OPERATION AND SERVICE MANUAL

Hypot III

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
EN
EN
EN
EN

61326: 1997 + A1: 1998 Class A

61000-4-2: 1995, EN 61000-4-3: 1996,
61000-4-4: 1995, EN 61000-4-5: 1995,
61000-4-6: 1996, EN 61000-4-8: 1993,
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 device according to article 10
of the EMC Directive 8/336/EEC.
The technical file and other documentation are on file with
Associated Research, Inc.

______________________________
Joseph Guerriero
Vice President / General Manager
Associated Research, Inc.
Lake Forest, Illinois USA
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 National Institute 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 or call 1-800-858-TEST ext. 210 to register over the phone
5-Year Program
AR recommends that your instrument be calibrated on a twelve-month cycle. Instruments
purchased and used in North America only, may have their warranty 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 eligible for extended warranty status. This extended warranty 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 the customer. The return method will be at the discretion of Associated
Research.
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

Calls attention to a procedure, practice, or condition that could possibly cause

bodily injury or death.

CAUTION

Calls attention to a procedure, practice, or condition that could possibly

cause damage to equipment or permanent loss of data

1.3. Glossary of Terms

(As used in this manual)
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 to effectively prevent the flow of current sometimes evidenced 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 103 ohm-cm or a surface resistivity of no more than
105 ohms per square.

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 103 ohm-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 conductive materials.
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 1012 ohm-cm and is used
for the purpose of resisting current flow between conductors.

Insulation Resistance Tester: An instrument or a function of an instrument capable of measuring

resistances in excess of 200 megohms. Usually employs a higher voltage power supply than used in ohmmeters
measuring up to 200 megohms.

Leakage: AC or DC current flow through insulation and over its surfaces, and AC current flow through a
capacitance. Current flow is directly proportional to voltage. The insulation and/or capacitance is thought of as a
constant impedance, 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
performance during a run test.

Voltage: Electrical pressure, the force which causes current through an electrical conductor.
Symbol = V

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.

WARNING

A Hipot produces voltages and currents that can cause harmful or fatal
electric shock. To prevent accidental injury or death, these safety procedures
must be strictly observed when handling and using the test instrument.

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, Inc. authorized service center.
ASSOCIATED RESEARCH, INC.

13860 WEST LAUREL DRIVE

LAKE FOREST, IL 60045-4546 U.S.A.

(PHONE: 1 (847) 367-4077

1 (800) 858-TEST (8378)
FAX: 1 (847) 367-4080
E-MAIL : info@asresearch.com

www.asresearch.com
Service Interval
The instrument, its power cord, test leads, and accessories 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 operating condition at the customers
expense.

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 careful 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 tester 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 station should be arranged so that it can be shut off by one prominently
marked switch located at the entrance to the test area. In case of an emergency, anyone can cut
off the power before entering the test area to offer assistance.

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 directly connected to earth ground, 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 dangerous. If contacted it may
cause heart-related 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

Never perform a hipot test on energized circuitry or equipment.

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 certain that the operator has control over any
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.

1.4.5. Device Under Test

WARNING

Never touch the Device Under Test (DUT) or anything connected to it while
high voltage is being applied by the hipot.

When testing with DC, always discharge the capacitance of the item under test and anything
the high voltage may have contactedsuch as test fixturesbefore 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 probe tip to the same place where the high voltage lead was connected.
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 connections during a test.

In case of any problem, turn off the high voltage first.

Properly discharge any item tested with DC before touching connections.

1.5. Introduction to Product Safety Testing

1.5.1. The Importance of Safety Testing
Product Safety Tests are specified during the design and development 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 costs, 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), the International Electrotechnical
Commission (IEC), the British Standards Institution (BSI), the Association of German
Electrical Engineers (VDE) and (TV), 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 function
in normal operating circumstances.
Common Applications of the Dielectric Withstand Test:

Design (performance) testing: Determining design adequacy to meet service conditions.

Production Line testing: Detecting 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 duration of time.
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 thumbfor testing is to subject the product to twice its normal
operating voltage, plus 1,000 volts.
However, specific products may be tested at much higher voltages than 2X operating 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 higher. Most double insulatedproducts
are tested at voltages much higher than the rule of thumb.
Testing during development 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

Pinholes in Insulation

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 specifications 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 capacitance so it continually reads the reactive current that flows when AC
is applied to a capacitive load.

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 of stressing the insulation alternately in both polarities, which
more closely simulates stresses the product will see in real use.
Since AC testing cannot charge a capacitive 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 voltage 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 item 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, reactive current is constantly flowing. In many cases, the
reactive component of the current can be much greater than the real component due to actual
leakage. This can make it very difficult 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 item under test is charged. The same test item capacitance that
causes reactive current in AC testing results in initial charging current which exponentially
drops to zero in DC testing.
DC testing advantages
Once the item under test is fully charged, the only current flowing 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 testing 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 item the more slowly the
voltage must be raised. This is important since most DC hipots have failure shut off circuitry
10

which will indicate failure almost immediately if the total current reaches the leakage threshold
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 insulation in one polarity. 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 Resistance Test
Some dielectric analyzers today come with a built in insulation resistance tester. Typically,
the IR function provides test voltages 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, TV and VDE are agencies that may under certain conditions, require an
IR test on the product before a Hipot test is performed. This typically is not a production line
test but a performance design test.
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.
Typically, the higher the insulation resistance value the better the condition of the insulation.
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 any component resistance which might also be connected between the two points.
Although the IR test can be a predictor of insulation condition it does not replace the need to
perform a dielectric withstand test.
1.6.3. Ground Bond Test
The Ground Bonding test determines whether the 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 quickly to protect the user from any serious electrical shock.
International compliance agencies such as CSA, IEC, TV, 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 connection.
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 terminated 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 on line power normally need to run the DUT (Device
Under Test) after final safety testing so that they can verify the functionality of their products.
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 System allows the
product to be powered up immediately after the safety tests are completed with a single
connection to the DUT. Measurements that are commonly 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 (IEC). The line leakage specifications vary as well
as the method in which 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 tests are general terms that actually describe three different
types of tests. These tests are Earth Leakage Current, Enclosure Leakage Current, and Applied
Part Leakage Current. The main differences in these tests are in the placement of the probe for
the measuring device. The Earth Leakage Current is the leakage current that flows through the
ground conductor in the line cord 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 Measuring Device (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
12

depending upon the type of test being performed as well as the 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 faulted 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 Testsor Design Testswhich are
performed during the development 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 safety
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.

13

1.7. Key Features and Benefits: HYPOT III

The first manual safety testing
instrument with an enhanced
graphic LCD display.

This provides the operator with complete test setup and

results in an easy-to-use interface. This eliminates the
need to decipher cryptic abbreviations. The graphic
display makes testing safer, easier and more reliable
than ever before.

Exclusive SmartGFI function

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
automatically activated if the DUT is not grounded.
The operator does not need to make the decision
whether to activate the 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 linked and run in any order.

Storage of up to 10 setups with 3

steps per setup

Line and Load regulation

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

Allows the operator to select whether low-level arcs

should be detected and provides the operator with the
ability to digitally select and program multiple
sensitivity levels.

No load setup of trip current and This provides the operator with an easy and safe way to
set trip currents and output voltages since parameters
output voltage
are set without the high voltage activated.
TUV & UL listing

This assures you that this instrument meets or exceeds

safety requirements to ensure operator safety.

Automatic storage of test

program
All parameters for the setups
can be adjusted through a
simple menu driven program
Tamper proof front panel
controls

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 correctly sets up all test parameters.

14

This makes it possible to limit user access to the setup

screens so that only authorized personnel with a
security code can change test parameters.

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 allows the Hypot III to be used even when test

requirements only allow a very low level of acceptable
leakage current.
The electronic dwell control helps keep test results
consistent by ensuring that the test duration is the same
for each product tested.
The standard 9 pin interfaces provide outputs for Pass,
Fail, Reset and Test in Process. Inputs include Test,
Interlock and Reset. Remote recall of memory program
#1, #2 and #3. This gives the user all the basic remotes
required to configure the Hypot III through simple PLC
relay control.
This makes this instrument 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 ohmrequirements.
Hypot III is calibrated through the front panel keypad.
All calibration information is stored in non-volatile
memory. This allows Hypot III to be completely
calibrated without removing any covers and exposing
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 hipot 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 increments 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 continuity test requirements
called out by UL and other safety agencies.
A flashing LED located directly over the high voltage
terminal clearly indicates when high voltage is active
to provide maximum operator safety.

15

Comes complete with a test box

for products terminated in a line
cord

User selectable input voltage

Low-current sense

Electronic ramping (up & down)

16

The standard US style receptacle box allows easy

testing of hipot and continuity on line cord terminated
products. As an additional benefit, termination boxes
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 performed.
Provides a gradual and timed method to increase or
decrease output voltage to the DUT, minimizing any
damage from quick high voltage changes to sensitive
DUTs.

2. Getting Started
Introduction
This section contains information for the unpacking, inspection, preparation for use and storage
of your Associated Research, Inc., product.

2.1. Unpacking and Inspection

2.1.1. Packaging
Your instrument was shipped in a custom foam insulated container that 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 such as dents,
scratches or broken display. If the instrument is damaged, notify the carrier and Associated
Researchs 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 (return 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 accessories and test leads. Indicate the
nature of the problem or type of service needed. Also, please mark the container FRAGILE
to insure proper handling. 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 information as
above.

17

Use a strong double-wall container that is made for shipping instrumentation. 350-lb. test
material is adequate.

Use a layer of shock-absorbing material 70 to 100 mm (3 to 4 inch) thick around all sides
of the instrument. Protect the control panel with cardboard.

Seal the container securely.

Mark the container FRAGILEto insure proper handling.

Please refer in all correspondence to your AR service number.

2.2. Installation
2.2.1. Work Area
Locate a suitable testing area and be sure you have read all safety instructions
WARNING for the operation of the instrument and suggestions on the test area set-up in
the Safety section. Make sure the work area you choose has a three-prong
grounded outlet. Be sure the outlet has been tested for proper wiring before connecting the
instrument to it.
2.2.2. Power Requirements
This instrument requires a power source of either 115 volts AC 10%, 50/60 Hz single phase
or 230 volts AC 10%, 50/60 Hz single phase. Please check the rear panel to be sure the
proper switch setting is selected for your line voltage requirements before turning your
instrument on. For operation at 115 and 230 Volts AC use a 3.15 Amp, fast acting 250VAC.

CAUTION

Do not switch the line voltage selector switch located on the rear panel while
the instrument is on or operating. This may cause internal damage and
represents a safety risk to the operator.

2.2.3. Basic Connections

Power Cable
Before connecting power to this instrument, the protective ground (Earth)
terminals of this instrument must be connected to the protective conductor of
the line (mains) power cord. The main plug shall only be inserted in a socket
outlet (receptacle) provided with a protective ground (earth) contact. This protective ground
(earth) must not be defeated by the use of an extension cord without a protective conductor
(grounding).
WARNING

The instrument is shipped with a three-wire power cable. When the cable is connected to an
appropriate AC power source, the cable will connect the chassis to earth ground. The type of
power cable shipped with each instrument depends on the country of destination.

18

Return Connection
The output power supplies of this instrument are referenced directly to earth
CAUTION
ground. Any conductor that completes a path between the high voltage and
earth ground will form a completed circuit.
When the instrument Return is grounded, any internal and external stray leakage will be
monitored due to currents that flow from High Voltage to earth ground (such as from HV to
the chassis of the instrument). This current is inherent and will cause errors when trying to
monitor very low leakage currents in the micoamp range.
2.2.4. Environmental Conditions
This equipment is intended for indoor use only. The equipment has been evaluated according
to Installation Category II and Pollution Degree 2 as specified in IEC 664.
This instrument may be operated in environments with the following limits:
Temperature .................. 32 - 104 F (0 - 40C)
Relative humidity ........... 0 80%
Altitude ......................... 6560 feet (2,000 meters)
Storage and Shipping Environment
This instrument may be stored or shipped in environments with the following limits:
Temperature .................. -40 - 167 F (-40 - 75C)
Altitude ......................... 50,000 feet (15,240 meters)
The instrument should also be protected against temperature extremes that may cause
condensation within the instrument.

19

3. Specifications and Controls

3.1. Hypot III Functional Specifications
INPUT
Voltage
115/230 VAC 10%, user selectable
Frequency
50/60 Hz 5%
Fuse
3.15 Amp, fast acting 250VAC
DIELECTRIC WITHSTAND TEST MODE
Output Rating
Voltage Setting

Maximum Limit

AC
DC

Minimum Limit

AC
DC

Arc Detection
Failure Detector
Ground Fault Interrupt
Voltage Display

20

5000V @ 20 mA AC
6000V @ 7.5 mA DC
Range:
0 5.00KV AC
0 6.00KV DC
Resolution: 0.01KV
Accuracy:
(2% of setting + 5V)
(Can be adjusted during operation.
Disabled when key lockout is active.)
Range:
0.00 20.00 mA
Resolution: 0.01 mA
Range:
0 7500 A
Resolution: 1A
Accuracy:
AC and DC (2% of setting + 2 counts)
Range:
0.000 9.999 mA
Resolution: 0.001 mA
Range:
0.0 999.9 A
Resolution: 0.1 A
Accuracy:
AC and DC (2% of setting + 2 counts)
Range:
0 9, 0 disabled
Audible and Visual
GFI Trip Current:
450A max (AC or DC)
HV Shut Down Speed: <1ms
Range:
0.00 5.00KV AC
0.00 6.00KV DC
Resolution: 0.01KV
Accuracy:
(2% of reading + 0.01KV)

DIELECTRIC WITHSTAND TEST MODE

Current Display

Auto Range
AC Range 1:
0.000mA 3.500mA
Resolution: 0.001mA
Range 2:
3.00 20.00 mA
Resolution: 0.01 mA
DC Range 1:
0.0 A 350.0 A
Resolution: 0.1 A
Range 2:
0.300 mA 3.500 mA
Resolution: 0.001 mA
Range 3:
3.00 mA 7.50 mA
Resolution: 0.01mA
Accuracy: All Ranges (2% of reading + 2 counts)
DC Output Ripple
5% Ripple RMS at 6 KV DC @ 7.5 mA, Resistive Load
Discharge Time
200 ms
The maximum capacitive load vs output voltage :
0.20 F --- < 1KV
0.050 F --- < 4KV
0.10 F --- < 2KV
0.040 F --- < 5KV
0.06 F --- < 3KV
0.015 F --- < 6KV
AC Voltage Wave Form
Sine Wave, Crest Factor = 1.3 1.5
Output Frequency
Range:
50 or 60 Hz, User Selectable
Accuracy:
0.1%
Output Voltage Regulation
(1 % of output + 5 volts)
from no load to full load and over input voltage range.
Dwell Timer
Range:
AC: 0, 0.3 999.9 sec (0 = Constant)
DC: 0, 0.4 999.9 sec (0 = Constant)
Resolution: 0.1 sec
Accuracy:
(0.1% of reading + 0.05 sec)
Ramp Timer
Range:
Ramp-Up: 0.1 999.9 sec
Ramp-Down: AC 0.0 999.9 sec
DC 1.0 999.9 sec 0=OFF
Resolution: 0.1 sec
Accuracy:
(0.1% of reading + 0.05 sec)
Ground Continuity
DC 0.1 A 0.01A, fixed
Current
Ground Continuity
Range:
0.0 - 1.50
Maximum Limit
Resolution: 0.01
Minimum Limit
Accuracy:
(3% of setting + 0.02)
Ground Continuity
Range:
0.0 - 0.50
Auto Offset
Resolution: 0.01
Accuracy:
(3% of setting + 0.02)

21

INSULATION RESISTANCE TEST MODE

Voltage Setting

Voltage Display

Resistance Display

Range:
Resolution:
Accuracy:
Range:
Resolution:
Accuracy:
Range:
Resolution:

Accuracy:

30 1000V DC
1V
(2% of setting + 5 volts)
0 1000 V
1V
(2% of reading + 2 counts)
1 9999 M (4 Digit, Auto Ranging)
500VDC 1000VDC
M
M
0.001
1.000
9.999
0.01
10.00
99.99
0.1
100.0
999.9
1
1000
9999
(2% of reading + 2 counts) at test voltage
500 1000V and 1 999.9 M
(5% of reading + 2 counts) at test voltage
500 1000V and 1000 9999 M

Maximum Limit

Minimum Limit

Short Circuit Current

Ramp Timer

Delay Timer

Ground Fault Interrupt

22

(8% of reading + 2 counts) at test voltage

30 500V and 1 1000 M
Range:
0,1 9999 M (0 = Off)
Resolution 1M
Accuracy
Same as Resistance display
Range:
1 9999 M
Resolution 1M
Accuracy
Same as Resistance display
Maximum: 9mAp
Ramp-Up: 0.1 999.9 sec
Range:
Ramp-Down: 1.0 999.9 sec 0=OFF
Resolution: 0.1 sec
Accuracy:
(0.1% of reading + 0.05 sec)
Range:
0, 0.5 999.9 sec (0 = Constant)
Resolution: 0.1 sec
Accuracy:
(0.1% of reading + 0.05 sec)
GFI Trip Current:
450A max
HV Shut Down Speed: <1ms

GENERAL
Remote Control And Signal
Output

Program Memory
Security

Safety
Display
Alarm Volume Setting
Line Cord
Terminations

Mechanical

Environmental
Calibration

The following input and output signals are provided

through two 9 pin D type connectors;
1. Remote control : Test, Reset, and Remote Interlock.
2. Remote recall of memory program #1, #2 and #3
3. Outputs : Pass, Fail, Test-in-Process, and Reset
10 Memories, 3 steps per memory, all steps within a
memory are linkable.
Key Lock capability to avoid unauthorized access to all
test parameters. Memory Lock capability to avoid
unauthorized access to memory locations.
Built-in Smart GFI circuit
128 x 64 dot resolution with front panel contrast setting.
Front panel adjustable volume setting with 10 set points.
Detachable 7 ft. (2.13m) power cable terminated in a three
prong grounding plug.
Detachable 5ft.(1.52m) high voltage and return leads (2)
with clips and a standard U.S. style (NEMA 5-15) remote
receptacle box for testing items terminated with a line cord.
International receptacles also available. Front and Rear
outputs standard.
Tilt up front feet.
Dimensions: (W x H x D) (215 x 89 x 370 mm)
Weight: 20.96 lbs. (9.53Kgs)
Operating Temperature : (0 - 40C)
Relative Humidity - 0 to 80%
Traceable to National Institute of Standards and
Technology (NIST). Calibration controlled by software.
Adjustments are made through front panel keypad in a
restricted access calibration mode. Calibration information
stored in non-volatile memory.

23

3.2. Instrument Controls

3.2.1. Front Panel Controls

ASSOCIATED
RESEARCH, INC.

6KVDC MAX.

AC/DC WITHSTAND VOLTAGE TESTER

with IR Test

8 9

1. RESET BUTTON: Momentary contact switch used to reset the instrument. If a failure
condition occurs during a test, you will need to reset the system to shut off the alarm and
signal the system that you are aware of a failure condition. The reset button must be
pressed before you can proceed to the next test or change any of the set-up parameters.
This switch also serves as an abort signal to stop any test in progress controlled by the
Hypot III.
2. TEST BUTTON: Momentary contact switch used to start tests. Press the green button to
activate the test that is set up in the test buffer shown on the display.
3. GRAPHIC LCD: 128 X 64 Monographic LCD.
4. SOFT KEYS: Multifunction parameter selection keys. Keys used to select screens and
change parameters.
5. CONTINUITY OUTPUT JACK: Connection for the low current return lead used for
continuity testing.
6. RETURN OUTPUT JACK: Connector used to attach the Return test lead, adapter box
return lead, or test fixture return lead to the instrument. This connections provides the
return current path for the high voltage and ground bond current.
7. POWER SWITCH: Rocker style power switch with international ON ( | ) and OFF (0)
markings.
8. HIGH VOLTAGE ON INDICATOR: This indicator flashes to warn the operator that
high voltage is present at the high voltage terminal.
9. HIGH VOLTAGE OUTPUT JACK: Connector used to attach the High Voltage test
lead, adapter box high voltage lead, or test fixture high voltage lead to the instrument. The
connector is recessed for safety when not being used.
24

3.2.2. Rear Panel Controls

45

115

1 2

1. REAR PANEL OUTPUT CONNECTORS: These connectors are in parallel with the
front panel connectors.
2. FUSE RECEPTACLE: To change the fuse, unplug the power (mains) cord and turn the
fuse receptacle counter-clockwise. The fuse compartment will be exposed. Please replace
the fuse with one of the proper rating.
3. INPUT POWER RECEPTACLE: Standard IEC 320 connector for connection to a
standard NEMA style line power (mains) cord.
4. INPUT POWER SWITCH: Line voltage selection is set by the position of the switch. In
the left position it is set for 115 volt operation, in the right position it is set for 230 volt
operation.
5. CHASSIS GROUND (EARTH) TERMINAL: This terminal should be connected to a
good earth ground before operation.
6. OPTION CONNECTOR: Undefined.
7. REMOTE SIGNAL OUTPUT: 9-Pin D sub-miniature female connector for monitoring
PASS, FAIL, and PROCESSING output relay signals.
8. REMOTE SIGNAL INPUT: 9-Pin D subminiature male connector for remote control of
test, reset, and interlock functions, as well as remote program memory selection.
9. CALIBRATION BUTTON: To put the instrument into the calibration mode, push this
button and turn on the power switch simultaneously.

25

3.3. Quickstart
This quick start guide assumes the operator has some familiarity with automated Electrical
Safety testing.
Locate a suitable testing area and be sure you have read all safety instructions
for the operation of the instrument and suggestions on the test area set-up in
the Safety section. Locate a three prong grounded outlet. Be sure the outlet has been tested for
proper wiring before connecting the instrument to it.
WARNING

Check to be sure that the correct input line voltage has been selected on the
CAUTION
rear panel, either 115 volts AC or 230 volts AC. Connect the power-input
plug into its socket on the rear panel of the instrument. Connect the male
end of the plug to the outlet receptacle. Please be sure that the safety ground on the power line
cord is not defeated and that you are connecting to a grounded power source.
Turn on the POWER switch located on the lower left-hand side of the front panel. The
initialization screen will appear with a message at the bottom indicating <TEST> to
verification. You now have the option to press the TEST button and activate the Verification
Menu (Refer to the section Instrument Verification). The option to activate the Verification
expires approximately 3 seconds after power-up. If you do not press the TEST button with in
the 3-second window, the initialization screen will disappear. The initialization screen will
appear as follows:

After the initialization screen disappears, the Perform Tests screen will be displayed. The
Perform Tests screen will appear as follows:

ACW
M2-2_

26

Settings
999.9s

Menu

The Hypot III comes with all of the memories and steps loaded with the AC withstand default
parameters. The initial test loaded for use is Memory 1, Step 1. If this test is unacceptable for
your DUT then refer to the section 4.3 Setting Up a Test, for instructions on how to program
tests into the instrument.
If these parameters are acceptable then connect an appropriate set of test leads to the device
under test (DUT) or test fixture. Connect the return lead (Black) to the DUT or test fixture
followed by the high voltage output lead (Red). Make sure the safety ground of this instrument
is connected to a known good ground.
Refer to section 4.1.3 System Parameters, Smart GFI, for an explanation of DUT grounding
configurations.
WARNING

DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE TEST HAS
BEEN STARTED.

Remote Interlock
Hypot III is equipped with a featured referred to as Remote Interlock. Remote Interlock is a
feature that utilizes a set of closed contacts to enable the instruments output. In other words, if
the Interlock contacts open, the output of the instrument will be disabled. Remote Interlock
could also be referred to as a remote system lockout, utilizing Fail When Openlogic. If the
Interlock contacts are open and the Test button is pushed, a pop-up message will be displayed
on the screen for two seconds. The message will appear as follows:

Interlock is Open
If the Interlock contacts are opened during a test, the pop-up message will be displayed and the
test will abort. The hardware has been configured to provide the interlock connections on pins
4 and 5 of the Remote Interface, Signal Input port. The instrument can still be used without the
external interlock device as long as the Interlock Connector (38075 provided with unit) is
plugged into the Remote Interface, Signal Input port. If there is nothing connected to the
Remote Interface, Signal Input port to provide a connection to the interlock, the instrument will
not perform tests.
Please check your connections to be sure they are making good contact. Clear the area of any
debris that may create a hazardous situation and ask any unnecessary personnel to leave the
area. To initiate the test, press the GREEN test button on the front panel. This is a momentary
button and does not need to be held in the pressed position during the test. The instrument will
then initiate the test presently loaded (in this case Memory 1, Step 1) .
If the DUT passes the test, you will hear a short audible beep. If a failure occurs you will hear
a long audible alarm and the red failure indicator will light up. If a failure occurs during the
test, a continuous alarm will sound and the red indicator light in the Reset button will
illuminate.
27

To stop the alarm you must press the illuminated RED button marked RESET. This will
silence the alarm, clear the red fail light, and reset the instrument for the next test. The RESET
button may also be used to quickly ABORT a test and cut off the power to the DUT.
When a test is being performed, a red lightning bolt indicator located in the lower right side of
the front panel will illuminate and flash until the test is finished. If the DUT passed the test,
you will hear a brief beep indicating the DUT passed and that the tests are complete.
Reviewing results
The most direct method for reviewing test results is to press the bottom soft key at the end of
the test. Pressing the bottom soft key from the Perform Test screen will display the Results
screen. For more information about reviewing test results, refer to section 4.2.3 Reviewing
Test Results.

28

4. Programming Instructions
4.1. Setup System (Refer to FIG.1).
1. From the Perform Test screen, press the Menusoft key. The Main Menu will now be
displayed.
2. From the Main Menu screen, press the Menusoft key. The Results, Tests and System
selections will now be displayed.
3. From this screen, press the System soft key. The Setup System menu will now be displayed.
4. At the Setup System menu, scrolling from the PLC Remote parameter is restricted to down
only. Press the down arrow key to access system parameters.
5. Scrolling to <More> will display the second page of System Parameters.
From the Setup System screen, fourteen different Hardware and Software controls may be
accessed; PLC Remote, Single Step, Alarm, Contrast, Results, Lock, Mem Lock, Smart GFI,
Cal Alert, Cal Date, Cal Due, Alert, Date, and Time. Pressing the EXIT key at any time will
return you to the Perform Test screen.
FIG.1
ACW

Settings

M2-2_

Menu

999.9s

Press the System key.

Section 4.1, Step 3

Press the Menu key.

Section 4.1, Step 1

M2-2_ ACW
Settings
2000V
20.00mA
1.00mA
999.9s

2000V
20.00mA
1.00mA
999.9s

ON
OFF
5
5
Last
OFF
OFF

+
Exit

Press the Arrow key.

Section 4.1, Step 4

Menu
Memory
Step
Exit

PLC Remote
Single Step
Alarm
Contrast
Results
Lock
Mem Lock
<More>

ON
OFF
5
5
Last
OFF
OFF

+
Exit

Scroll to <More>.
Section 4.1, Step 5

Press the Menu key.

Section 4.1, Step 2

M2-2_ ACW
Settings

PLC Remote
Single Step
Alarm
Contrast
Results
Lock
Mem Lock
<More>

Result
Test
System
Exit

Smart GFI
ON
Cal Alert
OFF
Cal Date10/16/04
Cal Due 10/16/04
Alert
09/16/05
Date mdy11/16/04
Time
02:14 PM

+
Exit

29

4.1.1. Setup System Soft keys

Directional soft keys >, ,
The >, , soft keys are used to scroll the cursor to the different system parameters.
+
The +and soft key is used to increase or decrease numerical values or toggle settings ON
and OFF.
Exit
The Exit soft key is used to return to the Perform Tests screen.
4.1.2. System Parameters
Directional soft keys, (down), (up), and >(right), are used to navigate the System
parameters during reviewing and editing. The directional soft keys in the system parameters
will change depending on which parameter the cursor is pointing to. At the PLC remote
parameter, only the down arrow key is available.
PLC Remote
Scroll the cursor to the PLC Remote parameter using the directional soft keys. When the
cursor is pointing to the PLC Remote parameter, you may turn the PLC remote function ON
and OFF by pressing the +soft key. Refer to the section 6.Connection of Remote I/O for
details.
When the PLC remote is turned ON, the front panel Test button is disabled and a test may
only be started through the rear panel I/O. If you attempt to start a test from the front panel
Test button when the PLC Remote function is turned ON, a pop-up message will be
displayed. The pop-up message will appear as follows:

PLC Remote ON
Single Step
Scroll the cursor to the Single Step parameter using the directional soft keys. When the cursor
is pointing to the Single Step parameter, you may turn the function ON and OFF by pressing
the +soft key.
This function is used to temporarily override the automatic connection feature. When the
Single Step function is ON the instrument will pause after each step is completed. To continue
the test sequence, press the Test button to execute the next connected step. Each time the Test
button is pressed the next connected step will execute. If you press the Reset button before
completing all connected steps, it will return you to the original starting step. If a step fails and
you wish to continue to the next step do not press Reset.
30

Alarm Volume
Scroll the cursor to the Alarm parameter using the directional soft keys. When the cursor is
pointing to the Alarm parameter, you may use the +soft key to increase and decrease the
volume of the Alarm.
The numbers corresponding to the different volume settings are 0 through 9, 0 meaning the
volume is off and 9 being the loudest setting. After the +or is pressed, a momentary alarm
chirp will occur to indicate the volume of the new setting.
LCD Contrast
Scroll the cursor to the Contrast parameter using the directional soft keys. When the cursor is
pointing to the Contrast parameter, you may use the +soft key to increase and decrease the
contrast of the LCD display.
The numbers corresponding to the different contrast settings are 0 through 9, 0 meaning the
lightest color of displayed characters and 9 meaning the darkest color of displayed characters.
After the +is pressed, the display will automatically adjust to the new display setting.
Results
Scroll the cursor to the Results parameter using the directional soft keys. When the cursor is
pointing to the Results parameter, you may use the +soft key to select what type of results
you would preferred displayed at the end of a test or sequence of connected steps. The
available selections are: All, P/F and Last.
When All is selected, a Results summary screen will be displayed at the end of the test or
sequence of connected steps, displaying the results of all of the steps. The Results summary
screen will appear as follows:

ACW _Pass
M2-1_5.00KV

999.9s
20.00mA

DCW _Pass
M2-2 1.20KV

999.9s
2000uA

IR _Pass
M2-3 1.00KV

999.9s
10.00M

31

When P/F is selected, a Pass or Fail screen will be displayed at the end of the test. The Pass
and Fail screens will appear as follows:

When P/F is selected, it is not possible to directly see the test results at the end of the test. In
order to review the test results refer to section 4.2.3 Reviewing Test Results.
When Last is selected, the results of the last step performed will be displayed on the Perform
Tests screen. There will not be a change in appearance or special screen displayed in this
mode.
Lock
Scroll the cursor to the Lock parameter using the directional soft keys. When the cursor is
pointing to the Lock parameter, you may turn the function ON and OFF by pressing the +
soft key. When the exit soft key is pressed, the security settings will take immediate effect.
Selecting Lock ONrestricts access to parameter and system settings. The level of security is
determined by the Mem Lock function.
Once the Lock function is activated, a special procedure is required to defeat the security. To
defeat the security, press the top soft key while powering up the instrument. Now you may
access the system menu and turn the security function OFF.
Mem Lock
Scroll the cursor to the Mem Lock parameter using the directional soft keys. When the cursor
is pointing to the Mem Lock parameter, you may turn the function ON and OFF by pressing
the +soft key.
Mem Lock is a sub-function of the Lock setting. In order for the Mem Lock function to work,
the Lock must first be turned ON. Selecting the Mem Lock OFFwill allow the user to
access all available Memory locations but restricts access to memory and step editing
capabilities. Selecting the Mem Lock ONwill allow the user to only run the currently
loaded memory.
Smart GFI
Scroll the cursor to the Smart GFI parameter using the directional soft keys. When the cursor
is pointing to the Smart GFI parameter, you may turn the function ON and OFF by pressing the
+soft key.
32

The High Voltage power supply of the instrument is internally referenced to earth ground. The
leakage current measuring circuits monitor only currents that flow through the Return lead.
Therefore, the possibility exists for current to flow directly from the High Voltage output to
earth ground that typically would not be monitored.
GFI is a circuit that monitors the current between the High Voltage output and earth ground.
The GFIs main purpose is to protect the operator from prolonged exposure to High Voltage in
the case of an accidental contact with the High Voltage lead and earth ground. If the operator
accidentally touches the High Voltage lead and earth ground, the High Voltage will be shut off
immediately and the test aborted. If the GFI threshold is exceeded, the display will indicate a
GFI Fail.
Smart GFI allows the user to automatically configure the instruments return configuration.
When the Return lead is earth grounded, the GFI circuit is disabled and the instrument operates
in a grounded return mode of operation. Grounded Return allows the user to perform tests on
devices that have their chassis earth grounded by the test fixture or test environment. The
standard configuration of Hypot III is a floating return connection that is not directly connected
to Earth ground. The standard configuration allows monitoring of very low level leakage
current without internal or external stray earth ground leakage currents being measured and
thereby causing errors in the reading. Grounding the return will create some amount of
leakage current that is proportional to the High Voltage output and can cause small amounts of
error depending on the test voltage and physical environment.
Cal Alert (Calibration Alert)
Calibration Alert is a feature that allows the instrument to give an advanced alert that the
calibration for the instrument is coming due. Scroll the cursor to the Cal Alert parameter using
the directional soft keys. When the cursor is pointing to the Cal Alert parameter, you may turn
the function ON and OFF by pressing the +soft key.
Turning this parameter ONwill activate the Cal Alert function and when the date matches
the Alert Date, the instrument will display the Calibration Alert warning screen upon power up.
If the Show this screen again?function has been turned OFFat the Calibration Alert
Warning screen, this parameter will automatically be set to OFF.
Cal Date(Calibration Date)
Calibration Date is a non-editable parameter that indicates the Date when calibration was last
performed on the instrument. This parameter automatically updates after calibrating the
instrument.
Cal Due (Calibration Due Date)
It is recommended that calibration should be performed at least once a year. It is
recommended that the Calibration Due date not bet set greater than one year from the
Calibration Date displayed. After a calibration is performed, the Calibration Due Date is
automatically set 1 year after the calibration date.

33

This parameter defaults to one year after the calibration date but may be overwritten to any
advanced date desired. Within the Calibration Due Date parameter are three separate fields,
month, day, and year. Use the > key to select the field within the date you want to edit then
use the + key to change the numeric value. Once you change the value, it is automatically
stored.
Alert (Alert Date)
The Alert date is like an alarm clock that will warn you in advance of the actual calibration due
date. After a calibration is performed, the Alert Date is automatically set 11 months after the
calibration date. For example, if the calibration is performed on 12/15/2002 the Alert Date will
automatically be set to 11/15/2003.
This parameter defaults to 11 months after the calibration date but may be overwritten to any
advanced date desired. Within the Alert Date parameter are three separate fields, month, day,
and year. Use the > to select the field within the date you want to edit. Use the + key to
change the numeric value. Once you change the value, it is automatically stored.
Date
Scroll the cursor to the Date parameter using the directional soft keys.
Within the Set Date parameter are four fields, date format (mdy / dmy), month, day, and year.
Use the > key to select the field within the date you want to edit. Using the + key to change
the numeric value. Once you change the value, it is automatically stored.
Time
Scroll the cursor to the Time parameter using the directional soft keys.
Within the Set Time parameter are three fields, hours, minutes, and Military or Standard time
setting. Use the > key to select the field within the time parameter you want to edit. Use the +
key to change the numeric value. Once you change the value, it is automatically stored.
The Calibration Alert Warning screen appears as follows:

Cal. Alert
Model 36XX is due
for calibration on
10/16/04.
Yes
Show

screen

again?
OK

At the Calibration Alert Warning screen, there are two options, Show screen again? Yes or
No. Show screen again?is asking if you would like to continue seeing the Calibration Alert
34

Warning screen every time you power up the instrument. The question must be answered by
toggling between the word Yes and Nousing its corresponding softkey and then pressing
the OK softkey. You may turn this screen OFFby toggling to the word Nousing the soft
key next to this parameter and pressing the OK soft key. Selecting the Show this screen
againparameter Nowill disable the Calibration Alert function. You may leave this screen
ONby toggling to the word Yesusing the soft key next to this parameter and the pressing
the OK soft key. Selecting the Show this screen againparameter Yeswill exit the
Calibration Alert Warning screen and go to the standard introduction screen without disabling
the Calibration Alert function.
If security is enabled you will not see the question Show screen againor the Yes/No soft
key.
It is possible to quickly bypass the security of the Calibration Alert by powering up the
instrument while depressing the soft key that is second from the top of the instrument. This
will temporarily start the instrument in an unsecured state. The Calibration Alert Warning
screen will be displayed and allow you to disable the Calibration alert by selecting Noand
then pressing the OK soft key. This type of security override only affects the Calibration alert
screen. It is not necessary to restart the instrument to activate the security setting.

35

4.2. Setting up Tests (Refer to FIG.2).

4.2.1. Reviewing Test parameters
1. From the Perform Test screen, press the Menusoft key. The Main Menu will now be
displayed.
2. Select the memory and step location you want to review or edit using their corresponding
soft keys.
3. From the Main Menu screen, press the Menusoft key. The Results, Tests and System
selections will now be displayed.
4. From this screen, press the Test soft key. The Test parameter review screen will now be
displayed (For the example an AC withstand test is displayed). You may now review the test
parameters by scrolling the cursor with the up and down arrow keys. It is important to note
that there are two screens of parameters for AC and DC withstand tests.
FIG.2
ACW

Settings

M2-2_

999.9s

M2-2_ ACW
Settings

Menu

Press the Menu soft key.

Section 4.2.1 Step 3

Press the Menu soft key.

Section 4.2.1, Step 1

M2-2_ ACW
Settings
2000V
20.00mA
1.00mA
999.9s

Menu
Memory
Step
Exit

Select the memory and step number using

their corresponding softkeys
Section 4.2.1, Step 2

2000V
20.00mA
1.00mA
999.9s

Test
System
Exit

Press the Test soft key.

Section 4.2.1, Step 4

Test Type ACW

Voltage
4360V
Max Lmt 20.00mA
Min Lmt 9.999mA
Ramp UP 999.9s
Dwell
999.9s
Ramp DN 999.9s
Arc Sense
9

^
v
Edit
Exit

Press the Edit soft key.

Section 4.2.2, Step 2

Test Type ACW

Voltage
4360V
Max Lmt 20.00mA
Min Lmt 9.999mA
Ramp UP 999.9s
Dwell
999.9s
Ramp DN 999.9s
Arc Sense
9

36

Result

+
_
Enter
Esc

4.2.2. Editing Test Parameters (Refer to FIG.2)

1. From the Test parameter review screen (refer to section 4.2.1), scroll the cursor to the test
parameter you wish to edit using the up and down arrow soft keys.
2. Press the Edit soft key. The Test parameter edit screen will now be displayed.
3. You may now change the value of the test parameter with the up and down arrow soft keys.
4. Press the Enter soft key to accept the new value or press Esc to escape from the edit.
All available test parameters may be edited using this procedure.
4.2.3. Reviewing Test Results
Method 1, Hot key
1. Pressing the bottom soft key at the Perform Test screen will display the Results screen.
Method 2, Menu Selection
1. From the Perform Test screen, press the Menusoft key. The Main Menu will now be
displayed.
2. From the Main Menu screen, press the Menusoft key. The Results, Test and System
selections will now be displayed.
3. From this screen, press the Resultsoft key. The Results screen will now be displayed.
The Results screen will appear as follows:

M1-1_ GND
Max-Fail
Settings
25.00A
100m
0m

Results
.A
>120m
0.0s

^
v

Exit

1.0s

For connected tests, use the up and down soft keys to scroll through the results.

4.3. Test Parameters

Description of Test Parameters
Voltage: The Voltage that is applied to the High Voltage and Return terminals or the Current
and Return terminals during a test.
Max Lmt: A maximum current or resistance threshold that when exceeded triggers a failure.
37

Min Lmt: A minimum current or resistance threshold that when not exceeded triggers a
failure.
Ramp Up: A length of time that is allowed for the test voltage to climb from 0 to the voltage
set point.
Dwell: A length of time that is allowed for the set point voltage to be applied.
Delay: A length of time that the set point voltage is applied but no judgment of the set
parameters is made. A judgment of the parameters is not made until the end of the delay time.
Ramp DN: A length of time that is allowed for the test voltage to decay from set point to 0.
Arc Sense: During hipot testing some low current arcing may be allowable. Arc sense is a
maximum allowable threshold for arcing.
The numbers corresponding to the different arc sensitivity levels are 0 through 9, 1 meaning
the maximum threshold of allowable arcing, 9 meaning the minimum threshold of allowable
arcing and 0=OFF. After the +or -is pressed, the arc sensitivity will automatically adjust
to the new setting.
Frequency: This parameter is available in AC tests only and is selectable using a softkey
between 50 and 60Hz.
Continuity: This function checks for a connection between the cont. check and return lead.
This is a basic DC continuity check that measures the continuity value but does not display it.
Continuity may be selected ON or OFFusing a softkey.
Connect: This function when turned ON will connect or link the current step to the next step.
The third step in a Memory will not have this function because it is the last step of the Memory
location.

38

4.3.1. AC Withstand
From the Test parameter review screen (refer to section 4.2.1), scroll the cursor, using the up
and down arrow soft keys, to the Test Type parameter. Press the Edit softkey. Select the AC
Withstand parameter using the +and -soft keys and press the Enter soft key. The default
AC Withstand parameters will now be loaded into the currently selected memory and step.
Press the Enter softkey to accept the parameters (or press Esc to escape). The AC Withstand
parameter review screens will now be displayed. The AC Withstand parameter review screens
will appear as follows:

Test Type ACW

Voltage
4360V
Max Lmt 20.00mA
Min Lmt 9.999mA
Ramp UP 999.9s
Dwell
999.9s
Ramp DN 999.9s
<More>

^
v

Edit
Exit

Arc Sense
9
Frequency
60Hz
Continuity
ON
Max Lmt
1.50
Min Lmt
0.10
Offset
0.00
Connect
ON

^
v
Edit
Exit

From the AC Withstand review screens the following parameters may be selected for editing:
Voltage, Max-Limit, Min-Limit, Ramp Up, Dwell Time, Ramp Down, Arc Sense, LO-Limit,
Frequency, Arc Detect (ON/OFF), Continuity selection (On/OFF), Continuity Max Limit,
Continuity Min Limit, and Continuity Offset.
Offset
When the Continuity is selected ON, the Offset function may be used to compensate for lead
and test fixture resistance during the continuity test. Using the up and down arrow keys, scroll
the cursor to the Offset parameter and press the Edit softkey. You may now manually or
automatically set an Offset value.
To manually set the Offset, use the +and -soft keys to increase and decrease the
resistance value. Press the Enter soft key to accept the new value or press the Esc soft key to
escape from the edit.
To automatically set an Offset value, set the output voltage, current, and frequency to the
values that will be used on the DUT and connect the test cables or test fixture with fixturing to
the instrument. Next, short circuit the ends of the test cables and press the TESTbutton.
The instrument will now read the lead resistance and update Offset parameter automatically.
Press the Enter soft key to accept the new value or press the Esc soft key to escape from the
edit.

39

4.3.2. DC Withstand (Models 3665 and 3670)

From the Test parameter review screen (refer to section 4.2.1), scroll the cursor, using the up
and down arrow soft keys, to the Test Type parameter. Press the Edit softkey. Select the DC
Withstand parameter using the +and -soft keys and press the Enter soft key. The default
DC Withstand parameters will now be loaded into the currently selected memory and step.
Press the Enter softkey to accept the parameters (or press Esc to escape). The DC Withstand
parameter review screens will now be displayed. The DC Withstand parameter review screens
will appear as follows:

Test Type
DCW
Voltage
1200V
Max Lmt
7500uA
Min Lmt
100uA
Ramp UP 999.9s
Dwell
999.9s
Ramp DN 999.9s
<More>

^
v
Edit

Arc Sense
9
Continuity
ON
Max Lmt 1.50
Min Lmt 0.10
Offset
0.00
Connect

Exit

^
v
Edit

ON
Exit

From the DC Withstand setting screen the following parameters may be controlled: Voltage,
Max-Limit, Min- Limit, Ramp Up, Dwell Time, Ramp Down, Arc Sense, Ramp-HI, Arc
Detect (ON/OFF), and Continuity (ON/OFF).
Offset
When the Continuity is selected ON, the Offset function may be used to compensate for lead
and test fixture resistance during the continuity test. Using the up and down arrow keys, scroll
the cursor to the Offset parameter and press the Edit softkey. You may now manually or
automatically set an Offset value.
To manually set the Offset, use the +and -soft keys to increase and decrease the
resistance value. Press the Enter soft key to accept the new value or press the Esc soft key to
escape from the edit.
To automatically set an Offset value, set the output voltage, current, and frequency to the
values that will be used on the DUT and connect the test cables or test fixture with fixturing to
the instrument. Next, short circuit the ends of the test cables and press the TESTbutton.
The instrument will now read the lead resistance and update Offset parameter automatically.
Press the Enter soft key to accept the new value or press the Esc soft key to escape from the
edit.

40

4.3.3. Insulation Resistance (Model 3670 only)

From the Test parameter review screen (refer to section 4.2.1), scroll the cursor, using the up
and down arrow soft keys, to the Test Type parameter. Press the Edit softkey. Select the IR
parameter using the +and -soft keys and press the Enter soft key. The default IR
parameters will now be loaded into the currently selected memory and step. Press the Enter
softkey to accept the parameters (or press Esc to escape). The IR parameter review screen will
now be displayed. The DC Withstand parameter review screen will appear as follows:

Test Type
IR
Voltage
1000V
Max Lmt
2000M
Min Lmt
1000M
Ramp UP 999.9s
Delay
999.9s
Ramp DN 999.9s
Connect
ON

^
v
Edit
Exit

From the Insulation Resistance parameter setting screen the following parameters may be
selected for editing: Voltage, Max-Limit, Min- Limit, Ramp Up, Delay Time, and Ramp
Down.

41

4.3.4. Default Test Parameters

Each of the test types (AC withstand, DC withstand and IR) have specific default test
parameters that automatically load when test type is selected from the parameter edit screen.
The following table is a listing of the Default Parameters for each of the different types of tests
that are available in the Hypot III. The Default Parameters are as follows:
Test Type
ACW

DCW

IR

42

Parameter
Voltage
Max Lmt (current)
Min Lmt (current)
Ramp UP
Dwell
Ramp DN
Arc Sense
Frequency
Continuity
Max Lmt (Continuity)
Min Lmt (Continuity)
Offset (Continuity)
Connect
Voltage
Max Lmt (Current)
Min Lmt (Current)
Ramp UP
Dwell
Ramp DN
Arc Sense
Continuity
Max Lmt (Continuity)
Min Lmt (Continuity)
Offset (Continuity)
Connect
Voltage
Max Lmt
Min Lmt
Ramp UP
Delay
Ramp DN
Connect

Value
1,24kV
10.00mA
0.000mA
0.1s
1.0s
0.0s
0
60Hz
OFF
1.00
0.00
0.00
OFF
1,50kV
5000A
0.0A
0.1s
1.0s
1.0s
0
OFF
1.00
0.00
0.00
OFF
1000V
0M
10M
0.1s
1.0s
1.0s
OFF

4.3.5. Memory, Step, and Default System Parameter Initialization

Warning Initializing the instrument will overwrite all memories and steps with ACW
default parameters!
Press the two bottom soft keys and power the instrument at the same time, then press the soft
key next to the word Yes. All memories and steps will be loaded with the ACW default
parameters and the System parameters will be set to the factory defaults. The default system
parameters are as follows:
Setup Sys.

PLC Remote
Single Step
Alarm
Contrast
Results
Lock
Mem Lock
Smart GFI

OFF
OFF
5
5
Last
OFF
ON
ON

The following System parameters will not be affected by the system initialization:

Setup Sys.

Cal Alert
Cal Date
Cal Due
Alert
Date m/d/y
Time

No change
No change
No change
No change
No change
No change

43

5. Operating Instructions
5.1. Instrument Connections
5.1.1. Adapter Box Connections
The adapter box provides an easy way to connect a DUT to the HYPOT III that is terminated
in a two or three-prong line cord. The following diagram shows how to connect the adapter
box to the Hypot III and to the device under test.
`

36544
G

Test Connections

DUT

L
N

RTN

CHASSIS

ASSOCIATED
RESEARCH, INC.

CONT
HV

6KVDC MAX.

AC/DC WITHSTAND VOLTAGE TESTER

with IR Test

The rear output connections on the Hypot III may be used as well.

5.2. Perform Tests, Main Menu, and Results Screens

The Hypot III automatically defaults to the Perform Tests screen upon power up. The Perform
Tests screen will appear as follows:
ACW
M2-2_

Settings
999.9s

Menu

From the Perform Tests screen the Main Menu may be accessed by pressing the Menu softkey

44

The Perform Tests screen is the main operational screen of instrument. From this screen, test
parameters are monitored while the test is being performed. This screen may also be used to
debug memories with connected steps, with the use of the single step function.
5.2.1. Connected Step indicator
The connected step indicator is an under score symbol located directly next to the Memory and
Step number and only will be displayed when the connect function has been turned Onin the
Test parameters.

ACW

Settings

ACW
M2-2_

M2-2_

Settings
999.9s

Menu

999.9s

Connected Step Indicator

5.2.2. Main Menu
From the Perform Tests screen, press the Menusoft key.

M2-2_ ACW
Settings
2000V
20.00mA
1.00mA
999.9s

Menu
Memory
Step
Exit

The Main Menu will now be displayed. From the Main Menu screen, three Software controls
may be accessed; Menu, Memory, Step. Pressing the Exit soft key at any time will return you
to the Perform Tests.
Menu
Pressing the Menu soft key from the Main Menu will display the Results, Tests and System
selections. Please refer to section 5.2.3 Results, Test, and System Selections.
Memory
The Hypot III has 10, three-step programmable memory locations (M0-M9). Press the
Memorysoft key to increment the instrument to the desired memory location. As the
Memory softkey is pressed, the parameters of the selected memory location are automatically
loaded into the instrument.
45

Step
Each of the ten memory locations in Hypot III has three programmable steps that may be
Connectedtogether to create multi-step testing. Press the Stepsoft key to increment the
step number.
5.2.3. Results, Tests and System Selections
From the Main Menu, press the Menusoft key.

M2-2_ ACW
Settings

Results
Test

2000V
20.00mA
1.00mA
999.9s

System
Exit

The Results, Tests and System selections will now be displayed. From this screen, three
Software controls may be accessed; Results, Test, and System. Pressing the Exit soft key at
any time will return you to the Perform Tests screen.
Results
Pressing the Resultssoft key from this menu will allow you to review the test results of the
last test performed. An example of a Results screen is shown below.

M2-2_ ACW
Max-Fail
Settings
2000V
15.00mA
1.00mA
999.9s

Results
1.99KV
15.78mA
1.4s

^
v

Exit

Test
Pressing the Testsoft key from this menu will allow you to access the Parameter Review
screen. For specific instructions for reviewing and editing test parameters, refer to section 4.2
Test Parameters.
System
Pressing the Systemsoft key from this menu will allow you to access the Setup System
screen. For specific instructions for editing system parameters, refer to section 4.1
Setup System.
46

5.3. Perform Tests Metering

Each test performed by the Hypot III contains a unique set of parameters and therefore requires
specialized metering for each test. The following table describes what meters will be displayed
for each of the different test types.
Test Type
AC Withstand
DC Withstand
IR

Current
X
X
-

Voltage
X
X
X

Time
X
X
X

Resistance
X

5.4. Performing a Test

1. From the Main Menu, select the memory and step you wish to perform then press the Exit
soft key to return you to the Perform Test screen.
2. Attach the appropriate load or DUT to the instrument (refer to section 5.1 for instrument
connections).
3. Press the TEST button.
4. The instrument will now perform the test or connected sequence of tests. If the Test is
started from any other step than 01, when you push Reset or Test buttons, it will always
return to the originally selected step.
5.4.1. Single Step
Single step is a function that allows you to run one step at a time from a sequence of connected
steps. To access the Single step function, refer to section 4.1 Setup System. This function is
used to temporarily override the automatic connection feature. When the Single Step function
is ON the instrument will pause after each step is completed. To continue the test sequence,
press the Test button to execute the next connected step. Each time the Test button is pressed
the next connected step will execute. If you press the Reset button before completing all
connected steps, it will return you to the original starting step. If a step fails and you wish to
continue to the next step do not press Reset.
5.4.2. Manual Voltage Adjustment
When HYPOT III is performing a test, +and -symbols will appear next to the two bottom
soft keys. These soft keys may be used to adjust the output voltage while performing a test.

ACW
M1-1

Dwell
1.0s

Menu

Use these soft keys to

adjust the output voltage
while performing a test.

47

Pressing the +soft key will increase the output voltage, pressing the -soft key will
decrease the output voltage. Manual voltage adjustment temporarily overrides the voltage
setting and only remains in effect until the test is terminated by Pass, Fail, or Abort.
When the Lock parameter is selected Onin the system menu, manual voltage adjustment is
disabled. Therefore, you will not see the +and -symbols next to the bottom soft keys.
5.4.3. Description of displayed messages.
While performing tests, a number of messages will be displayed to indicate the test state or test
results. These messages are displayed in the status area of the screen, located on the first line at
the top of the LCD. These messages also used on other screens where test results are displayed.
Messages

ACW

xx

xx

ACW
M2-2_

M2-2_

Settings
999.9s

Menu

999.9s

Dwell: This message appears on the display during the AC/DC Withstand test in process, when
the values are being updated in real time.
Delay: This message appears on the display during the Insulation Resistance test in process,
when the values are being updated in real time.
Ramp UP: This message appears on the display at the beginning of the test, when the output
voltage is ramping up.
Ramp DN: This message appears on the display at the end of the dwell or delay cycles, when
the output voltage is ramping down.
Pass: This message appears on the display, when the test process is complete and the DUT
passed the test.
Abort: This message appears on the display, if the test in process is aborted with the RESET
button or remote Reset control.
Max-Fail: This message appears on the display, if the measured reading exceeds the Max Lmt
current setting of the AC/DC Withstand test, or Max Lmt resistance setting of the Insulation
Resistance test.

48

Min-Fail: This message appears on the display, if the measured reading drops below the Min
Lmt current setting of the AC/DC Withstand test, or Min Lmt resistance setting of the
Insulation Resistance test.
Cont. Max: This message appears on the display, if the measured reading exceeds the Max
Lmt continuity resistance setting and the Continuity function is set to ON of the AC/DC
Withstand test.
Cont. Min: This message appears on the display, if the measured reading drops below the Min
Lmt continuity resistance setting and the Continuity function is set to ON of the AC/DC
Withstand test.
Arc-Fail: This message appears on the display, if the DUT arcing current exceeds the Arc
Sense limit and Arc function is active (Arc Sense = 1 9) of the AC/DC Withstand test.
Short: This message appears on the display, if the DUT current is well beyond the metering
range of the test.
Breakdown: This message appears on the display, if the DUT current is well beyond the
metering range of the test and the arcing condition is beyond the arc sense limit.
GND-Fault: This message appears on the display, if the GFI threshold is exceeded during the
test.
Out-Error: This message appears on the display, after exiting from the Output Error screen. If
the instrument has an internal problem and the TEST button is pressed, the Output Error screen
will appear as follows:

Output Error
Device malfunction
Setting = x.xxkV
Reading = x.xxkV
Press Exit to
continue or call
1-800-858-8378.

Exit

The RESET button is not active while this screen is displayed. To clear this screen and return
to test mode the Exit soft key must be pressed. When the Exit soft key is pressed the
instrument will continue with its normal failure indication process. The failure light and Alarm
can then be cleared by pressing the RESET button.

49

6. Instrument Verification
Verification is a process by which an instruments fail detectors are proven to be functioning
properly and thereby Verifyingthe functionality of the electrical safety tester and connected
accessories. Verification of failure detect circuitry of the electrical safety tester is required by
safety agencies such as CSA, UL, and TV.

6.1. Verification Initialization

Turn on the POWER switch located on the lower left-hand side of the front panel. The
initialization screen will appear with a message at the bottom indicating <TEST> to
verification. You now have the option to press the TEST button and activate the Verification
Menu. The option to activate the Verification expires approximately 3 seconds after power-up.
The Initialization screen will appear as follows:

6.2. Verification Menu

From the Initialization screen (First start up screen), press the TEST button.
The Verification Menu will now be displayed. From the Verification screen, four different
Verification processes may be accessed; Continuity, AC Hipot, DC Hipot, and IR.

Verification
Continuity
AC Hipot
DC Hipot
IR

^
v

Select
Exit

During the Verification process, all Remote control output signals, except the Fail output, are
disabled.

50

6.2.1. Continuity Verification

From the Verification screen, press the Up or Down soft keys to select Continuity, then press
Select soft key. An instructional prompt will now be displayed. The prompt will appear as
follows:

Cont.

Verification

Open DUT connection

between Cont. and
Return. Unplug H.V.
from the instrument.
<TEST> to Begin
<RESET> to Exit

Follow the instructions given in the prompt and then press TEST to begin the verification
process.
At the end of the Verification process, a message will appear indicating the outcome of the
process. If the instrument passes the Verification (test failure, indicating the fail detectors are
working properly) the RESET button will illuminate, the alarm will sound and the following
message will appear:

ACW
0.0s
M1-1
-.--kV
-.--mA
Verification OK
Continuity failure
detected.

<RESET>

to

Exit

If the instrument fails the Verification (test pass, indicating the fail detectors are not working
properly) the following message will appear:

ACW
1.0s
M1-1
0.00kV
0.00mA
Continuity failure
not detected. Check
leads or call
1-800-858-8378
<TEST> to Retest
<RESET> to Exit

51

6.2.2. AC Hipot Verification

From the Verification screen, press the Up or Down soft keys to select AC Hipot, then press
the Select soft key. An instructional prompt will now be displayed. The prompt will appear as
follows:

AC

Hipot

Verification

Short DUT connection

between H.V. and
Return. Do not touch
during test.
<TEST> to Begin
<RESET> to Exit

Follow the instructions given in the prompt and then press TEST to begin the verification
process.
At the end of the Verification process, a message will appear indicating the outcome of the
process. If the instrument passes the Verification (test failure, indicating the fail detectors are
working properly) the RESET button will illuminate, the alarm will sound and the following
message will appear:

ACW
0.0s
M1-1
-.--kV
>20mA
Verification OK
AC Hipot failure
detected.

<RESET>

to

Exit

If the instrument fails the Verification (test pass, indicating the fail detectors are not working
properly) the following message will appear:

ACW
1.0s
M1-1
0.99kV
0.00mA
AC Hipot failure
not detected. Check
leads or call
1-800-858-8378
<TEST> to Retest
<RESET> to Exit

52

6.2.3. DC Hipot Verification

From the Verification screen, press the Up or Down soft keys to select DC Hipot, then press
the Select soft key. An instructional prompt will now be displayed. The prompt will appear as
follows:

DC

Hipot

Verification

Short DUT connection

between H.V. and
Return. Do not touch
during test.
<TEST> to Begin
<RESET> to Exit

Follow the instructions given in the prompt and then press TEST to begin the verification
process.
At the end of the Verification process, a message will appear indicating the outcome of the
process. If the instrument passes the Verification (test failure, indicating the fail detectors are
working properly) the RESET button will illuminate, the alarm will sound and the following
message will appear:

DCW
0.0s
M1-1
-.--kV
>7.5mA
Verification OK
DC Hipot failure
detected.

<RESET>

to

Exit

If the instrument fails the Verification (test pass, indicating the fail detectors are not working
properly) the following message will appear:

DCW
1.0s
M1-1
0.99kV
0.0uA
DC Hipot failure
not Detected. Check
leads or call
1-800-858-8378
<TEST> to Retest
<RESET> to Exit

53

6.2.4. IR Verification
From the Verification screen, press the Up or Down soft keys to select IR, then press the
Select soft key. An instructional prompt will now be displayed. The prompt will appear as
follows:

IR

Verification

Short DUT connection

between H.V. and
Return. Do not touch
during test.
<TEST> to Begin
<RESET> to Exit

Follow the instructions given in the prompt and then press TEST to begin the verification
process.
At the end of the Verification process, a message will appear indicating the outcome of the
process. If the instrument passes the Verification (test failure, indicating the fail detectors are
working properly) the RESET button will illuminate, the alarm will sound and the following
message will appear:

IR
M1-1
----V
Verification OK
IR failure
detected.

<RESET>

to

0.0s
<1M

Exit

If the instrument fails the Verification (test pass, indicating the fail detectors are not working
properly) the following message will appear:

IR
1.0s
M1-1
1000V
>10G
IR failure
not Detected. Check
leads or call
1-800-858-8378
<TEST> to Retest
<RESET> to Exit

54

7. Connection of Remote I/O

Two 9-pin Dtype connectors are mounted on the rear panel that provide REMOTEINPUT-OUTPUT control and information. These connectors mate with standard 9 pin
D-sub-miniature connector provided by the user. The output mates to a male (plug)
connector while the input mates to a female (receptacle) connector. For best
performance, a shielded cable should be used. To avoid ground loops the shield should
not be grounded at both ends of the cable. Suggested AMP part numbers for
interconnecting to the Remote I/O are shown below:
205204-4
205203-3
745254-7
745253-7
745171-1
747784-3

PLUG SHELL WITH GROUND INDENTS

RECEPTACLE SHELL
CRIMP SNAP-IN PIN CONTACT (for plug)
CRIMP SNAP-IN SOCKET CONTACT (for receptacle)
SHIELDED CABLE CLAMP (for either plug or receptacle)
JACKSCREW SET (2)
Remote Interface Rear Panel:

SIGNAL OUTPUT
FAIL

SIGNAL INPUT
RESET

PASS

TEST
INTERLOCK
5

RESET
OUT

MEMORY 1

PROCESSING

MEMORY 2
MEMORY 3

7.1. Signal Outputs on Remote I/O

The rear panel connector provides three output signals to remotely monitor PASS, FAIL,
and PROCESSING conditions. The monitoring signals are provided by three normally
open internal relays that toggle on and off to indicate the condition of the tester. These
are normally open free contacts and will not provide any voltage or current. The ratings
of the contacts are 1 AAC / 125 VAC (0.5 ADC / 30 VDC). The signal outputs are
provided on the 9-pin female D connector. Below is a listing that indicates what
conditions activate each pin. When a terminal becomes active the relay closes thereby
allowing the external voltage to operate an external device.

55

Pins 1 and 2 provide the PASS signal.

Pins 3 and 4 provide the FAIL signal.
Pins 5 and 6 provide the PROCESSING signal.
Pins 7 and 8 provide the RESET OUT signal.
The following describes how the relays operate for each test condition:
PROCESSING The relay contact closes the connection between pin (5) and pin (6)
while the instrument is performing a test. The connection is opened at the end of the test.
PASS The relay contact closes the connection between pin (1) and pin (2) after
detecting that the item under test passed all tests. The connection is opened when the
next test is initiated or the reset function is activated.
FAIL The relay contact closes the connection between pin (3) and pin (4) after
detecting that the item under test failed. The connection will open when the next test is
initiated or the reset function activated.
RESET OUT The relay contact closes the connection between pin (7) and pin (8) while
the reset function is activated. This is only a continuous closure dependent on the length
of time the reset button is held in an active state.

7.2. Signal Inputs of Remote I/O and Memory Access

The Hypot III remote connector enables remote operation of the TEST, RESET, and
REMOTE INTERLOCK functions, and allows the operator to select Memory 1, Memory
2, and Memory 3.
When the PLC Remote mode is on, the Hypot III will respond to simple switch or relay
contacts closures. A normally open momentary switch can be wired across pins 3 and 5
to allow remote operation of the TEST function. A normally open momentary switch can
be wired across pins 2 and 5 to allow remote operation of the RESET function. When the
PLC remote function is (ON) the TEST switch on the front panel will be disabled to
prevent a test from being activated through this switch. For safety, the front panel
RESET switch remains active even when a remote reset switch is connected so that high
voltage can be shut down from either location.
The Hypot III also allow access to three MEMORY PROGRAMS through the remote
control connector. This gives the user the capability to quickly change parameters and
initiate a test remotely. The Hypot III basically operates in a PLC mode by responding to
simple switch or relay contact closures. The built in memory programs of the instrument
are used to accomplish this. Three internal memory programs can be accessed, by
connecting terminals 7, 8, and 9 in different combinations.

56

WARNING

ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE

REMOTE CONNECTOR, SELECTS THE PROGRAM AND STARTS
THE TEST WHICH IS PREPROGRAMMED INTO THAT MEMORY

CAUTION

DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL

INPUTS, THIS COULD RESULT IN DAMAGE TO THE CONTROL
CIRCUITRY.

MEMORY ONE Momentarily connecting terminal 7 to 8 signals the instrument to

immediately begin the test program that is stored in memory one.
MEMORY TWO Momentarily connecting terminal 7 to 9 signals the instrument to
immediately begin the test program that is stored in memory two.
MEMORY THREE Momentarily connecting terminal 7 to terminals 8 and 9 signals the
instrument to immediately begin the test program that is stored in memory three.
Remote Interlock
Hypot III is equipped with a featured referred to as Remote Interlock. Remote
Interlock is a feature that utilizes a set of closed contacts to enable the instruments output.
In other words, if the Interlock contacts open, the output of the instrument will be
disabled. Remote Interlock could also be referred to as a remote system lockout, utilizing
Fail When Openlogic. If the Interlock contacts are open and the Test button is pushed,
a pop-up message will be displayed on the screen for two seconds. The message will
appear as follows:

Interlock is Open
If the Interlock contacts are opened during a test, the pop-up message will be displayed
and the test will abort. The hardware and has been configured to provide the interlock
connections on pins 4 and 5 of the Remote Interface, Signal Input port. The instrument
can still be used without the external interlock device as long as the Interlock Connector
(38075 provided with unit) is plugged into the Remote Interface, Signal Input port. If
there is nothing connected to the Remote Interface, Signal Input port to provide a
connection to the interlock, the instrument will not perform tests.

57

PLC Remote Pop-up message

If you attempt to start a test from the front panel Test button and the PLC remote function
is turned ON, a pop-up message will be displayed. The pop-up message will appear as
follows:

PLC Remote ON

58

8. Options
Introduction
This section contains a list and descriptions of available factory installed options at the time of
this printing. The list of options contains an option code number that can be referenced on the
data plate on the rear panel of the unit.
Option Label
On the rear panel of the instrument, you will find a label that contains the option code.
For example, your options code would appear as follows:
Fitted with option 01 ..........................................................
Fitted with option 01 and 02 ................................................

OPT: 01
OPT: 0102

Hypot III Options

Option List
Code
01
02
03
04
05

Description
High Resolution IR Limits
5mA Output Current
5 Continuity
PLC Ready Output
3mA Output Current

Description
01 High Resolution IR Limits
The High Resolution IR Limits option, increases the resolution of the Max and Min trip point
limits from 1M to 0.1M, in the range of 0.0 to 999.9M.
The Max and Min Lmt set points automatically range while being edited according to the
specification table below. This is unique only to this feature because this option has multiple
ranges.

59

INSULATION RESISTANCE TEST MODE

Maximum Limit

Range:
Resolution
Range
Resolution
Accuracy
Range:
Resolution
Range
Resolution
Accuracy

Minimum Limit

0.0 , 1.0 999.9 M (0 = Off)

0.1 M
1000 9999 M
1 M
Same as Resistance display
1.0 999.9 M
0.1 M
1000 9999 M
1 M
Same as Resistance display

02 5mA Output
The 5mA Output option limits the output current with software control. The trip points are
adjusted to a maximum of 5mA and the software has been modified so the high-speed
maximum current shutdown is fixed at 5mA. The following specifications have been changed
for this option:
DIELECTRIC WITHSTAND TEST MODE
Output Rating
Maximum Limit
Minimum Limit

AC
DC
AC
DC

5000V @ 5 mA AC
6000V @ 5 mA DC
Range:
0.00 - 5.00 mA
Range:
0 - 5000 A
Range:
0.000 - 0.500 mA
Range:
0.0 - 50.0 A

03 5 Continuity
The 5 Continuity option increases the ground continuity maximum limit from 1.5 to 5,
and increases the ground continuity offset range from 0.0 0.50 to 0.0 0.99. The
following specifications have been changed for this option.
DIELECTRIC WITHSTAND TEST MODE
Ground Continuity
Maximum Limit
Minimum Limit

Range:
Resolution
Accuracy

Ground Continuity
Auto Offset

Range:
Resolution
Accuracy

60

0.0 5.00
0.01
(3% of setting + 0.02)
0.0 - 0.99
0.01
(3% of setting + 0.02)

Calibration
The Calibration Procedure varies slightly with this option installed. The changes to the
calibration procedure are as follows:
During Calibration of Continuity, the instrument should be calibrated to a standard

5.0 resistor rather than a 1.0 resistor. This change is reflected on the display
during calibration of continuity.
All other items in the Calibration Procedure remain unchanged. Please refer to the Calibration
section for details.
04 PLC Ready Output
The PLC Ready Output Option creates a signal that acts as an instrument power-on indicator.
The signal is available through the Remote I/O output connector which is located on the back
of the instrument. This option closes the relay contact between pin (1) and pin (2) on the
output connector once the instrument is powered on. The PLC Ready Output signal replaces
the Pass signal that is present on the standard instrument.
It should be noted that the term Readyin PLC Ready Outputonly implies that the
instrument is powered on. To perform a test, it should be verified that an interlock device is
used or the interlock disable connector that was provided with the instrument is installed, and
that there are no failure indicators active on the instrument. For more information on the
Remote I/O signals/connections and interlock refer to Section 7. Connection of Remote I/O.
05 3mA Output
The 3mA Output option limits the AC output current with software control. The trip points are
adjusted to a maximum of 3mA and the software has been modified so the high-speed
maximum current shutdown is fixed at 3mA. The following specifications have been changed
for this option:
DIELECTRIC WITHSTAND TEST MODE
Output Rating
Maximum Limit
Minimum Limit

AC
AC

5000V @ 3 mA AC
Range:
0.00 - 3.00 mA
Range:
0.000 - 3.000 mA

61

9. Calibration Procedure
This instrument has been fully calibrated at the factory in accordance to our published
specifications. It has been calibrated with standards traceable to the National Institute
Standards & Technology (NIST). You will find in this manual a copy of the "Certificate of
Calibration". It is recommended that you have this instrument re-calibrated and a safety check
done at least once per year. AR recommends you use "Calibration Standards" that are NIST
traceable, or traceable to agencies recognized by NIST to keep this instrument within published
specifications.
End user metrology standards or practices may vary. These metrology standards determine the
measurement uncertainty ratio of the calibration standards being used. Calibration adjustments
can only be made in the Calibration mode and calibration checks or verifications can only be
made while operating in Test mode.

9.1. Warranty Requirements

AR offers a standard one-year manufactures warranty. This warranty can be extended an
additional four years provided that the instrument is returned each year to Associated Research,
Inc. for its annual calibration. In order to be eligible for the extended warranty instruments
must be returned to Associated Research, Inc. for calibration service at least once every twelve
months.
A return material authorization number (RMA) must be obtained from AR before returning
this instrument for calibration. To obtain an RMA number or for information regarding our
warranty please contact our Customer Support Representatives at 800-858-TEST.
Required Calibration Equipment
0 - 5 KV AC/DC Metered Voltage Divider.
20 mA AC, 10 mA DC Ammeter.
0 - 30 mV AC Millivoltmeter.
10, 0.25 watt resistor, 250 volt.
50M, 0.25 watt resistor, 1000 volt.
500M, 0.25 watt resistor, 1000 volt.
100K, 175 watt resistor, 4000 volt.
1M, 20 watt resistor, 4000 volt.

62

9.2. Calibration Initialization

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

Calibration
AC
5000V
DC
6000V
IR
1000V
AC
20.00mA
AC
3.500mA
(More)

Calibration

Select
Exit

DC
7.50mA
DC
3.500mA
DC
350 0uA
IR
999.9M
IR
9999M
CONT
1.50

Select
Exit

9.2.1. Calibration of Parameters

From the Calibration screens, use the soft key to scroll the Cursor to the parameter you
wish to calibrate. Once the cursor is pointing to the parameter you wish to calibrate, press the
Select soft key. A calibration prompt screen will now appear that describes the necessary load
and connection information for the parameter being calibrated.
The following is a list of the calibration parameters and an example of the prompt screen with
the details that will be displayed for each parameter (screen shown at left). Once you press
TEST, the Calibration data entry screen will appear for the selected parameter (screen shown at
right). Adjust the numeric value of the parameter using the +and -soft keys and press the
Enter soft key to accept the new parameter or press RESET to escape the edit.
Calibration of AC Hipot Voltage

Calibration
Connect the standard
5KVAC kilovolt meter
from H.V. to Return

Calibration
Enter standard
Voltage reading

_
Voltage=

<TEST> to Start
<RESET> to Exit

XXXXV
Enter

<RESET>

to

Exit

63

Calibration of DC Hipot Voltage

Calibration
Connect the standard
6KVDC kilovolt meter
from H.V. to Return

Calibration
Enter standard
Voltage reading

_
Voltage=

<TEST> to Start
<RESET> to Exit

XXXXV
Enter

<RESET>

to

Exit

Calibration of IR DC Voltage

Calibration
Connect the standard
1KVDC kilovolt meter
from H.V. to Return

Calibration
Enter standard
Voltage reading

_
Voltage=

<TEST> to Start
<RESET> to Exit

XXXXV
Enter

<RESET>

to

Exit

Calibration of AC Current 20.00mA range

Calibration
Connect the 100K
load in series with
the 20mAAC standard
current meter.
<TEST> to Start
<RESET> to Exit

Calibration
Enter standard
Current reading

+
_

Current=

XXXXV
Enter

<RESET>

to

Exit

Calibration of AC Current 3.50mA range

Calibration
Connect the 100K
Load in series with
The 3.5mAAC standard
current meter.
<TEST> to Start
<RESET> to Exit

64

Calibration
Enter standard
Current reading

+
_

Current=

XXXXV
Enter

<RESET>

to

Exit

Calibration of DC Current 7.50mA range

Calibration
Connect the 100K
load in series with
the 7.5mADC standard
current meter.
<TEST> to Start
<RESET> to Exit

Calibration
Enter standard
Current reading

+
_

Current=

XXXXV
Enter

<RESET>

to

Exit

Calibration of DC Current 3.50mA range

Calibration
Connect the 100K
load in series with
the 3.5mADC standard
current meter.
<TEST> to Start
<RESET> to Exit

Calibration
Enter standard
Current reading

+
_

Current=

XXXXV
Enter

<RESET>

to

Exit

Calibration of DC Current 350A range

Calibration
Connect the 1M load
in series with the
350uADC standard
current meter.
<TEST> to Start
<RESET> to Exit

Calibration
Enter standard
Current reading

+
_

Current=

XXXXV
Enter

<RESET>

to

Exit

Calibration of IR 999.9M and 9999M Ranges

Calibration
Connect the standard
50Mload from H.V.
to Return.

Calibration
Automatic
calibration
processing...

<TEST> to Start
<RESET> to Exit

65

Calibration of Continuity, Step 1

Calibration
Step 1:
Short the Cont. Check
and Return.leads
together.

Calibration
Automatic
calibration
processing...

<TEST> to Start
<RESET> to Exit

Calibration of Continuity, Step 2

Calibration
Step 2:
Connect the standard
1.0 from Cont. Check
to Return.
<TEST> to Start
<RESET> to Exit

66

Calibration
Automatic
calibration
processing...

10. Replacement Parts List

ECO: 4993 Rev.E
Part
Number
35999
37497
37555
37571
37605
37673
37783
37784
37880
38075
38101
38102
36544
38262
38367
38264
38265
38266
38267
38268
38271
38272
38287
38288
38320
04040A-08
02100A-13

Qty.
4
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2

Reference
Designator
Fail, Ready
RY1
RY2
IC16
CON 3670
HV 3670
HRY 3670
AMP 3670
KEY 3670
PWR 3670
T1
T2
-

Description
Black Banana Jacks
Reset Switch, Red
Power Switch 2P 10A/250V
Earth Connector
Bulbs
Switch Test, Green
Relay Gunther 3390-1290-246
Relay Gunther 3392-1290-246
3.15 Amp, fast acting 250VAC
Interlock Connector
Feet Kit w/o Rubber Inserts
Rubber Insert for Feet
Adapter Box
Microcontroller 78E516B PLCC
Main Control Board
High Voltage Board
HV Relay Board
Power Amplifier Board
Keypad Board
Input Voltage Select PCB
High Voltage Connector w/10cm cable
High Voltage Connector w/10cm cable
Input Transformer
Output High Voltage Transformer
128 x 64 Graphic Display
High Voltage Output cable
Return cable

For safety tester interconnect cables, refer to INSTRUMENT CONNECTIONS; section 1.3
Specific Integrated System Connections

67

11. Schematic Index

Drawing Number

68

Description

Reference
Designator

Pages

S03605

Wiring Diagram 3605

S03670

Wiring Diagram 3665, 3670

S38367

Main Control Board

CON 3670

S38264

High Voltage Board

HV 3670

S38265

HV Relay Board 3665, 3670

HRY 3670

S38266

Power Amplifier Board

AMP 3670

S38267

Keypad Board

KEY 3670

S38268

Input Voltage Select PCB

PWR 3670

Index
AC Withstand................................................................................................. 27, 36, 39, 42, 47
Adapter Box...............................................................................................................17, 24, 44
Alarm Parameter ................................................................................................................... 31
Arc ......................................................................................................14, 20, 38, 39, 40, 42, 49
Benefits................................................................................................................................. 14
Breakdown........................................................................................................................ 3, 49
Calibration Alert
Alert Date.....................................................................................................................33, 34
Cal Alert.......................................................................................................................29, 33
Cal Date .......................................................................................................................29, 33
Cal Due ........................................................................................................................29, 33
Date........................................................................................................................29, 33, 34
Time.............................................................................................................................29, 34
Calibration Procedure............................................................................................................ 62
Connected Steps....................................................................................... 17, 30, 31, 45, 47, 63
Continuity Test............................................................................................... 11, 15, 24, 39, 40
Contrast................................................................................................................ 23, 29, 31, 43
Controls ..............................................................................................14, 20, 24, 25, 29, 45, 46
DC Withstand......................................................................................36, 40, 41, 42, 47, 48, 49
Default Parameters ...........................................................................................................27, 42
Delay.............................................................................................................. 22, 38, 41, 42, 48
Dielectric Withstand Test ................................................................................... 8, 9, 42, 45, 48
Discharge ............................................................................................................... 7, 10, 11, 21
DUT............................................................... 6, 7, 12, 13, 14, 16, 27, 28, 39, 40, 44, 47, 48, 49
Dwell ..................................................................................................15, 21, 38, 39, 40, 42, 48
Edit Parameters ............................................................................. 34, 36, 37, 39, 40, 41, 42, 63
Features............................................................................................................................. 8, 14
Frequency .......................................................................................9, 15, 20, 21, 38, 39, 40, 42
Front Panel Controls.........................................................................................................14, 24
Glossary .................................................................................................................................. 3
Hypot ...................................................................................................................................... 3
Insulation Resistance ...............................................................................3, 8, 11, 13, 41, 48, 49
Interlock......................................................................................................... 15, 23, 25, 27, 57
LCD ..................................................................................................................... 14, 24, 31, 48
Leakage................................................................................. 3, 6, 10, 11, 12, 13, 14, 15, 19, 33
Limits....................................................................................................... 37, 38, 42, 48, 49, 59

Lock............................................................................................................... 23, 29, 32, 43, 48

Lockout......................................................................................................................20, 27, 57
Max Lmt .............................................................................................................. 37, 42, 48, 49
Medical Restrictions................................................................................................................ 6
Memory ................................................15, 23, 25, 27, 32, 36, 38, 39, 40, 41, 45, 46, 47, 56, 57
Menu......................................................................12, 14, 26, 29, 32, 36, 37, 44, 45, 46, 47, 50
Min Lmt ............................................................................................................... 38, 42, 49, 59
Operator ................................................................................ 5, 6, 10, 14, 15, 18, 24, 26, 33, 56
Options.............................................................................................................................34, 59
Parameters
System Parameters ........................................................................................... 27, 29, 30, 46
Test Parameters ...............................................................................14, 23, 36, 37, 42, 45, 46
PLC.......................................................................................................... 15, 29, 30, 43, 56, 58
Programming......................................................................................................................... 29
Ramping...........................................................................................................................16, 48
Rear Panel Controls............................................................................................................... 25
Receptacle................................................................................................ 16, 18, 23, 25, 26, 55
Regulation........................................................................................................................14, 21
Remote......................................................... 6, 15, 23, 25, 27, 29, 30, 43, 48, 50, 55, 56, 57, 58
Remote Interlock........................................................................................................23, 27, 57
Resistance .........................................3, 5, 6, 8, 11, 12, 13, 22, 37, 38, 39, 40, 41, 47, 48, 49, 60
Reviewing Test Results ..............................................................................................28, 32, 37
Safety......................................................................................................... 2, 4, 7, 8, 18, 23, 26
Safety Symbols ....................................................................................................................... 2
Schematic.............................................................................................................................. 68
Schematic Index.................................................................................................................... 68
Security................................................................................................................ 14, 23, 32, 35
Sequence ........................................................................................................ 17, 30, 31, 47, 63
Service Interval ....................................................................................................................... 4
Setup........................................................................................................ 14, 29, 30, 43, 46, 47
Short .............................................................................................................. 22, 27, 39, 40, 49
Single Step ..................................................................................................... 29, 30, 43, 45, 47
Smart GFI ................................................................................................ 23, 27, 29, 32, 33, 43
Specifications ........................................................................................................................ 20
Test Station ......................................................................................................................... 5, 7
Trip Point ............................................................................ 3, 37, 38, 39, 40, 41, 42, 48, 49, 59
TUV...................................................................................................................................... 14
UL.................................................................................................................... 8, 12, 14, 15, 50
Unpacking............................................................................................................................. 17
Verification .............................................................................................. 26, 50, 51, 52, 53, 54

Warranty ........................................................................................................................1, 4, 62