested will operate on AC voltages. AC hipot
testing offers the advantage o f stressing the insulation alternat e ly in both po larities, which
more closely simulates stresses the product will see in real use.
Since AC testing cannot charge a capacit ive 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 vo ltage 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 ite m under test after the test.
AC testing disadvantages
One disadvantage of AC testing surfaces when testing capacitive products. Again, since AC
cannot charge the item under test, react ive current is constantly flowing. In many cases, the
reactive component of the current can be much great er than the real component due to actual
leakage. This can make it very d ifficu lt to detect products that have excessively high leakage
current.
Another disadvantage of AC testing is that the hipot has to have the capability of supplying
reactive and leakage current continuously. This may require a current output that is actually
much higher than is really required to monitor leakage current and in most cases is usually
much higher than would be needed with DC testing. This can present increased safety risks as
operators are exposed to higher currents.
DC testing characteristics
During DC hipot testing the ite m under test is charged. The same test item capacitance that
causes reactive current in AC testing results in initia l charging current which exponentially
drops to zero in DC testing.
DC testing advantages
Once the item under test is fully charged, the only current flow ing is true leakage current. This
allows a DC hipot tester to clearly display only the true leakage of the product under test.
Another advantage to DC t esting is that the charging current only needs to be applied
momentarily. This means that the output power requirements of the DC hipot tester can
typically be much less than what would be required in an AC tester to test the same product.
DC testing disadvantages
Unless the 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 ite m the more slowly the
voltage must be raised. This is important since most DC hipots have failure shut off circuitr y
10
which will indicate failure almost immediately if the total current reaches the leakage thresho ld
during the initial charging of the product under test.
Since a DC hipot does charge the item under test, it becomes necessary to discharge the item
after the test.
DC testing unlike AC testing only charges the insulat ion in one polarit y. This becomes a
concern when testing products that will actually be used at AC voltages. This is an important
reason that some safety agencies do not accept DC testing as an alternative to AC.
When performing AC hipot tests the product under test is actually tested with peak voltages
that the hipot meter does not display. This is not the case with DC testing since a sinewave is
not generated when testing with direct current. In order to compensate for this most safety
agencies require that the equivalent DC test be performed at higher voltages than the AC test.
The multiplying factor is somewhat inconsistent between agencies which can cause confusion
concerning exactly what equivalent DC test voltage is appropriate.
1.6.2. Insulation Resi stance Test
So me “dielectr ic a nalyzer s tod ay come with a built in insulation resistance tester. Typ ica lly,
the IR function provides test volt ages 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 t ypically is not a production line
test but a performance design t est.
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.
Typ ically, the h igher the insulatio n res ista nce valu e the better the cond itio n of the insula tion.
The connections to perform the IR test are the same as the hipot test. The measured value
represents the equivalent resistance of all the insulation which exists between the two points
and a ny co mponent resist a nc e wh ich might a lso be connected be twe e n the two points.
Although the IR test can be a predicto r of insulation condition it does not replace the need to
perform a dielectric withst and t est.
1.6.3. Ground Bond Test
The Ground Bonding test determines whether t he safety ground circuit of the product under
test can adequately handle fault current if the product should ever become defective. A low
impedance ground system is critical in ensuring that in case of a product failure, a circuit
breaker on the input line will act quick ly to protect the user from any serious electrical shock.
International compliance agencies such as CSA, IEC, TÜV, VDE, BABT and others, have
requirements calling out this test. This test should not be confused with low current continuity
tests that are also commonly called out in some safety agency specifications. A low current
test merely indicates that there is a safety ground connection. It does not completely test the
integrity of that co nnect ion.
11
Compliance agency requirements vary on how different products are to be tested. Most
specifications call for test currents of between 10 and 30 amps. Test voltages at these currents
are typically required to be less than 12 volts. Maximum allowable resistance readings of the
safety ground circuit are normally between 100 and 200 milliohms.
If you are testing a product that is terminat ed in a three-prong plug, you are required to perform
a continuity or ground bond test on the ground conductor to the chassis or dead metal of the
product.
1.6.4. Run Test
All manufacturers of a product that runs o n line power normally need to run the DUT (Device
Under Te st) aft e r final sa fety testing so that the y can ve rify the functionality o f their produ cts.
In addition to running the DUT to test its basic functionality many customers also require some
basic test data to be recorded while the DUT is powered up. A Run Test Syste m allows the
product to be powered up immediately after the safety tests are completed with a single
connection to the DUT. Measurements that are commo nly made while the DUT is running can
include Amperage, Voltage, Watts and Power Factor.
1.6.5. Line Leakage Test
The Line Leakage test is one of many product safety tests that are normally specified for
electrical products by safety testing agencies such as Underwriters Laboratories (UL) and the
International Electrotechnical Committee (I EC). The line leakage specif ications vary as well
as the method in w hich the measurements are taken depending upon the application or function
of a product and the standard to which the product is being tested.
Current Leakage or Line Leakage t ests are general terms that actually descr ibe three d ifferent
types of tests. These tests are Earth Leakage Current, Enclosure Leakage Curr ent , and Applied
Part Leakage Current. The main differe nces in t hese tests are in the placement of the probe for
the measuring device. The Earth Leakage Current is the le akage current that flows through the
ground conductor in the line cor d back to earth. The Enclosure Leakage Current is the current
that flows from any enclosure part through a person back to ground if it were contacted by a
person. The Applied Part Leakage Current or Patient Lead Leakage Current is any leakage that
flows from an applied part, between applied parts or into an applied part. The Applied Part
Leakage Current test is required only for medical equipment. All of these tests are used to
determine if products can be safely operated or handled without posing a shock hazard to the
user.
Line Leakage Testers provide the capability of meeting the line leakage test specified in the
following standards; UL 544, IEC 950, UL 1950, IEC 601-1, UL 2601, UL 1563, UL 3101,
IEC 1010 and others. The Line Leakage test, is a test which measures the leakage current of a
product, through a circuit that is designed to simulate the impedance of the human body. The
simulation circuit is called the Measur ing Dev ice (MD). The instrument has five different MD
circuits, selectable through the menu, which are representative circuits designed to simulate the
impedance of the human body under different conditions. The impedance of the human body
will vary depending upon point of contact, the surface area of the contact and the path the
current flows. For these reasons, the specifications of the Measuring Devices are different
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depending upon the type of test being performed as well as t he maximum allowable leakage
current. Leakage current measurements are performed on products under normal conditions
and single fault conditions as well as reversed polarity. This simulates possible problems,
which could occur if the product under test is fau lted or misused while the product is operating
under high line conditions (110% of the highest input voltage rating of the product).
Line Leakage tests are normally specified as “Type Tests” or “Design Tests” which are
performed during the develo pment of the product. This helps verify that the design is safe but
it does not guarantee the safety of the products being produced on the production line. The
only way to be sure you are shipping safe products is to test each product at the end of the
production line. The user may perform a Leakage Current test along with other common safet y
test such as Dielectric Withstand, Insulation Resistance, and Ground Bond on the production
line with a single connection to the device under test.
IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION OF
YOUR INSTRUMENT CALL 1-800-858-TEST(8378) IN THE U.S.A.
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1.7. Key Features and Benefits: HYPOT III
The first manual safety testing
instrument with an enhanced
graphic LCD display.
Exclusive SmartGFI function
Storage of up to 10 setups with 3
steps per setup
Line and Load regulation
This provides the operator with complete test setup and
results in an easy-to-use interface. This eliminates the
need to decipher cryptic abbre viations. The graphic
display makes test ing safer, easier and more reliable
tha n ever befo re.
The SmartGFI (patent pending) provides maximum
operator protection to the user. If the circuit detects
excessive leakage to ground, it shuts down the high
voltage in less than 1 millisecond. SmartGFI is
automat ically activated if the DUT is not grounded.
The operator does not need to make the decision
whether to activate t he SmartGFI.
A real benefit for manufacturers that test different
products. Each setup can store up to 3 steps, which can
be configured to perform any of the safety tests. Tests
can be link ed and run in any o rder.
Maintains the output voltage to within 1% of setting
even if the load or the line voltage varies. This ensures
that the test results remain consistent and within safety
agency requirements.
Digitally controlled arc detection
system
No load setup of trip current and
output voltage
TUV & UL listing
Automatic storage of test
program
All parameters for the setups
can be adjusted through a
simple menu driven program
Tamper proof front panel
controls
Allows the operator to select whether low-level arcs
should be detected and provides the operator wit h the
ability to digitally s el ect a n d p rogra m multiple
sens it iv ity leve ls.
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.
This assures you that this instrument meets or exceeds
safety requirements to ensure operator safety.
Hypot III powers up with the parameters that were used
during the last test to avoid operator set-up errors.
The easy to follow setup screens ensure that the
operator corr ectly sets up all test parameters.
This makes it possible to limit user access to the setup
screens so that on ly authorized per son nel wit h a
security code can change test parameters.
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The Graphic display allows
monitoring of current down to 1
microamps AC and DC
Electronic dwell settings
PLC remote inputs and outputs
Maximum output current 20
milliamps AC and 7.5 milliamps
DC
Software calibration control
User selectable output voltage
frequencies of 50 or 60 hertz
Output voltage fine adjustment
Built-in adjustable Continuity
test mode
Flashing high voltage indicator
This allow s the Hypot III to be used even when test
requirements on ly allo w a very low level of acce ptable
leakage current.
The electronic dwell control helps keep test result s
consistent by ensuring that the test duration is the same
for each product tested.
The standard 9 pin interfaces provide output s for Pass,
Fail, Reset and Test in Process. Inputs include Test,
Interlock and Reset. R emote reca ll of memory pr ogr am
#1, #2 and #3. This gives the user all the basic remotes
required to configure the Hypot III through simple PLC
relay c ontr ol.
This makes this instr ument a true hipot tester with
enough output current to test capacitive loads in AC
mode and allows the instrument to comply with the UL
“120 K ohm” requirements.
Hypot III is calibrated through the front panel keypad.
All calibr a tio n in fo rmation is sto red in no n-volatile
memory. This allows Hypot III to be completely
calibra ted without removing any covers a nd expos ing
the technician to hazardous voltages.
Hypot III was designed for the global market. This
feature makes it simple for the user to select the output
frequency in the AC hipo t mode so that products can
be tested at the same frequency they will be used at.
To make Hypot III usable in all types of applications,
the operator can manually bring the voltage up or down
in 10 volt incre ments by simply pressing the up and
down arrow keys. This makes it very easy to adjust the
output voltage even while Hypot III is in the dwell
mode so you can analyze test results at different
voltages.
Hypot III meets ground continu it y test requirements
called out by UL and other safety agencies.
A flashing LED lo cated directly over the high voltage
terminal cle arly indic ates w hen hig h voltage is active
to provide maximum operator safety.
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Comes complete with a test box
for products terminated in a line
cord
User selectable input voltage
Low-current sense
Electronic ramping (up & down)
The standard US style receptacle box allows easy
testing of hipot and continuity on line cord terminated
produ cts. As a n add itio nal benefit, termina tion bo xes
are available for testing products with line cords
configured for other countries.
Hypot III can be switched for either 115 or 230 volt
input operation through an easy access rear panel
mounted switch to allow it to be used in any country.
Monitors the minimum level of current flow, thus
ensuring that the DUT is properly connected and that
the hipot test is being perfo rmed.
Provides a gradual and timed method to increase or
decrease output voltage to the DUT, minimizing any
damage from quick hig h voltage changes to sensitive
DUTs.
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2. Getting Started
Introduction
This section contains information for the unpacking, inspection, preparation for use and stor age
of your Associated Research, Inc., product.
2.1. U npac king and Inspecti on
2.1.1. Packaging
Your instrument was shipped in a custom foam insulated container t hat 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 suc h as dents,
scratches or broken display. If the instrument is damaged, notify the carrier and Associated
Research’s customer support department. Please save the shipping carton and packing material
for the carriers inspection. Our customer support department will assist you in the repair or
replacement of your instrument. Please do not return your product without first notifying us
and receiving an RMA (ret urn material authorization) number. To receive an RMA number,
please contact our customer support department at (1-800-858-8378).
• Please retain all of the original packaging materials.
2.1.2. Contents of the Carton
Inside the carton should be the following:
Description AR Part Number
Hypot III Instrument 36XX
High Voltage Cable 04040A-08
Return Cable 02100A-13 (Qty. 2)
Fuse 37880, 3.15 Amp, fast acting
250VAC
Line Cord* 33189 Standard
Adapter Box* 36544 Standard
*The Adapter Box and Line Cord listed are American. Other combinations of Line Cord and
Adapter Box are available upon request.
2.1.3. Returning the Instrument
When it is necessary to return the instrument for servicing or calibration, repackage the
instrument in its original container, please include all accessor ies and test leads. Indicate the
nature of the problem or type o f service needed. Also, please mark the container “FRAGILE”
to insure proper hand ling. Upon receipt, your instrument will be issued an AR service number.
Please refer to this number in all correspondence.
If you do not have the original packaging materials, please follow these guidelines:
• Wrap the instrument in a bubble pack or similar foam. Enclose the same informat ion as
above.
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