Vanguard IRM-5000P User Manual

TM

IRM-5000P

INSULATION RESISTANCE METER

USER’S MANUAL

Vanguard Instruments Company, Inc.

1520 S. Hellman Ave.
Ontario, California 91761, USA

TEL: [phone]
FAX: [phone]

May 2010

Revision 2

IRM-5000P USER’S MANUAL REV 2

SAFETY SUMMARY

FOLLOW EXACT OPERATING PROCEDURES

Any deviation from the procedures described in this User’s Manual may create one or more
safety hazards, may damage the IRM-5000P, or cause errors in the test results. Vanguard
Instruments Company, Inc. assumes no liability for unsafe or improper use of the IRM-5000P.

All safety precautions provided in this manual must be observed during all phases of testing
including test preparation, test lead connection, actual testing, and test lead disconnection.

SAFETY WARNINGS AND CAUTIONS

All devices under test shall be off-line and fully isolated.

The area around the IRM-5000P’s charging circuits and test terminals must be kept clean and
dry to prevent high-voltage leakage paths which can cause hazardous conditions or erroneous
measurements. Failure to heed these precautions may result in unsafe operating conditions,
cause erroneous test results, and will void the manufacturer’s warranty.

DO NOT MODIFY TEST EQUIPMENT

To avoid the risk of introducing additional or unknown hazards, do not install substitute parts or
perform any unauthorized modification to any IRM-5000P test unit. To ensure that all designed
safety features are maintained, it is highly recommended that repairs be performed only by
Vanguard Instruments Company factory personnel or by an authorized repair service provider.
Unauthorized modifications can cause safety hazards and will void the manufacturer’s
warranty.

WARNING

Do not remove test leads during a test. Failure to heed this warning can result in electrical
shock to personnel and damage to the equipment.

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TABLE OF CONTENTS

CONVENTIONS USED IN THIS DOCUMENT ..................................................................................... 1

1.0 INTRODUCTION .................................................................................................................. .. 2

1.1 General Description and Features ................................................................................... 2

1.2 Furnished Accessories ...................................................................................................... 4

1.3 Technical Specifications ................................................................................................... 5

1.4 IRM-5000P Controls and Indicators ................................................................................. 6

2.0 PRE-TEST SETUP ................................................................................................................... 8

2.1 Operating Voltages .......................................................................................................... 8

2.2 LCD Screen Contrast Control ............................................................................................ 9

2.3 Printer Paper Control ....................................................................................................... 9

2.4 Printer Paper .................................................................................................................... 9

3.0 OPERATING PROCEDURES ................................................................................................. 11

3.1 Performing Tests ............................................................................................................ 11

3.1.1. Entering Test Record Header Information ............................................................. 11

3.1.2. Performing an Insulation Resistance Test .............................................................. 14

3.1.3. Performing a Polarization Index Ratio (PI) Test ..................................................... 22

3.1.4. Performing a Step Voltage (SV) Test ...................................................................... 28

3.1.5. Performing a Dielectric Discharge (DD) Test .......................................................... 34

3.2 Working With Test Records ........................................................................................... 40

3.2.1. Saving a Test Record ............................................................................................... 40

3.2.2. Restoring a Test Record From Flash EEPROM ........................................................ 41

3.2.3. Printing a Test Record from the Working Memory ................................................ 42

3.2.4. Printing a Directory of Test Records Stored in the IRM-5000P’s Memory ............ 44

3.2.5. Erasing Test Records From the Flash EEPROM ...................................................... 46

4.0 CHANGING SETUP PARAMETERS ....................................................................................... 48

4.1 Setting the Clock ............................................................................................................ 48

4.2 Setting the Frequency .................................................................................................... 49

4.3 Setting the Temperature Units of Measure ................................................................... 50

4.4 Enabling the Computer Interface .................................................................................. 51

APPENDIX A - DIELECTRIC DISCHARGE RATIO TEST DESCRIPTION ............................................... 52

APPENDIX B - GUARD TERMINAL APPLICATION ........................................................................... 53

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IRM-5000P USER’S MANUAL REV 2

LIST OF TABLES

Table 1. IRM-5000P Technical Specifications ................................................................................. 5

Table 2. Functional Descriptions of IRM-5000P Controls and Indicators ....................................... 7

Table 3. Voltage Selection Jumper Settings .................................................................................... 8

Table 4. PI Ratio Table ....................................................................................................... ............ 27

LIST OF FIGURES

Figure 1. IRM-5000P Controls and Indicators ................................................................................. 6

Figure 2. 100-120 Vac Jumper Settings ........................................................................................... 8

Figure 3. 200-240 Vac Jumper Settings ........................................................................................... 8

Figure 4. Resistance Test Results Report Printout ........................................................................ 20

Figure 5. Resistance Plot from a Resistance Test ......................................................................... 20

Figure 6. Current Plot from a Resistance Test .............................................................................. 21

Figure 7. Polarization Index Test Results Report Printout ............................................................ 26

Figure 8. Polarization Index Test Resistance Plot ......................................................................... 27

Figure 9. Polarization Index Test Current Plot .............................................................................. 27

Figure 10. Step Voltage Test Results Report Printout .................................................................. 32

Figure 11. Step Voltage Test Resistance and Current Plots .......................................................... 33

Figure 12. Dielectric Discharge Test Results Report Printout ....................................................... 37

Figure 13. Dielectric Discharge Test Resistance Plot .................................................................... 38

Figure 14. Dielectric Discharge Test Current Plot ......................................................................... 39

Figure 15. Typical Test Record Directory Printout ........................................................................ 45

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CONVENTIONS USED IN THIS DOCUMENT

This document uses the following conventions:

• A key or switch on the IRM-5000P is indicated as [KEY] and [SWITCH].

Menu options are referenced as (MENU OPTION).

•

Screen and menu names are referenced as “SCREEN/MENU NAME”.

•

The terms “test record” and “test shot” are used interchangeably.

•

• IRM-5000P LCD screen output is shown as:

1. OPTION 1

2. OPTION 2

3. OPTION 3

4. OPTION 4

• When instructions are provided, the menu item that should be selected is shown in bold as

shown below (option 3 should be selected):

1. OPTION 1

2. OPTION 2

3. OPTION 3

4. OPTION 4

• Warning messages are indicated as:

Warning message

WARNING

• Important notes are indicated as:

Note details

NOTE

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IRM-5000P USER’S MANUAL REV 2

1.0 INTRODUCTION

1.1 General Description and Features

The IRM-5000P is a microprocessor-based, high-voltage, insulation-test ohmmeter. The rugged
and portable IRM-5000P is ideal for use in electric utility substations and for industrial
applications.

This sophisticated insulation tester uses a dual-microprocessor design. One microprocessor is
dedicated to the control of the power supply and measuring circuitry, while the second is
dedicated to the user interfaces and printer control. To ensure operator safety, the
microprocessors communicate via an optical link, thus isolating the operator controls from the
dangerous high test voltages inside the unit.

The IRM-5000P measures the insulation resistance of a test material by applying a known test
voltage and measuring the resultant leakage current. The measured insulation resistance is
then displayed on the back-lit LCD screen. The IRM-5000P’s built-in 2.5-inch wide thermal
printer can print test reports in both tabular and graphic formats. Up to 100 test reports can be
stored in the unit’s internal memory. Test reports can also be transferred to a PC via the built-in
RS-232C interface. The IRM-5000P can automatically perform industry-standard tests such as
Polarization Index (PI) test, Step Voltage (ST) test, and Dielectric Discharge (DDS) test.

Test Voltage

The IRM-5000P can perform tests with preset voltages (500, 1000, 2500, 5000 Vdc), or with
user-selectable voltages ranging from 50 Vdc to 5000 Vdc with a ±2 Vdc resolution.

Insulation Resistance Test

The test voltage for an insulation resistance test can be user-selected, and the test duration can
range from 1 to 90 minutes. The IRM-5000P will then collect resistance readings throughout the
selected test period. The resistance value, test voltage, leakage current, and capacitance are
displayed on the back-lit LCD screen. The tabulated test report can be printed on the built-in

2.5-inch wide thermal printer. The report can also be printed as a graph of the resistance over
time.

Polarization Index (PI) Test

The Polarization Index (PI) measures the ratio of insulation resistance after one minute and
then after ten minutes. The Polarization Index is derived from a ratio of the two periods, where
the resistance value at ten minutes is divided by the resistance value at one minute.

PI tests can be run at preset voltages (500, 1000, 2500, 5000 Vdc) or at a user-specified voltage
from 50 Vdc to 5000 Vdc. Test results can be printed in both tabular and graphic formats.

Step Voltage (SV) Test

The Step Voltage test is based on an ideal insulator producing the same resistance
measurement at all voltages. As an example, an insulator that is over-stressed will measure
lower resistance values at higher voltages. Accordingly, the resistances measured on an over­stressed insulator at increasingly higher voltages (steps) will produce decreasingly lower
resistance values.

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The SV test measures insulation resistances in five equal voltage steps up to a final test voltage
of 2500 Vdc or 5000 Vdc. The voltage is stepped up in 1/5 increments of the final test voltage
every one minute, five minutes, or other user-defined time interval.

Dielectric Discharge (DDS) Test

The DDS test measures the dielectric absorption of an insulator. This test can be used to
diagnose an insulation problem in cases where multi-layered insulation is used. The default test
requires 30 minutes of applying full voltage followed by a one minute discharging of the Device
Under Test (DUT). The DD value is then calculated using the formula:

DD Ratio = Current after 1 minute (mA) / (Test Voltage X Capacitance)

Capacitor Discharge

After each test, the IRM-5000P automatically discharges any test voltage left on the test
material. An audible alarm and a message on the screen warn the operator of the shock hazard
during each discharging period.

Capacitance Display

The IRM-5000P automatically measures the capacitance of the device being tested. The
capacitance-measuring range is from 0.01 µF to 10.0 µF.

Volt Meter

The IRM-5000P can also be used to measure voltages. Measurable input voltage ranges from 50
V to 1250 V, AC or DC.

User Interface

The IRM-5000P features a back-lit LCD screen (20 characters by 4 lines) that is viewable in both
bright sunlight and low-light levels. A rugged, 16-key, membrane keypad is used to control the
unit.

Built-in Thermal Printer

The IRM-5000P’s built-in 2.5-inch wide thermal printer can print the test reports in both tabular
and graphic formats.

Internal Test Record Storage

The IRM-5000P can store up to 100 test records in Flash EEPROM. Test records can be retrieved
and printed on the built-in thermal printer, or they can be transferred to a PC via the unit’s RS­232C interface.

Computer Interface

The IRM-5000P can be computer-controlled via its RS-232C interface. A Windows® XP/Vista­based analysis software application is provided with each unit. Using this software, test records
can be retrieved from the IRM-5000P and then stored on the PC for future analysis and report
generation. A special feature of the software can overlay several resistance curves on-screen
and can be used to monitor the resistance deterioration of a test material over time.
Additionally, test records can be exported in Microsoft® Excel format for further analysis.

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IRM-5000P USER’S MANUAL REV 2

Temperature Probe

A non-contacting, infrared, temperature sensor is provided with each unit for recording test
material temperatures.

Power Source

The IRM-5000P can operate continually for up to 6-hours using its internal rechargeable SLA
batteries, or it can be operated with an external power source.

1.2 Furnished Accessories

The IRM-5000P comes furnished with the following:

• One 6-foot cable set

• One 15-foot cable set

• One RS-232C Cable

• One power cord

• Cable carrying duffel bag

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1.3 Technical Specifications

Table 1. IRM-5000P Technical Specifications

TYPE Insulation resistance meter

PHYSICAL SPECIFICATIONS 19”W x 7”H x 15”D, (48 cm x 17 cm x 38 cm); Weight: 24lbs (10.9 kg)

INPUT POWER 100 – 120 Vac or 220 – 240 Vac (selectable), 50/60Hz

RESISTANCE READING

RANGE

(0°C to +30°C)

TEST VOLTAGE Selectable from 50Vdc – 5 KVdc, in 2 Vdc steps

OUTPUT VOLTAGE

ACCURACY

(0°C to +30°C)

SHORT CIRCUIT CURRENT 2 mA max

CURRENT READING RANGE

(0°C to +30°C)

CAPACITANCE READING

RANGE

(0°C to +30°C)

VOLTAGE READING RANGE

(0°C to +30°C)

CAPACITOR DISCHARGE Less than 2 Sec/μF, automatic at the end of test

HUM REJECTION 1mA per 1kv of test voltage, 2mA rms maximum

BATTERIES Two 12V, 2.0 Ah sealed lead acid batteries. Battery life: typical 6 hrs,

PRINTER Built-in 2.5-inch wide thermal printer can print test results in both tabulated

COMPUTER INTERFACE One RS-232C port

INTERNAL TEST RECORD

STORAGE

SAFETY UL Certified (UL 61010A-1), CAN/CSA Certified (C22.2 No. 1010.1-92)

ENVIRONMENT Operating: -10˚ to 50˚ C (15˚ to +122˚ F); Storage: -30˚ C to 70˚ C (-22˚ to

HUMIDITY (MAX) 90% RH @ 40˚ C (104˚ F) non-condensing

ALTITUDE (MAX) 2000m (6562 ft) to fully safety specifications

CABLES One 6-foot cable set, one 15-foot cable set, ground cable, power cord, cable

OPTIONS

WARRANTY One year on parts and labor

100 K-ohms – 1 M-ohm ±20%,
1 M-ohm – 1 T-ohm ±5%,
1 T-ohm – 5 T-ohm ±20% , 5kV
100 K-ohms – 1 M-ohm ±20%,
1 M-ohm – 100 G-ohms ±5%,
100 G-ohms – 500 G-ohms ±5%, 500 V
1 M-ohm – 10 G-ohms ±5%, 50 V

±2%, ±1v of selected voltage with load resistance greater than 100 MΩ

0.03 nA – 2 mA; Accuracy: ±5% ±0.2 nA

0.01 μF – 10.0 μF (Test voltage greater than 100V); Accuracy: ±5% ±0.03 μF

50 – 1250 Vac (rms) or dc; Accuracy: ±5%, ±1V

continuous testing. The IRM-5000P can be used while charging.

and graphic formats

Store up to 100 test records in Flash EEPROM

+158˚ F)

bag

Transportation Case

The above specifications are valid at nominal operating voltage and at a
temperature of 25°C (77°F). Specifications may change without prior notice.

NOTE

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IRM-5000P USER’S MANUAL REV 2

1.4 IRM-5000P Controls and Indicators

The IRM-5000P’s controls and indicators are shown in Figure 1 below. A leader line with an
index number points to each control and indicator, which is cross-referenced to a functional
description in Table 2. The table describes the function of each item on the control panel. The
purpose of the controls and indicators may seem obvious, but users should become familiar
with them before using the IRM-5000P. Accidental misuse of the controls will usually cause no
serious harm. Users should also be familiar with the safety summary found on the front page of
this User’s Manual.

Figure 1. IRM-5000P Controls and Indicators

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Table 2. Functional Descriptions of IRM-5000P Controls and Indicators

Item

Number

1

2

3
4

5
6

7
8

9
10
11

Panel Markings Functional Description

RS-232C RS-232C PC interface.

110-120 Vac, 2A,

50-60Hz

Fuse: 250Vac, 3A

Fast-Blow

HIGH VOLTAGE

PRESENT

CHARGE Battery charging indicator.

Built-in 2.5-inch wide thermal printer.

POWER Power switch.

Rugged alpha-numeric keypad.

NEG Negative test lead terminal.

GUARD Guard test lead terminal.

POS Positive test lead terminal.

Power plug and fuse holder.

Test voltage presence indicator.

Back-lit LCD Screen (20 characters by 4 lines). Viewable in both bright sunlight
and low-light levels.

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IRM-5000P USER’S MANUAL REV 2

2.0 PRE-TEST SETUP

2.1 Operating Voltages

The IRM-5000P’s operating voltage is preset at the factory and is selectable between 100-120
Vac, 50/60 Hz or 200-240 Vac, 50/60 Hz. The voltage is set by placing jumpers at the JP16 and J1
jumper blocks on the main board as listed in Table 3 and illustrated in Figure 2 and Figure 3.

Table 3. Voltage Selection Jumper Settings

Voltage

Selection

100 – 120 Vac
200 – 240 Vac

JP16 Settings

Jumper Pin 1 and 2
Jumper Pin 3 and 4

Jumper Pin 2 and 3 Jumper Pin 2 and 3

Figure 2. 100-120 Vac Jumper Settings

J1 Settings

Jumper Pin 1 and 2
Jumper Pin 3 and 4

Figure 3. 200-240 Vac Jumper Settings

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2.2 LCD Screen Contrast Control

To increase the LCD screen contrast, press and hold the [PAPER ∧ Contrast] key for two
seconds. Release the button when the desired contrast level has been reached.

To decrease the LCD screen contrast, press and hold the [PAPER ∨ Contrast] key for two
seconds. Release the button when the desired contrast level has been reached.

2.3 Printer Paper Control

To advance the thermal printer paper, press and release the [PAPER ∧ Contrast] key.

To retract the thermal printer paper, press and release the [PAPER ∨ Contrast] key.

2.4 Printer Paper

The IRM-5000P’s built-in thermal printer uses 2.5-inch wide thermal paper for printing test
results. To maintain the highest print quality and to avoid paper jams, the use of thermal paper
supplied by Vanguard Instruments Company is highly recommended. Additional paper can be
ordered from the following sources:

Vanguard Instruments Co, Inc.

1520 S. Hellman Avenue
Ontario, CA 91761
Tel: [phone]
Fax: [phone]
Part Number: VIC TP-3 paper

BG Instrument Co.

13607 E. Trent Avenue
Spokane, WA 99216
Tel: [phone]
Fax: [phone]
Part Number: VIC TP-3 paper

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IRM-5000P USER’S MANUAL REV 2

2.5 Replacing the Thermal Printer Paper

The roll of thermal paper is housed inside a dispenser underneath the printer cover. To replace
the paper, follow the steps below:

• Unscrew the two large printer cover screws and remove the printer cover.

• Remove the leftover thermal paper roll from the paper holder.

• Unroll the new thermal paper roll.

• Feed the thermal paper into the slot between the paper pocket and the rubber roller.

The printer will automatically pull the paper under the thermal head.

• Place the paper roll into the paper holder.

• Lift the thermal head and align the thermal paper if necessary.

• Re-install the printer cover.

Thermal paper has a chemical coating on one side of the paper. This side should be
facing the thermal print head. Incorrect paper loading may result in blank output on

NOTE

the thermal paper.

The thermal paper will show a red stripe to indicate that the roll is about to run out
of paper.

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3.0 OPERATING PROCEDURES

3.1 Performing Tests

3.1.1. Entering Test Record Header Information

You can enter the test record header information before performing tests. The record header
includes identifying information such as company, location, test description, etc. Once the
header information has been entered, it will apply to all subsequent test records. To enter the
header information:

a. When the unit is turned on, you will be presented with the “START-UP” menu:

1. RUN TEST 05/05/10

2. UTILITIES 10:10:15
Bat:
TERMINAL VTG: 1 V

NOTES

• If the IRM-5000P is running on battery power, the battery icon will be

displayed on the LCD screen as shown above. The icon also represents the
charge level of the battery.

If the IRM-5000P is plugged in, a plug icon will be displayed on the LCD
screen as shown below:

1. RUN TEST 05/05/10

2. UTILITIES 10:10:15
Bat:
TERMINAL VTG: 1 V

• The test terminal voltage is displayed at the bottom of the LCD screen. The

IRM-5000P can be used as a voltmeter by connecting the positive and
negative leads to a voltage source. The voltage measurement range is
from 50-1250 V(AC/DC).

Press the [2] key (UTILITIES).

b. The following screen will be displayed:

1.PRINT 2.SAVE/RES

3.SETUP

TERMINAL VTG: 1 V

Press the [3] key (SETUP).

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c. The following screen will be displayed:

1.TEST ID 2.CLOCK

3.COMP INT 4.50/60Hz

5.°C/°F
TERMINAL VTG: 1 V

Press the [1] key (TEST ID).

d. The following screen will be displayed:

COMPANY
_
ENTER to Confirm
TERMINAL VTG: 1 V

Type the company name using the alpha-numeric keypad.

When pressing a key, the corresponding number on the key will be displayed first.
Pressing the key again will display the first letter on the key. Pressing the key again will
display the second letter on the key. For example, to type the letter “A”, you must press
the [2] key twice. To erase the character at the cursor position, press the [CLEAR] key.
Press the [PAPER ∧ Contrast] key to move to the next character. Press the [PAPER

∨ Contrast]

key to move to the previous character. Press the [ENTER] key when you

are done typing the company name.

IRM-5000P USER’S MANUAL REV 2

e. The following screen will be displayed:

LOCATION
_
ENTER to Confirm
TERMINAL VTG: 1 V

Type the location name using the alpha-numeric keypad and then press the
key.

f. The following screen will be displayed:

TEST DESCRIPTION
_
ENTER to Confirm
TERMINAL VTG: 1 V

Type the test description using the alpha-numeric keypad and then press the
key.

g. The following screen will be displayed:

[ENTER]

[ENTER]

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OPERATOR
_
ENTER to Confirm
TERMINAL VTG: 1 V

Type the operator’s name using the alpha-numeric keypad and then press the [ENTER]
key. All header information will be saved, and you will be returned to the “START-UP”
menu.

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IRM-5000P USER’S MANUAL REV 2

3.1.2. Performing an Insulation Resistance Test

The insulation resistance test measures the insulation resistance at selected voltages. Since the
insulation resistance is continuously monitored during each test, users can plot the resistance
or current values versus time. Use the steps below to perform an insulation resistance test:

a. Start from the “START-UP” menu:

1. RUN TEST 05/05/10

2. UTILITIES 10:10:15
Bat:
TERMINAL VTG: 1 V

Press the [1] key (RUN TEST).

If you had previously performed a test and had not saved the test results, the
following screen will be displayed:

NOTE

Test Not Saved!
“Enter” To continue

TERMINAL VTG: 1 V

Press the [ENTER] key if you do not want to save the results from the
previous test. Continue to step b.

Press any other key if you would like to save the results from the previous test.
You will be returned to the “START-UP” menu. Please see section 3.2.1 for
instructions on how to save test results to the IRM-5000P’s Flash EEPROM.

b. The following screen will be displayed:

1. R 2. PI

3. DD 4. SV

TERMINAL VTG: 1 V

Press the [1] key (R).

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