7100 Series Safety Testers

OPERATION MANUAL (7130,7132,7140,7142)

EXTECH ELECTRONICS CO., LTD.

Version 1.2

WARRANTY POLICY

EXTECH ELECTRONICS CO., LTD., 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 Taiwan.

Your new instrument is warranted to be free from defects in workmanship and material for a period of (1) year from date of shipment. During the warranty period, you must return the instrument to Extech Electronics Co., or its branches or its authorized distributor for repair. Extech Electronics Co., reserves the right to use its discretion on replacing the faulty parts or replacing the assembly or the whole unit.

Any unauthorized modification, tampering with or physical damage to this instrument will render your warranty void. Elimination of any connection in the earth grounding system or by-passing any safety system will void this warranty. This warranty does not cover accessories not of Extech Electronics Co., Ltd. manufacture. Parts used must be parts that are recommended by Extech Electronics Co. Ltd. as an acceptable specified part. Use of non-authorized parts in the repair of this instrument will void the warranty.

Extech Electronics Co., Ltd. recommends that your instrument be calibrated on a twelve month cycle.

Except as provided herein, Extech Electronics Co., Ltd. makes no warranties to the purchaser of this instrument. All other warranties, express or implied are hereby excluded, disclaimed and waived.

EXTECH ELECTRONICS CO., LTD 4F, NO. 252,Nan Yang Street, Shih City, Taipei Hsien, Taiwan, R.O.C. Tel : 886-2-26943030 Fax : 886-2-26945563 Email : mailto:extech@ms1.hinet.net Website://www.extech.com.tw

1.1 INFORMATION ON SAFETY PRECAUTION ........................................... 1

1.2 TEST STATION ......................................................................................................... 2

1.3 TEST OPERATOR ..................................................................................................... 2

1.4 TEST PROCEDURES ................................................................................................ 3

1.5 SERVICE AND MAINTENANCE ................................................................................ 3

1.6 THE IMPORTANCE OF TESTING.... USER SAFETY ............................................... 4

1.7 UNPACKING AND INSPECTION .............................................................................. 7

1.8 OPERATING ENVIRONMENT .................................................................................. 7

1.9 FIELD INSTALLATION OF OPTIONS ....................................................................... 7

CHAPTER 2: SPECIFICATIONS ...................................................................................... 8

2.1 PRODUCT SPECIFICATIONS................................................................................... 8

CHAPTER 3: PANEL ...................................................................................................... 10

3.1 FRONT PANEL DESCRIPTION ............................................................................... 10

3.2 REAR PANEL DESCRIPTION ................................................................................. 11

CHAPTER 4: OPERATION ............................................................................................. 12

4.1 Introduction .............................................................................................................. 12

4.2 Front Panel Operation .............................................................................................. 12

4.3 Test Parameters Setup ............................................................................................ 14

4.4 System Parameter Setting ....................................................................................... 17

4.5 Display Message ...................................................................................................... 20

CHAPTER 5: REMOTE I/O ............................................................................................. 24

5.1 Remote Interface ..................................................................................................... 24

5.2 RS485 Commands List ............................................................................................ 26

CHAPTER 6: CALIBRATION ........................................................................................ 28

6.1 Calibration Procedure .............................................................................................. 28

6.2 Test verification ........................................................................................................ 30

CHAPTER 7: OTHER INFORMATION ......................................................................... 32

7.1 Accessories Supplied ............................................................................................... 32

7.2 Optional Accessories ............................................................................................... 32

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CHAPTER 1: INTRODUCTION

1.1 INFORMATION ON SAFETY PRECAUTION

1.1.1 GENERAL

This product and its related documentation must be reviewed for familiarization with safety markings and instructions before operation. The 7001 is Safety Class I instrument (provided with a protective earth terminal). Before applying power verify that the instrument is set to the correct line voltage (110V or 220V) and the correct fuse is installed.

1.1.2 SAFETY SYMBOLS

INSTRUCTION MANUAL SYMBOL. PLEASE REFER TO THE INSTRUCTION MANUAL FOR SPECIFIC WARNING OR CAUTION INFORMATION TO AVOID PERSONAL INJURY OR DAMAGE TO THE PRODUCT.

INDICATES HAZARDOUS VOLTAGES MAY BE PRESENT.

CHASSIS GROUND SYMBOL.

CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR CONDITION, THAT COULD POSSIBLY CAUSE BODILY INJURY OR DEATH.

CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR CONDITION, THAT COULD POSSIBLY CAUSE DAMAGE TO EQUIPMENT OR PERMANENT LOSS OF DATA.

WARNING: HIPOT test produces voltages and current which can be harmful

or fatal. To prevent accidental injury or death, these safety procedures must be strictly observed when handling and using the test instrument.

WARNING

CAUTION

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1.2 TEST STATION 1.2.1 LOCATION

Select an area away from the main stream of activity where employees do not walk through when 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.”

1.2.2 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 the event of an emergency, anyone can cut off the power before entering the test area to offer assistance.

1.2.3 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 securely grounded to a good earth ground and insulate the high voltage connection 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 that the operator does not have to reach over the product under test to activate or adjust the tester. If the DUT is small, it may be possible to construct guards or an enclosure, made of a non-conducting material such as clear acrylic, such that the DUT is within the guards or enclosure during the test. Fit them with switches so that the tester will not operate unless the guards are in place or the enclosure closed. Keep the area clean and uncluttered. All test equipment and test leads not absolutely necessary for the test should be removed from the test bench and put away. It should be clear to both the operator and to any observers that which product is being tested, and which product is waiting to be tested or has already been tested. Do not perform HIPOT test in a combustible atmosphere or in any area where combustible materials are present.

1.3 TEST OPERATOR

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1.3.1 QUALIFICATIONS This instrument generates voltage and current which may cause electric shock. This instrument must be operated by a skilled operator. 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 lead directly connected to earth ground and therefore, current from the high-voltage output will flow through any available ground path.

1.3.2 SAFETY PROCEDURES Operators should be thoroughly trained to follow these and all other applicable safety rules and procedures before they begin a test. Defeating any safety system should be treated as a serious offense and should result in 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 offence.

1.3.3 DRESS Operators should not wear jewelry which could accidentally complete a circuit.

1.3.4 MEDICAL RESTRICTIONS This instrument should not be operated by personnel with heart ailments, or by those wearing devices such as pacemakers.

1.4 TEST PROCEDURES

NEVER PERFORM A HIPOT TEST ON ENERGIZED CIRCUITRY OR EQUIPMENT

If the instrument has an external safety ground connection be sure that this is connected. Then connect the return (ground) lead first for any test regardless of whether the item under test is a sample of insulating material tested with electrodes, a component tested with the high voltage test lead, or a cord-connected device with a two or three prong plug.

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 instrument.

Double check the return (ground) and high voltage connections to be certain that they are properly connected and secure. NEVER TOUCH THE ITEM UNDER TEST OR ANYTHING CONNECTED TO IT WHILE HIGH VOLTAGE IS PRESENT DURING THE WITHSTAND VOLTAGE TEST.

1.5 SERVICE AND MAINTENANCE

1.5.1 USER SERVICEE To prevent electric shock do not remove the instrument cover. There are no user serviceable

INTRODCTION

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parts inside. Refer servicing to Extech Electronics Co. Ltd. or its authorized service center.

1.5.2 USER MODIFICATIONS Unauthorized user modifications will void your warranty. Extech Electronics will not be responsible for any injuries sustained due to unauthorized equipment modifications or use of parts not specified by Extech Electronics. Instruments returned to Extech Electronics with unsafe modifications will be returned to their original operating condition at your expense.

1.6 THE IMPORTANCE OF TESTING.... USER SAFETY

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), the Japanese

Standards Association (JSI). These same agencies may also require that an insulation resistance test

and high current ground bond test be performed.

1.6.1 THE DIELECTRIC VOLTAGE 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.

The most common applications of the dielectric voltage withstand test are:

Design (performance) Testing determine design adequacy to meet service conditions Production Line Testing detect defects in material or workmanship during processing Acceptance Testing verify minimum insulation requirements of purchased parts. Repair Service Testing determine reliability and safety of equipment repairs

The specific technique varies with each product, but basically, during a dielectric voltage withstand test, an electrical device is exposed to a voltage significantly higher than it normally encounters. The high voltage is continued for a given period of time.

If, during the time the component is tested, stray current flow remains within specified limits, the device is assumed to be safe under normal conditions. The basic product design and use of the insulating material will protect the user against electrical shock.

The equipment used for this test, a dielectric withstand tester, is often called a "HIPOT" (for high potential tester). The "rule of thumb" for testing is to subject the product to twice its normal operating voltage, plus 1,000 volts.

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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 insulated" products 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 each and 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 tester 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.

1.6.2 Advantages and Disadvantages of AC Testing and DC Testing

Please check with the Compliance Agency you are working with to see which 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.

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 acapacitive load.

1.6.3 ADVANTAGES AND DISADVANTAGES OF AC TESTIN

A) Advantages

1. 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 at AC voltages and 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.

2. 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. 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.

3. 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.

B) Disadvantages

1. A key 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.

2. 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.

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1.6.4 ADVANTAGES AND DISADVANTAGES OF DC TESTING 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.

A) DC testing advantages

1. 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. 2. The other advantage to DC testing is that since the charging current only needs to be applied momentarily 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.

B) DC testing disadvantages

1. 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 which will indicate failure almost immediately if the total current reaches the leakage threshold during the initial charging of the product under test.

2. Since a DC HIPOT does charge the item under test it becomes necessary to discharge the item after the test.

3. 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 a key reason that some safety agencies do not accept DC testing as an alternative to AC.

4. 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 sine wave 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.

1.6.5 The Ground Continuity Test

The Ground Continuity test is checking to verify that there is low impedance path between the chassis and safety ground wire of the line cord. A low impedance ground system is critical in ensuring that in the event 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, TÜV, VDE, BABT and others, have requirements calling out this test. A low current test merely indicates that there is a safety ground connection, it does not completely test the integrity of that connection that would be accomplished when using much higher currents in the range from 10 to 30amps. The high current test is know as a Ground Bond test.

1.6.6 The 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, TÜV 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.

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1.6.7 TYPES OF FAILURES DETECTABLE ONLY WITH A HIPOT TEST

• Weak Insulating Materials • Pinholes in Insulation • Inadequate Spacing of Components • Pinched Insulation

1.7 UNPACKING AND INSPECTION

Your instrument was shipped in a custom foam insulated container that complies with ASTM D4169-92a AssurancLevel 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 meters. If the instrument is damaged, notify the carrier and the EXTECH customer support department OR local distributor immediately. 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 RGA (return goods authorization) number.

1.71 ACCESSORIES SUPPLIED

PART NUMBER DESCRIPTION QUANTITY

1101 High Voltage Cable, Molded Male White to Alligator 1 1102 Return Cable, Molded Female Black to Alligator 1

WC-10 Power Cable 1 Interlock Key 1 Operation Manual 1

1.8 OPERATING ENVIRONMENT Operating Environment This instrument may be operated in temperatures from 0° - 40° C. and relative humidity of 20 to 80%, altitude 2000 meters (6560 feet) . Storage Environment This instrument may be stored or shipped in environments with the following limits: Temperature......................... -40° to +55°C Altitude..........................….. 7,620 meters (25,000 feet) The instrument should also be protected against temperature extremes, which may cause condensation within the instrument.

1.9 FIELD INSTALLATION OF OPTIONS

There are no field installable options for 7100 series of safety testers.

NOTE : THE WORD “HIPOT” IS USED INTERCHANGABLY WITH “VOLTAGE WITHSTAN

SPECIFICATIONS

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CHAPTER 2: SPECIFICATIONS

2.1 PRODUCT SPECIFICATIONS

MODEL NO. FUNCTIONS

7142 AC/DC Withstand Voltage/Insulation Tester 7140 AC/DC Withstand Voltage Tester 7132 AC Withstand Voltage/Insulation Tester 7130 AC Withstand Voltage Tester

AC WITHSTAND VOLTAGE Range Resolution Accuracy

Output Voltage, ACV 0-5000 10 ±(2％ of setting + 5V)

Output Frequency 50/60Hz±0.1%

Output Regulation (±1％ of setting + 5V),from no load to full load

Hi Limit, current, mA 0-20.00 0.01 ±(2.0％ of setting+2 counts) Lo Limit, current, mA 0-9.999 0.001 Dwell Time, second 0,0.3-999.9 0.1

±(0.1％ of reading + 0.05 sec)Ramp Up Time, second 0.1-999.9 0.1 Ramp Down Time,second 0.0-999.9 0.1 ARC Detection 1-9 DC WITHSTAND VOLTAGE (7140,7142 only)

Output Voltage, DCV 0-6000 10 ±(2.0％of setting + 5 V)

Hi Limit, current, µA 0-7500 1 ±(2.0％of setting + 2 counts) Lo Limit, current, µA 0-999.9 0.1 Dwell Time, second 0,0.4-999.9 0.1

±(0.1％ of reading + 0.05 sec ) Ramp Up Time, second 0.1-999.9 0.1 Ramp Down Time, second 0,1.0-999.9 0.1 INSULATION RESISTANCE (7132,7142 only) Output Voltage, DC,V 30-1000 10 ± (2% of setting + 5 volts)

Hi Limit, Resistance, MΩ 0-9999 1 Same as Resistance display Lo Limit, Resistance, MΩ 1-9999 1 Ramp Down Time, second 0,1.0-999.9 0.1

±(0.1％ of reading + 0.05 sec ) Delay Time, second 0,0.5-999.9 0.1

SPECIFICATIONS

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MEASUREMENT Range Resolution Accuracy Voltage, KV 0.00-6.00 0.01

±(1.5％of reading + 0.01KV)

Voltage, V 30 - 1000 ± (1.5% of setting + 0.005KV)

AC Current, mA 0.000 - 3.500 0.001

±(2.0％of setting + 2 counts) 3.00-20.00 0.01

DC Current, µA 0.0 - 350.0 0.1

DC Current, mA 0.300 - 3.500 0.001 3.00 - 7.50 0.01

Resistance, MΩ 1- 9999 (auto range)

0.001 0.01 0.1 1

± (2% of reading + 2 counts) @500 - 1000VDC/ 1 - 1000 MΩ ± (5% of reading + 2 counts)@500 - 1000VDC / 1000 - 9999 MΩ ± (8% of reading + 2 counts) @30 - 500V DC/ 1 - 1000 MΩ

GENERAL Memory Memory10, Step3 PLC Remote Control Test, Reset, Memory1.2.3, Interlock PLC Signal Output Pass, Fail, Processing, Reset Safety Built-in Smart GFI circuit LCD Display 128x64 Graphic LCD Key Lock To prevent unauthorized alteration of the test parameters Calibration Built-in software and external calibrated meters Verification AC, DC, IR Dimension/Wight 215(W) x 89(H) x 370(D) mm/10Kg Input Voltage 115/230VAC ±15％,50/60HZ±5％ Environment 0-40 ﾟ C,RH 0-80％

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CHAPTER 3: PANEL

3.1 FRONT PANEL DESCRIPTION 2 3 11 4 5 6 9

1 7 10 8 1 Power Switch Rocker style switch with ON (I) and OFF (0) markings. 2 RESET Button Press to abort test or stop audible alarm. In parameter setting

mode, it has the same function as EXIT key. It is lighted RED to indicate DUT fails test.

3 TEST Button Press to start test. Lighted Green when DUT passes test. 4 Menu/Result Key For entering memory, test and front panel key functions. 5 Memory/Test Key Select memory locations to recall of test functions and

parameters stored in that memory location. 6 Step/System Key Press Step key to select test step and System key to set display

constrast, alarm volume, remote PLC and result display format. 7 Exit/Esc Key Press to return to main display and clear error entry. 8 HV Output AC 5KV/DC 6KV output socket, use model 1101 HV test cable.

9 RETURN AC 5 KV/DC 6 KV return socket, use model 1102 Return test

cable. 10 HV Indicator Flashes when HV is present at HV output socket. 11 Display 128 x 64 graphic LCD display

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3.2 REAR PANEL DESCRIPTION

5 6 7 8 9 10

1 2 3 4

1 OPITION Not use, For future option. 2 SIGNAL OUTPUT Output relay contact signal for PASS, FAIL and

PROCESSING. 3 SIGNAL INPUT Accept relay contact signal for TEST, RESET and MEMORY. 4 CAL Switch Hold down this switch and turn on the instrument to enter

calibration mode. 5 RETURN HV return socket, parallel to front panel RETURN. 6 HV AC 5KV/DC 6KV output socket, parallel to front panel HV. 7 Fuse Input fuse holder. 8 AC Input Power Standard IEC 320 power receptacle for connection to a

standard NEMA line power cord. 9 Earth Terminal Chassis ground terminal. This safety terminal should be

connected to a good earth ground before operation. 10 AC Input selector For setting Line voltage, AC 115V or 230V operation.

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CHAPTER 4: OPERATION 7100 series safety testers are designed for use in production environment. Front panel setup is user friendly. Operation error will be responded by two short beeps and return to original setting. Please follow the instruction in this manual to operate the safety tester.

4.1 Introduction 1. Care must be taken to ensure that the working area for safety test is a safe environment. 2. Before power ON, be sure the voltage selector switch is set to correct AC input voltage.

Connect earth wire to the tester earth terminal at the rear panel. 3. Do not connect test cable until you are familiar with the tester. 4. Turn on power, the tester will display the last settings before the unit was turn off. Note the test

function and the memory location shown in the display. 5. Press Menu key to select memory location and step. Press Memory key will scroll the settings

of each memory location. Press Step key will scroll the settings of next step within the memory location.

6. Press Menu key again to change the keys for test and system parameters settings. 7. Press Test key to enter test parameter setting mode. Refer to section 4.6 8. Press System key to enter system parameter setting mode. Refer to section 4.7. 9. Setup the required test. 10. Press Test without connecting to DUT to make sure the test step is set properly.

High Voltage is present when Red lighting mark is flashing.

11. Connect 1101 HV cable and 1102 Return cable to DUT. Check connection carefully. Ensure

safety measures are taken. 12. Press Test to start testing. Do not touch DUT when the Red Lighting mark is flashing.

High Voltage is present when Red lighting mark is flashing.

13. Press RESET to abort test if necessary.

4.2 Front Panel Operation Turn on the instrument, the main display will show as follow:

If the Interlock key is not attached to the SIGNAL INPUT connector at the rear panel, this display is shown to warn user that the interlock connection is opened when the TEST key is pressed.

WARNING

WARNING

POWER UP Screen

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Please attached the Interlock key at the SIGNAL INPUT connector and tighten firmly.

If the Key Lock function is ON, this display is shown to indicate that the instrument is LOCK with a password. Only TEST and RESET keys are active. To enter setup mode, enter the password to unlock the instrument, please refer to Key Lock function in this manual.

4.2.1 Menu Key

At the main display, press “Menu” key to enter sub-menu of Menu, Memory, Step and Exit functions. Press Menu key again will enter the next sub-menu of Results, Test, System and Exit. Press Exit key will return to the main display.

4.2.2 Memory Key

There are 10 memory locations. In each memory location, there are 3 steps. Each step can be set for ACW, DCW or IR test. Please note that for 7130 & 7140, IR test is not available. Pressing Memory key will index to the next memory location in ascending order, after Memory 9 will increment to Memory 0.

MEMORY 0 STEP 1 STEP 2 STEP 3 One test per step.

ACW DCW IR*

ACW DCW IR*

ACW DCW IR*

MEMORY 2 STEP 1 STEP 2 STEP 3 One test per step.

ACW DCW IR*

ACW DCW IR*

ACW DCW IR*

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*Not available for 7130 and 7140 4.2.3 Step Key

Press Step key to increment to the next step, i.e. step 1 to step 2 to step 3 and repeat. The setting in each step is shown accordingly. If “Connect” is set to ON, the tester will continue the test of next step.

4.2.4 Exit Key

Press Exit key to return to main display. 4.2.5 Test Key

On the Main display, press Menu key to enter Test and System menu. Press Test key will enter test setup menu as shown on the right.

4.3 Test Parameters Setup For setting test functions and test parameters, use “∧” or “∨” key to move cursor and “Edit” key to edit each item. Press “Enter” key to confirm setting and “Esc” key to cancel setting.

Setup Parameters ACW DCW IR

Voltage,AC 0 – 5.00KV Voltage, DC 0 – 6.00KV Voltage, DC 30 – 1000V Max Lmt 0 – 20.00mA Max Lmt 0 – 7500µA Max Lmt 0 – 9999 MΩMin Lmt 0 – 9.999mA Min Lmt 0.0 – 999.9µA Min Lmt 1 – 9999 MΩRamp UP 0.1 – 999.9 Ramp UP 0.1 – 999.9s Ramp UP 0.1 – 999.9s Dwell 0 – 999.9s Dwell 0 – 999.9s Delay 0 – 999.9s Ramp DN 0 – 999.9s Ramp DN 0 – 999.9s Ramp DN 0 – 999.9s

MEMORY 9 STEP 1 STEP 2 STEP3 One test per step.

ACW DCW IR*

ACWDCW IR*

ACWDCW IR*

Model Functions 7130 ACW 7132 ACW、IR 7140 ACW、DCW 7140 ACW、DCW、IR

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Arc Sense 0 9 Arc Sense 0 - 9 Frequency 50/60Hz Connect ON/OFF Connect ON/OFF Connect ON/OFF

4.3.1 Voltage Setting for ACW or DCW or IR

Move cursor to “Voltage” location by “∧” or “∨” key. Press Edit Key will enter voltage setting mode. Set voltage using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

4.3.2 Upper Trip Limit, Max Lmt, setting for ACW or DCW or IR Move cursor to “Max Lmt” location by “∧” or “∨” key. Press Edit Key will enter Upper trip current limit setting mode. Set limit using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

4.3.3 Lower Trip Limit, Min Lmt, setting for ACW or DCW or IR

Move cursor to “Min Lmt” location by “∧” or “∨” key. Press Edit Key will enter Lower trip current limit setting mode. Set limit using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

.

4.3.4 Ramp Up Time, Ramp UP, setting for ACW or DCW or IR Ramp Up Time is the time taken for output voltage to reach the set value. Move cursor to “Ramp UP” location by “∧” or “∨” key. Press Edit Key will enter Ramp Up Time setting mode. Set time using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

圖(五)

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4.3.5 Dwell Time, Dwell, setting for ACW or DCW Dwell Time is the time duration for output voltage to remain at the set value. Move cursor to “Dwell” location by “∧” or “∨” key. Press Edit Key will enter Dwell Time setting mode. Set time using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

4.3.6 Delay Time, Delay, setting for IR

The Delay Time is the time delay before the measured value is compared to the limits in above. Move cursor to “Delay” location by “∧” or “∨” key. Press Edit Key will enter Delay Time setting mode. Set time using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

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4.3.7 Ramp Down Time, Ramp DN, setting for ACW or DCW or IR Ramp Down Time is the time taken for output voltage to reach zero from the set value. Move cursor to “Ramp DN” location by “∧” or “∨” key. Press Edit Key will enter Ramp Down Time setting mode. Set time using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

4.3.8 Arc Sensitivity, Arc, setting for DCW or IR Arc Sensitivity is to set the sensitivity level for arc detection. Level 9 is most sensitive. Move cursor to “Arc Sense“ location on next page by “∧” or “∨” key. Press Edit Key will enter Arc Sensitivity setting mode. Set sensitivity level using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

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4.3.9 Test Frequency, Frequency, setting for ACW Move cursor to “Frequency” location by “∧” or “∨” key. Press Edit Key will enter frequency setting mode. Set frequency using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen.

4.3.10 Multiple Test Step, Connect, setting Move cursor to “Connect” location by “∧” or “∨” key. Press Edit Key will enter multiple test step setting mode. Set “Connect” to ON or OFF using “ + ” or “ - “ key. Press “Enter” to confirm. The display will return to setup screen. In main display, “underscore” after memory location, MX-X_, denote this step is connected to the next step.

This is the last parameter setting. Press Exit key will return to Memory setting screen. The setting of voltage, Upper limit, Lower limit and test time are shown. Press Step key will show the setting of next test step. Press Exit key will return to the Main screen.

4.4 System Parameter Setting At the setup screen, press System key to enter System Parameter setting screen.

4.4.1 PLC Remote Setting

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Move the cursor to “PLC Remote” location by “∨” key, then press “ + ” or “ - “ key to change the setting from OFF to ON or vise versa. When “PLC Remote” is set to ON, “TEST” button on the front panel is disable. Relay contact signal is required to start test. However “RESET” button is still active. See PLC remote section for pin assignment. When “PLC Remote” is OFF, the RESET function is still active but not the TEST function at the rear connector.

4.4.2 Single Step Setting

Move the cursor to “Single Step” location by “∨” key, then press “ + ” or “ - “ key to change the setting from OFF to ON or vise versa. When “Single Step” is set to ON, the tester will stop after completion of current test. Then press TEST button for the next step. When “Single Step” is set to OFF, the tester will continue to next step automatically if “Connect” is set to ON.

4.4.3 Alarm Volume Setting Move the cursor to “Alarm” location” by “∨” key, then press “ + ” or “ - “ key to change the volume of the tone from 0 to 9. When the reading is changed, a tone correspond to the level can be heard.

4.4.4 LCD Contrast Setting

Move the cursor to “Contrast” location by “∨” key, then press “ + ” or “ - “ key to change the contrast level of the LCD screen from 1 to 9.

4.4.5 Result Display Setting

Move the cursor to “Results” location by “∨” key, then press “ + ” or “ - “ key to change the display

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format of the test results, P/F, Last or ALL.

4.4.6 Lock Setting Move the cursor to “Lock” location by “∨” key, then press “ + ” or “ - “ key to change the Lock status o ON or vise versa. When “Lock” is set to ON, all setting cannot be modified. Only TEST and RESET buttons are active for testing. Attempt to modify setting will see “Key Lockout” warning message on the screen.

To unlock, follow this procedures: 1. Turn off the power. 2. Hold down the top soft key and turn on the power. 3. Release after Main screen is shown. 4. Press Menu key twice and then System key. 5. Change the Lock status to OFF.

4.4.7 Memory Lock, Mem Lock, Setting

When “Lock” is set to OFF, this function is inactive, regardless of its status. When “Lock” is set to ON and “Mem Lock” is set to OFF, user can recall test setup in any location and start test. However, test

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setup cannot be modified. When “Lock” is set to ON and “Mem Lock” is set to ON, user cannpt recall test setup in any location and start test, except the current memory location. Test setup cannot be modified.

Move the cursor to “Mem Lock” location by “∨” key, then press “ + ” or “ - “ key to change the Lock status to ON or vise versa. When “Mem Lock” is set to ON, no memory location can be recalled. If “Mem Lock” is set to OFF and “Lock” is set to ON, then settings in any memory location can be recalled but cannot be edited. The setting from the factory is “Mem Lock” is set to ON.

4.4.8 Smart GFI setting Move the cursor to “Smart GFI” location by “∨” key, then press “ + ” or “ - “ key to change the Lock status to ON or vise versa. When “Smart GFI” is set to ON, the tester will shut down when it detect Earth Leakage current.

This is the last step of System setting. Press Exit key will return to main screen. The tester is ready for testing.

4.5 Display Message This tester has many display messages to indicate various conditions. Understanding the meaning of each display will help to identify the status of testing and the condition of the DUT.

4.5.1 Abort

If testing is in progress, press “RESET” key or Remote PLC Reset signal is present will abort the test. ACW Abort or DCW Abort or IR Abort is shown in one of the following format.

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4.5.2 Ramp UP If “Ramp UP” time is set in the test setup, during the voltage ramp up before the test, ACW Ramp UP or DCW Ramp UP or IR Ramp UP is shown in the main display.

4.5.3 Ramp DN

If “Ramp DN” time is set in the test setup, during the voltage ramp down after the test, ACW Ramp DN or DCW Ramp DN or IR Ramp DN is shown in the main display.

4.5.4 Dwell

After the voltage reaches the set voltage, ACW Dwell or DCW Dwell is shown in the main display. During the Dwell period, the testing result is being updated

continuously. 4.5.5 Max-Fail

If the result of the test exceeds the upper limit setting, the tester will judge DUT fails the test. ACW Max-Fail, DCW Max-Fail or IR Max-Fail is shown in one of the following format.

4.5.6 Short If the current drawn during ACW or DCW test exceeds the current range of the tester and the tester detects short circuit in DUT, the test is terminated immediately. ACW Short or DCW Short is shown in one of the following format.

4.5.7 Breakdown

If the current drawn during ACW or DCW test exceeds the current range of the tester and the tester detects excessive arcing current, the test is terminated immediately. ACW Breakdown or DCW Breakdown is shown in one of the following format.

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4.5.8 Min-Fail If the result of the test is below the lower limit setting, the tester will judge DUT fails the test. ACW Min-Fail, DCW Min-Fail or IR Min-Fail is shown in one of the following format.

4.5.9 Arc Fail

If the leakage current is within the upper limit, but the arc current exceeds the sensitivity level set during ACW or DCW test, the tester will judge DUT fails arc test and terminate the test immediately. ACW Arc-Fail or DCW Arc-Fail is shown in one of the following format.

4.5.10 Pass If the result of the test is within the upper and lower limits, DUT passes the test. ACW Pass or DCW Pass or IR Pass is shown in one of the following format.

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4.5.11 Delay If Delay time is set for IR test, during the Delay time period, IR Delay is shown in the main display. No judgment of result is made during Delay time period.

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CHAPTER 5: REMOTE I/O

5.1 Remote Interface Two 9 pin “D” type connectors are mounted on the rear panel which provide REMOTE INPUT and OUTPUT control. These connectors mate with standard 9 pin “D” subminiature connector provided by the user.. 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 PLUG SHELL WITH GROUND INDENTS 205203-3 RECEPTACLE SHELL 745254-7 CRIMP SNAP-IN PIN CONTACT (for plug) 745253-7 CRIMP SNAP-IN SOCKET CONTACT (for receptacle) 745171-1 SHIELDED CABLE CLAMP (for either plug or receptacle)

747784-3 JACKSCREW SET (2)

5.1.1 Signal Outputs

The rear panel connector provides output signals to remotely monitor PASS, FAIL, and PROCESSING conditions. These signals are provided by three normally open internal relays that switch on to indicate the current condition of the tester. These are normally open free contacts and will not provide any voltage or current. The ratings of the contacts are 1A / 250 VAC ( 0.5 ADC ). The signal outputs are provided on the 9 pin female type 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.

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, 8, and 9 are blank.

PROCESSING - The relay contact closes the connection between pin (5) and pin (6) while the analyzer is performing a test. The connection is opened at the end of the test.

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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 any test. The connection is opened when the next test is initiated or the reset function activated.

5.1.2 Signal Inputs and Memory Programs

The Signal Input remote connector enables remote operation of the TEST and RESET functions or allows the operator to select one of three pre-programmed tests. When the remote function is (ON) the “TEST” switch on the front panel will be disabled to prevent a test from being activated through the test switch. A normally open momentary switch can then be wired across pins 3 and 5 to allow remote operation of the TEST function. A normally open momentary switch can also be wired across pins 2 and 5 to allow remote operation of the RESET function. For safety reason, 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.

5.1.3 Interlock

When Pin 4 and 5 is open, the tester will not start. Pin 4 and 5 must remain shorted for the tester to operate normally. In manual operation, an interlock key is attached to this connector to provide a short for Pin 4 and 5. A protective cover with a micro switch can replace this interlock key. When the cover is closed, the switch is closed to complete the circuit so that the tester is ready to start testing.

is series analyzers 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 7400 series analyzers 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.

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.

CAUTION

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5.2 RS485 Commands List Test parameters editing

Command Description Value Test Types

TEST TEST RESET RESET

MSS <value> Edit MEMORY & STEP Memory：1-8 Step：1-3 ALL

ACW ACW Function Select DCW DCW Function Select IR IR Function Select

VOLT <value> Edit Voltage 0.00-5.00 0.00-6.00 30-1000

ACW DCW IR

MAXL <value> Edit HI-Limit 0.00-20.00 0-7500 0-9999

ACW DCW IR

MINL <value> Edit LO-Limit 0.00-20.00 0-7500 0-9999

ACW DCW IR

RUP <value> Edit RAMP UP 0.1-999.9 ALL

DDT <value> Edit Dwell Time (ACW,DCW) Edit Delay Time (IR)

0.3-999.9 0.4-999.9 0.5-999.9

ACW DCW IR

RDN<value> Edit RAMP DOWN 0-999.9 1.0-999.9 1.0-999.9

ACW DCW IR

ARC <value> Edit ARC 0-9 ACW DCW

FREQ <value> Edit Frequency 50 or 60 ACW CONN <value> Edit Connect 1=ON,0=OFF System parameters editing

Command Description Value

PLC <value> PLC Remote 1=ON,0=OFF SSTP <value> Single Step 1=ON,0=OFF ALAR <value> Alarm Volume 0-9 CNTR <value> Contrast 0-9 RLT <value> Results L=Last ,A=All ,P=P/F SGFI <value> Smart GFI 1=ON,0=OFF Query Commands

Command status TD? MX-X_,FUNC,STATUS,V,A(R),T RD n? MX-X_,FUNC,STATUS,V,A(R),T SALL? SALL nn,nn...

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RR? n (0=CLOSE,1=OPEN) RI? n (0=CLOSE,1=OPEN)

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CHAPTER 6: CALIBRATION This tester has been calibrated in the factory by standard instruments traceable to the National Institute of Standards Taiwan. Extech Electronics recommends that this tester should be calibrated at least once a year. Instruments used for the calibration should be within 0.5% basic accuracy to ensure the performance will meet the specifications stated in this manual. Instruments used for calibration: 1. Calibrated AC High Voltage Meter, 5000V 2. Calibrated DC High Voltage Meter, 6000 V 3. Calibrated AC Current Meter, 4. 100KΏ resistor 5. 1MΏ resistor 6. 50MΩ standard resistor

6.1 Calibration Procedure Hold down the “CAL KEY” at the rear panel and turn on the power. The tester will enter calibration mode.

6.1.1 ACW Voltage Calibration

Use “Move” key to move cursor to AC 5000V location and press Select Key. Connect a calibrated AC HV meter to HV and Return and press “TEST” key. The tester will output a AC high voltage about 5000V. Take the reading shown on the calibrated HV meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of AC voltage is completed.

6.1.2 DCW Voltage Calibration

Use “Move” key to move cursor to DC 6000V location and press Select Key. Connect a calibrated DC HV meter to HV and Return and press “TEST” key. The tester will output a DC high voltage

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about 6000V. Take the reading shown on the calibrated HV meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of DC voltage is completed.

6.1.3 IR Voltage Calibration

Use “Move” key to move cursor to IR 1000V location and press Select Key. Connect a calibrated DC HV meter to HV and Return and press “TEST” key. The tester will output a DC high voltage about 1000V. Take the reading shown on the calibrated HV meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of IR voltage is completed.

6.1.4 ACW High Range Current Calibration Use “Move” key to move cursor to AC 20.00mA location and press Select Key. Connect a calibrated Current meter in series with a 100KΏ resistor to HV and Return and press “TEST” key. The tester will output an AC high voltage about 1000V. Take the reading shown on the calibrated Current meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of AC high range current is completed.

6.1.5 ACW Low Range Current Calibration Use “Move” key to move cursor to AC 3.50mA location and press Select Key. Connect a calibrated Current meter in series with a 100KΏ resistor to HV and Return and press “TEST” key. The tester will output an AC high voltage about 300V. Take the reading shown on the calibrated Current meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of AC high range current is completed.

6.1.6 DCW High Range Current Calibration Use “Move” key to move cursor to DC 7.50mA location and press Select Key. Connect a calibrated Current meter in series with a 100KΏ resistor to HV and Return and press “TEST” key. The tester will output an DC high voltage about 700V. Take the reading shown on the calibrated Current meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of DC high range current is completed.

6.1.7 DCW Low Range Current Calibration Use “Move” key to move cursor to DC 3.500mA location and press Select Key. Connect a calibrated Current meter in series with a 100KΏ resistor to HV and Return and press “TEST” key. The tester will output an DC high voltage about 300V. Take the reading shown on the calibrated Current meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of DC low range current is completed.

6.1.8 DCW Low Range Current Calibration Use “Move” key to move cursor to “DC 350µA” location and press Select Key. Connect a calibrated Current meter in series with a 1MΏ resistor to HV and Return and press “TEST” key. The tester will output a DC high voltage about 300V. Take the reading shown on the calibrated Current meter and enter the value by “+” or “-“ key. Press “Enter” to confirm the reading. Calibration of DC low range current is completed.

6.1.9 IR Low Resistance Calibration

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Use “Move” key to move cursor to “IR 999.9MΩ” location and press Select Key. Connect a 50MΩ standard resistor across HV and Return terminal and press “TEST” key. The tester will automatically read the value of current. Calibration of IR low resistor is completed

6.1.10 IR High Resistance Calibration

Use “Move” key to move cursor to “IR 9999MΩ” location and press Select Key. Connect a 50MΩ standard resistor across HV and Return terminal and press “TEST” key. The tester will automatically read the value of current. Calibration of IR high resistor is completed.

Note: After calibration, the tester must be power OFF to allow the tester to save the calibration data into memory.

6.2 Test verification At the initial display showing <TEST> to verification, press TEST button to enter verification mode. The user can verify the tester is in good working condition before testing DUT. The verification display is shown below.

6.2.1 AC Hipot Verification

Use “∧” or “∨” key to move cursor to “AC Hipot” location and press Select key. Follow the on screen instruction to verify the tester is in good working condition to detect AC Hipot failure.

6.2.2 DC Hipot Verification

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Use “∧” or “∨” key to move cursor to “DC Hipot” location and press Select key. Follow the on screen instruction to verify the tester is in good working condition to detect DC Hipot failure.

6.2.3 IR Verification Use “∧” or “∨” key to move cursor to “IR” location and press Select key. Follow the on screen instruction to verify the tester is in good working condition to detect IR failure.

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CHAPTER 7: OTHER INFORMATION

7.1 Accessories Supplied

Model Description 1101 High Voltage Test Lead1102 Return Test Lead

7.2 Optional Accessories

Model Description 1112 Hipot/IR Test Cable Fixture 1129 Gvound link Cable,7130/7140 Series to 7315 1127 High Voltage Test Probe 1110 Remote Test/Reset Controller 1217 Signal Link Cable,7130/7140 Series to 7315 1218 Signal Link Cable,7315 to 7130/7140 Series

Please contact Customer Support

Department of EXTECH for further Service.

Te l : 886-2-26943030 Ext 202 Fax : 886-2-26945563 Email :support@extech.com.tw website : www.extech.com.tw ***************************************************************************