Quadtech Guardian 5000 User Manual

Guardian 5000

AC/DC/IR/GC Safety Analyzer

Instruction Manual

Form 150206/B3

©QuadTech, Inc., 1996

5 Clock Tower Place, 210 East

Maynard, Massachusetts, U.S.A. 01754-2530

November, 1999

Tel. [phone]

800-253-1230 (Sales & Service)

Fax. [phone]

Email: [e-mail]

Web site: http://www.quadtech.com

The material in this manual is for informational purposes only and is subject to change,
without notice. QuadTech assumes no responsibility for any error or for consequential
damages that may result from the misinterpretation of any procedures in this publication.

IEC417

Symbol
information to prevent injury or equipment damage

!

on equipment signifies that the manual contains

ii

Contents

Warranty ...........................................................................................................v

Specifications ...........................................................................................................vii

Introduction - Section 1

1.1 Unpacking and Inspection.............................................................................1-1

1.1 Product Overview..........................................................................................1-1

1.3 Front Panel Description.................................................................................1-2

1.4 Rear Panel Description..................................................................................1-6

1.5 Accessories Included.....................................................................................1-7

1.6 Accessories/Options Available......................................................................1-7

1.7 Power Requirements......................................................................................1-8

Operation - Section 2

2.1 Startup ...........................................................................................................2-1

2.2 Instrument Zeroing/Offset.............................................................................2-1

2.3 Connection to Device Under Test .................................................................2-3

2.4 Measurement Procedure................................................................................2-6

2.5 Programming Test Modes .............................................................................2-8

2.6 Programming Hipot Test...............................................................................2-10

2.7 Programming Insulation Resistance (IR) Test ..............................................2-12

2.8 Programming Ground Continuity Test..........................................................2-14

2.9 Initial Parameter Setting................................................................................2-16

2.10 Front Panel Lockout......................................................................................2-18

2.11 Software Version Display..............................................................................2-18

2.12 Clear Setup Memory......................................................................................2-18

Input/Output Interfaces - Section 3

3.1 Remote...........................................................................................................3-1

3.2 IEEE-488 Interface........................................................................................3-3

3.2.1 Description ........................................................................................3-3

3.2.2 Interface Commands..........................................................................3-4

3.2.2.1 Listener Functions..............................................................3-5

3.3.2.2 Talker Functions....................................................................3-9

3.2.3 Sample QuickBASIC Program..........................................................3-11

3.3 Scanner Interface...........................................................................................3-14

3.3.1 Scanner Accessories..........................................................................3-14

3.3.2 Scanner Card Installation ..................................................................3-14

3.3.3 Scanner Connections.........................................................................3-15

3.3.4 Scanner Programming.......................................................................3-17

3.4 G16 International Power Strip.......................................................................3-19

iii

Contents Continued

Maintenance/Calibration - Section 4

4.1 General ..........................................................................................................4-1

4.2 Instrument Return..........................................................................................4-1

4.3 Calibration.....................................................................................................4-1

4.3.1 Calibration Procedure........................................................................4-2

4.3.2 AC Voltage Calibration.....................................................................4-3

4.3.3 DC Voltage Calibration.....................................................................4-4

4.3.4 IR Voltage Calibration ......................................................................4-4

4.3.5 AC Current Calibration .....................................................................4-5

4.3.6 DC Current Calibration .....................................................................4-6

4.3.7 GC Calibration...................................................................................4-7

4.3.8 Finalize Calibration...........................................................................4-8

iv

Warranty

echuad

T

QuadTech warrants that Products are free from defects in material and workmanship and,
when properly used, will perform in accordance with QuadTech's applicable published
specifications. If within one (1) year after original shipment it is found not to meet this
standard, it will be repaired, or at the option of QuadTech, replaced at no charge when
returned to a QuadTech service facility.

Changes in the Product not approved by QuadTech shall void this warranty.

QuadTech shall not be liable for any indirect, special or consequential damages, even if
notice has been given of the possibility of such damages.

This warranty is in lieu of all other warranties, expressed or implied, including, but not
limited to any implied warranty or merchantability or fitness for a particular purpose.

SERVICE POLICY

QuadTech policy is to maintain product repair capability for a period of at least five (5) years

after original shipment and to make this capability available at the then prevailing schedule of

charges.

v

Specifications

Dielectric Strength
Output Voltage: Range: • 0.1 to 5 KV AC, in 10V/steps, 50 - 600Hz

Accuracy: +/- (1% of reading + 5 counts)
Regulation: <1% + 5V, rated load

Breakdown: Detection:

Leakage Current: Accuracy: +/- (1.5% + 5 counts), unspecified 0.01 - 0.3mA

Test Time: Ramp: 0.1 to 99.9sec (+/-20ms)
Hold: 0.1 to 999sec (+/-20ms)

Insulation Resistance

Measurements: Range: 10MΩ - 10GΩ
Test Voltage: 100 - 1000V DC
Accuracy: Measurement: +/- 5% ≥ 500V, 10MΩ - 1GΩ
+/- 15% ≥ 500V, 1GΩ - 10GΩ
+/- 10%<500V, 1 - 200MΩ
+/- 15%<200V, 200MΩ - 1GΩ
Voltage: +/- (1% of setting + 5 counts)

Measure Time: 0.1 - 999sec (+/-20ms)
Limit Delay: 0.3 - 99.9sec (+/-20ms)

Voltage

• 0.1 to 6 KV DC, in 10V/steps

• Imax: 0.3 - 40mA AC, 0.3 - 20mA DC

• ∆I: 0.5 to 40mA, ≤ 20µsec

1000V

500V

100V

vi

10M>

20M 50M>>

Specification Range

Resistance

>>>500M 1G 2G

Specifications Continued

Ground Continuity

Output Current:Range: 1.0 to 30.0A AC, setting 0.1A/step

Accuracy: +/- (1% of setting + 0.3A)
+/- (1% of reading + 3 counts)
Frequency: 50 or 60Hz, 6 to 15V
Resistance: Range: 0 - 500.0mΩ, 4 digits, Hi Limit
Accuracy: +/- (1% of reading + 3 counts)
Offset Function: 0 to 100mohm offset, user selectable

Test Time: 0.5 - 999sec (+/-20ms)

Current

30A

Specification Range

10A

1A

Resistance

>> >>

100m 150m

500m10m

General

Safety Features: Fast Cutoff (<0.4msec), Fast Discharge, Panel Lock
Setup Storage: 50 Memory Groups
Remote Control: Remote start & reset, Go/NoGo output, IEEE-488 Intf.
Pass/Fail: Display indication & alarm
Mechanical: Bench mount

Dimensions: (w x h x d):17x8.5x22in (430x215x550mm)
Weight: 50 lbs (23kg) net, 60 lbs (27kg) shipping

Environmental: Meets MIL-T-28800E, Type 3, Class 5
Operating: 0 to + 45o C
Humidity: <75%
Storage: - 10 to + 60o C
Power:

• 115 V/230V +/- 10% • 47 - 63Hz • 650W max

Supplied: • Instruction Manual • Power Cable

• Calibration Certificate • Test Leads

Ordering
Information:

Description Catalog No.
AC/DC/IR/GC Safety Analyzer Guardian 5000

vii

Section 1 Introduction

1.1 Unpacking and Inspection

Inspect the shipping carton before opening, if damaged contact the carriers agent
immediately. Inspect the instrument for any damage. If the instrument appears damaged or
fails to meet specifications notify QuadTech (refer to instruction manual front cover) or its
local representative. Retain the shipping carton and packing material for future use such as
returning for recalibration or service.

1.2 Product Overview

The Guardian 5000 Safety Analyzer combines four critical safety tests into a single
instrument, these being AC hipot, DC hipot, insulation resistance measurements and
ground continuity test. The hipot test can be programmed over a voltage range of 0.1 to
5KV AC and 0.5 to 6KV DC with a min/max leakage current detection range of 300µA to
40mA AC and 20mA DC. Insulation resistance measurements are possible to 10GΩ at
programmable DC test voltages between 100 and 1000V. A ground continuity test to 30A
AC is also possible. The instrument comes standard with internal storage of up to 50 memory
groups and an IEEE-488.2 interface for remote control operation and communication with
other instrumentation.

Figure 1-1

Guardian 5000

Introduction 1-1

1.3 Front Panel Description

Figure 1-2 shows the controls and indicators on the front panel of the Guardian 5000. Table
1-1 identifies them with descriptions and functions.

12345 678 9 10 11 12 13 14 15 16

Introduction 1-2

Figure 1-2

Front Panel Controls & Indicators

17181920212223242526

Table 1-1

Front Panel Controls and Indicators

Fig 1-2
Ref. # Item Function

1 Step Display indicates step number selected in the auto test sequence
(1 to 15). Indicates memory group number (1 to 50) when RCL
(recall) or STO (store) is selected.

2 Mode Light indicates that tester is in Ground Continuity, AC Hipot,
RΩ/W-ACV DC Hipot or Insulation Resistance mode status.
W-DCV/IR

3 RMT Light indicates when instrument is in remote mode.
Indicator

4 Voltage or Display shows voltage/voltage setting value when test is not in
Current process and shows output voltage/current when test is in process.
Display 0.1 - 5KV for AC Hipot, 0.5 - 6KV for DC Hipot,
100 - 1000V for IR, and 1.0 - 30.0A for GC,

5 LOCK Light indicates when instrument front panel keys are locked
Indicator

6 Display Units Indicates the units for the current/voltage display (AC or DC, A,
KV for hipot, V for IR or A for GC)

7 OFFSET Light indicates when instrument offset function is enabled.
Indicator

8 Limit Indicates the function of the limit shown on the Limit Display
Indicator (HI, LO, or ARC)

9 Limit/Measure Display shows limit setting when test is not in process and
shows measured value when test is in process.

10 Result Lights indicate test results based on set limits.
Indicators HI NG - Measured value exceeded high limit
LO NG - Measured value less than low limit
ARC NG - Measured value exceeded arc limit
PASS - Measured value is good based on all set limits

Introduction 1-3

Table 1-1

Front Panel Controls and Indicators (continued)

Fig 1-2
Ref. # Item Function

11 Limit/Measure Indicates the units for the entered limits or the measured display
Display Units (mA for hipot, MΩ for IR or mΩ for GC)

12 Timer Indicates when test time shown is RAMP time
Indicator

13 CAL For use by qualified service personnel during instrument
ENABLE calibration.

14 Timer Display shows set time or time countdown when test is in
Display process. A test time of 0 (zero) places the instrument in a
continuous measure mode.

15 TEST ON When indicator light is blinking high voltage is present on the
Indicator output terminals.

16 HIGH High voltage output terminal (Hipot or Insulation Resistance
VOLTAGE tests)

17 LOW SENSE Low potential terminal (SENSE) for Ground Continuity test.

18 LOW Ground reference terminal for all tests
DRIVER

19 HIGH SENSE High potential terminal (SENSE) for Ground Continuity test.

20 HIGH High current terminals (DRIVER) for Ground Continuity test.
DRIVER

21 BUZZER Audible output for pass/fail results.

Introduction 1-4

Table 1-1

Front Panel Controls and Indicators (continued)
Fig 1-2
Ref. # Item Function

22 CURSOR Under STOP status:
keys UP or DOWN to examine 1 - 15 steps
Under Hipot test On:
UP or DOWN to increase or decrease test voltage in
continuous mode
Under PROG status:

LEFT or RIGHT to select parameter for programming
UP

23 Data Entry [0] [.] .....[9] Numerical keys to input test parameters

Keys [OFF] For turning off test parameters (limits, arc, etc.)
[PROG] To enter and exit parameter setting status
[DELE] To delete a test step, those below move up
[CLEAR] To cancel parameter number and input again
[ENTER] Press to confirm enter parameter
[RCL] Recalls stored parameters (1 - 50) from memory
[STO] Stores parameter (1 - 50) into memory
[OFFSET] Initiates zeroing offset function

24 START Pressing this button starts a test and applies high voltage/current
button to the test terminals.

25 STOP Pressing this button stops a test in process and must be pressed
button as a reset function before a test can be started (after a failed test
or after test conditions have been reprogrammed).

26 OFF/ON Applies AC power to the tester, 0 is off, 1 is on.

or DOWN to change status status

Introduction 1-5

1.4 Rear Panel Description

12 3 456 7

Figure 1-3

Rear Panel View

Table 1-2

Rear Panel Connectors and Controls
Fig 1-3
Ref. # Item Function

1 IEEE Input/output connections according to IEEE
STD-488.2. 24 pin socket for standard
IEEE-488 cable. Refer to paragraph 3.2

2 SCAN Input/output scanner interface for QuadTech 5000-01 or 5000-02
Multiport Scanner Matrix. Refer to Paragraph 3.3.

3 Voltage Switches for selecting range of AC power source
Selector - Set to 100V position for 90 - 100VAC operation

- Set to 120V position for 110 - 130VAC operation

- Set to 220V position for 200 - 240VAC operation

- Set to 240V position for 220 - 250VAC operation

!

4

AC Inlet Fuse drawer and 3-wire connection for AC power source. Module

Contains 7A, 250V, 5x20mm fuse for 90-130V operation or

3.5A, 250V, 5x20mm fuse for 200-250V operation
5 SIGNAL Contact closures for test in process, test results good, and test

OUTPUT results no good. Maximum contact rating is 115V at 0.3A.
6 Ground Chassis ground connection
7 Fan Temperature control fan

- on for > 50oC

- off for < 45oC

Introduction 1-6

1.5 Accessories Included

Table 1-3
Item Quantity

Instruction Manual 1
Calibration Certificate 1
Power Cord 1
Power Line Fuse, 7A 2
S02, Test Lead Set, Hipot (1 red, 1 black, with alligator clips) 1
G15, Test Lead Set, GC (1 red, 1 black, with spring clips) 1
G14, Test Lead Set, Hipot (115V Receptacle) 1

1.6 Accessories/Options Available

Table 1-4
Item Part Number

Multiport Scanner Matrix (8 channel high V) 5000-01
Multiport Scanner Matrix (8 channel high V, 4 GC) 5000-02
Multiport Scanner Matrix, rack (8 channel high V) 5000-03
Multiport Scanner Matrix, rack (8 channel high V, 4 GC) 5000-04

High Voltage Lead Set, high & low, 1m (std w/unit) S02
High Voltage Lead Set, high & low, 2m S04
Foot Switch S05
High Voltage Probe S06
Gun Probe S08
High Voltage Lead, 1 meter, unterminated S09
High Voltage Lead, 2 meters, unterminated S10
Gun Probe with remote start S11
Load Box, resistive S12
Load Box custom resistors S14
Corded Product Adaptor G13
Power Entry Adaptor Cable, GC (std w/unit) G14
Ground Continuity Lead Set (std w/unit) G15
International Power Strip G16
Rear Panel Connection (factory installed) G22
Rack Mount Flanges (factory installed) G23
Corded Product Adaptor (240V) G25
RS232 Interface G26

Introduction 1-7

1.7 Power Requirements

!

The Guardian 5000 can be operated from a power source of 90 to 130 VAC or 200 to

250 VAC. Power connection is via the rear panel through a standard receptacle. Before
connecting the 3-wire power cord between the unit and AC power source make sure the
voltage selection switches on the rear panel (as indicated) and fuses are in accordance with
the power source being used. 7A, 250V, 5x20mm, for 90-130V source and 3.5A, 250V,
5x20mm, for 200-250V source. Always use an outlet which has a properly connected
protection ground.

To change the fuse proceed as follows:

WARNING

MAKE SURE THE UNIT HAS BEEN DISCONNECTED FROM ITS AC POWER

SOURCE FOR AT LEAST FIVE MINUTES BEFORE PROCEEDING.

Remove the fuse drawer, by inserting a flat head screwdriver behind the small tab located just
below the 3 prong receptacle, and force outward.

Once the fuse drawer has been removed from the instrument snap the fuse from the holder
and replace. Make sure the new fuse is of the proper rating. Note that the fuse drawer can
also be used to store a spare fuse.

Install the fuse drawer back in the inlet module (fuse down) by pushing in until it locks
securely in place.

Introduction 1-8

Section 2 Operation

2.1 Startup

Check to make sure the Voltage Selector Switch on the rear panel agrees with the power
source available (Depending on the power source the switch positions should be in the up or
down positions as shown).

WARNING

NEVER TOUCH THE TEST LEADS IN ANY MANNER (this includes insulation on all

wires and clips) WHEN THE HIGH VOLTAGE IS APPLIED AND RED DANGER

LIGHT ON.

USE ALL PRECAUTIONS NECESSARY TO AVOID TOUCHING THE DEVICE

UNDER TEST WHEN THE RED DANGER LIGHT IS ON OR BLINKING.

Connect the instrument power cord to the source of proper voltage. The instrument is to be
used only with three wire grounded outlets.

Power is applied to the Guardian 5000 by pressing the front panel POWER switch to ON (1
position).

WARNING

DO NOT TURN INSTRUMENT POWER ON OR OFF WITH TEST DEVICES CONNECTED.

2.2 Instrument Zeroing/Offset

The Guardian 5000 provides automatic zeroing/offset for lead or fixture effects. During the
zeroing/offset process a correction is made (subtracted out) as the result of lead leakage
current and stored in instrument memory to be applied to ongoing measurements. For
maximum measurement accuracy it is recommended that the unit be zeroed after power-up
and any time the test leads or fixture is changed (the offset is not saved under setup storage, 1

- 50 setups, but is saved on a power down and power back up. The instrument should

warm-up for at least 15 minutes before zeroing.

Operation 2-1

Proceed as follows for automatic zeroing/offset:

• Plug the appropriate cable (or other fixture) into the front panel OUTPUT connectors,

with no device connected. Refer to paragraph 2.3 for cable configurations based on test
to be made. Test leads used for an AC Hipot, DC Hipot or Insulation Resistance
measurement should be open and those leads used for the ground continuity measurement
be shorted together before performing the zeroing offset.

• With the instrument in the power-up state (or in any other desired setup, refer to

paragraph 2.4 for recalling setups) press the OFFSET key.

STEP

1

>R
W-ACV
W-DCV

I-R

A

HI

KV

OFSt

RMT LOCK OFFSET HI-NG LO-NG ARC-NG PASS

AC
DC

LO

GEt

ARC

V

>m
uA

M >

TIMER

mA

TEST

>G

RAMP

SEC

5.0

Offset Key

OFF ON

STOP START

7 8 9 PROG

45

1

0

6

23

.

CLEAROFFSET

OFF ENTER

RCL

STODELE

CURSOR

• Display should read OFSt and GEt. Push the START button to initiate the automatic

storage of the offset value for all tests within a sequence.

• The offset will remain on until turned off by pressing the OFFSET key twice. If the

instrument is powered down with the offset on it remains in effect when the unit is again
powered up.

The following formulas apply to the offset function:
For AC offset current < 80µA:

22

−

Display current = current read offset current

()( )

For DC offset or AC offset current ≥ 80µA:
Display current = (current read) - (offset current)

Operation 2-2

2.3 Connection to Device Under Test

Before connecting the device for test Press the STOP key and make sure the red DANGER
light is not on.

Depending on the test to be conducted (Hipot, IR or Ground Continuity) connect the test
cables to the front panel OUTPUT connectors. Refer to the following figures to determine the
correct configuration. When using the black cable, with the metal retaining bracket, make
sure it is locked behind the connector to prevent this cable from accidentally coming loose.

WARNING

NEVER TOUCH THE TEST LEADS OR THE DEVICE UNDER TEST WHEN THEY

ARE CONNECTED TO THE INSTRUMENT AND THE RED DANGER LIGHT IS

ON OR BLINKING.

HIGH-VOLTAGE

UNKNOWN

HIGH LOW

SENSE

DRIVER

Connection for Hipot/IR Test

(Using S02 Two Lead Test Set)

Alligator Clip Lead

(Red)

WV

With Retaining Bracket
Alligator Clip Lead

(Black)

Figure 2-1

Shorted
Together

Device Under
Test

(DUT)

Operation 2-3