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.

Symbol	!	IEC417
		on equipment signifies that the manual contains

information to prevent injury or equipment damage

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

uadTech

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
			• 0.1 to 6 KV DC, in 10V/steps
	Accuracy:		+/- (1% of reading + 5 counts)
Breakdown:	Regulation: <1% + 5V, rated load
	Detection: • Imax: 0.3 - 40mA AC, 0.3 - 20mA DC
Leakage Current:			• ∆I: 0.5 to 40mA, ≤ 20µsec
	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
Accuracy:	Test Voltage: 100 - 1000V DC
	Measurement: +/- 5% ≥ 500V, 10MΩ - 1GΩ
			+/- 15% ≥ 500V, 1GΩ - 10GΩ
			+/- 10%<500V, 1 - 200MΩ
			+/- 15%<200V, 200MΩ - 1GΩ
Measure Time:	Voltage:		+/- (1% of setting + 5 counts)
	0.1 - 999sec (+/-20ms)
Limit Delay:	0.3 - 99.9sec (+/-20ms)

Voltage

1000V

500V	Specification Range

100V

Resistance

10M > 20M> 50M >

500M> 1G > 2G >

vi

		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)
Resistance:	Frequency: 50 or 60Hz, 6 to 15V
	Range:	0 - 500.0mΩ, 4 digits, Hi Limit
Offset Function:	Accuracy: +/- (1% of reading + 3 counts)
	0 to 100mohm offset, user selectable
Test Time:	0.5 - 999sec (+/-20ms)

Current

30A

Specification Range

10A

1A

Resistance

10m >	100m >		150m >			500m >
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%
Power:	Storage: - 10 to + 60o C
	• 115 V/230V +/- 10%			• 47 - 63Hz		• 650W max
Supplied:	•	Instruction Manual		•	Power Cable
	•	Calibration Certificate		•	Test Leads
Ordering	Description					Catalog No.
Information:	AC/DC/IR/GC Safety Analyzer					Guardian 5000

vii

Section 1

Introduction

1.1Unpacking 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.

1.2Product 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

1.3Front 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.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

26

25 24

23

22

21

20

19

18

17

Figure 1-2

Front Panel Controls & Indicators

Introduction 1-2

		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.

2Mode RΩ/W-ACV W-DCV/IR

Light indicates that tester is in Ground Continuity, AC Hipot, DC Hipot or Insulation Resistance mode status.

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

11Limit/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
Fig 1-2		Front Panel Controls and Indicators (continued)
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	or DOWN		to change status status
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.

Introduction 1-5

1.4Rear Panel Description

1

2

3

4

5

6

7

Figure 1-3

Rear Panel View

Table 1-2

Fig 1-3

Rear Panel Connectors and Controls

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

1.7Power 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

2.1Startup

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.

2.2Instrument 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	R >	OFSt		A	HI	GEt		m >		TIMER	SEC
			DC						G>
1	W-ACV			V	ARC			M >		RAMP 5.0
	W-DCV		AC	KV	LO			uA	mA	TEST
	I-R
		RMT LOCK		OFFSET		HI-NG	LO-NG	ARC-NG	PASS
											Offset Key
OFF ON		7	8	9	PROG		RCL
	STOP START
		4	5	6	DELE		STO
		1	2	3	CLEAR OFFSET				CURSOR

0. OFF ENTER

•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:

Display current = (current read)2 −(offset current)2

For DC offset or AC offset current ≥ 80µA:

Display current = (current read) - (offset current)

Operation 2-2

2.3Connection 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
			Shorted
UNKNOWN	Alligator Clip Lead		Together
HIGH LOW
	(Red)
SENSE WV
DRIVER	With Retaining Bracket	Device Under
		Test	(DUT)
	Alligator Clip Lead
	(Black)

Figure 2-1 Connection for Hipot/IR Test (Using S02 Two Lead Test Set)

Operation 2-3