Associated Research HypotULTRA 7800 Operation manual

1
Operation and Service Manual
13860 West Laurel Drive, Lake Forest, Illinois, 60045 USA
© Associated Research 2017
HypotULTRA®Series
Models 7800, 7804, 7820, 7850 and 7854
Electrical Safety Compliance Analyzer
AC/DC Hipot, Insulation Resistance, Continuity and Ground Bond Test Instruments
USB/RS-232 Interface standard on all models
Serial ————————
Item 39658 •Version 2.03
Printed June 20th, 2018
RoHS 2
COMPLIANT
2011/65/EU
*
*Select models only.
See specs for details.

© Associated Research 2017 2
DECLARATION OF CONFORMITY
Manufacturer: Associated Research
A Divison of Ikonix USA
Address: 13860 W. Laurel Dr.
Lake Forest, IL 60045 USA
Product Name: HypotULTRA®Electrical Safety Compliance Analyzer
Model Number: 7800/7820/7850
Conforms to the following Standards:
Safety: IEC 61010-1:2010
IEC 61010-2-030 :2010
IEC 61010-031 :2002+A1 :2008/EN 61010-031 :2002+A1 :2008
UL 61010-1:2012, UL 61010-2-030:2012
CAN/CSA-C22.2 NO. 61010-1-12
CAN/CSA-C22.2 NO. 61010-2-030-12
EMC: EN 61326-1:2013 Class A
EN 61000-3-3 :2013/IEC 61000-3-3 :2013
EN 61326-1 :2013 (industrial locations)
EN 61000-4-2 :2009/IEC 61000-4-2 :2008
IEC 61000-4-3 :2006+A1 :2008+A2 :2010
EN 61000-4-4 :2012/IEC 61000-4-4 :2012
EN 61000-4-5 :2006/IEC 61000-4-5 :2005
EN 61000-4-6 :2014/IEC 61000-4-6 :2013
EN 61000-4-8 :2010IEC 61000-4-8 :2009
EN 61000-4-11 :2004/IEC 61000 :4-11 :2004
Supplementary Information
The product herewith complies with the requirements of the Low Voltage Directive 2014/35/EU and the EMC Directive
2014/30/EU and the RoHS Directive 2011/65/EU with respect to the following substances: Lead (Pb), Mercury (Hg), Cadmium
(Cd), Hexavalent chromium (Cr (VI)), Polybrominated biphenyls (PBB), Polybrominated diphenyl ethers (PBDE), Deca-BDE
included.
Last two digits of the year in which the CE marking was afxed: 14
The technical le and other documentation are on le with Associated Research
Joseph Guerriero
President
Associated Research
Lake Forest, Illinois USA
July 20th, 2017

© Associated Research 2017 3
DECLARATION OF CONFORMITY
Manufacturer: Associated Research
A Divison of Ikonix USA
Address: 13860 W. Laurel Dr.
Lake Forest, IL 60045 USA
Product Name: HypotULTRA®Electrical Safety Compliance Analyzer
Model Number: 7804/7854
Conforms to the following Standards:
Safety: IEC 61010-1:2010
IEC 61010-2-030 :2010
IEC 61010-031 :2002+A1 :2008/EN 61010-031 :2002+A1 :2008
UL 61010-1:2012, UL 61010-2-030:2012
CAN/CSA-C22.2 NO. 61010-1-12
CAN/CSA-C22.2 NO. 61010-2-030-12
EMC: EN 61326-1:2013 Class A
EN 61000-3-3 :2013/IEC 61000-3-3 :2013
EN 61326-1 :2013 (industrial locations)
EN 61000-4-2 :2009/IEC 61000-4-2 :2008
IEC 61000-4-3 :2006+A1 :2008+A2 :2010
EN 61000-4-4 :2012/IEC 61000-4-4 :2012
EN 61000-4-5 :2006/IEC 61000-4-5 :2005
EN 61000-4-6 :2014/IEC 61000-4-6 :2013
EN 61000-4-8 :2010IEC 61000-4-8 :2009
EN 61000-4-11 :2004/IEC 61000 :4-11 :2004
Supplementary Information
The product herewith complies with the requirements of the Low Voltage Directive 2014/35/EU and the EMC Directive
2014/30/EU and the RoHS Directive 2011/65/EU with respect to the following substances: Lead (Pb), Mercury (Hg), Cadmium
(Cd), Hexavalent chromium (Cr (VI)), Polybrominated biphenyls (PBB), Polybrominated diphenyl ethers (PBDE), Deca-BDE
included.
Last two digits of the year in which the CE marking was afxed: 14
The technical le and other documentation are on le with Associated Research
Joseph Guerriero
President
Associated Research
Lake Forest, Illinois USA
July 20th, 2017

© Associated Research 2017 4
Warranty Policy
Associated Research, certies that the instrument listed in this manual meets or exceeds published manufacturing specications.
We calibrated this instrument 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 (3) year from the date of
shipment.
5-Year Program
All Associated Research instruments include the opportunity to extend the standard warranty for up to a period of 5 years.
Returning instruments to Associated Research for their annual calibration and inspection will extend the instrument’s warranty
for an additional year. This warranty is extendable for up to ve years and annual returns must be made in succession starting
one year after the original purchase date. There are no additional costs for the 5 year product warranty. You are responsible
for the annual calibration fees and shipping costs. This extended warranty is non-transferable and is offered only to the original
purchaser. You must obtain a return material authorization (RMA) from Associated Research before returning this instrument for
warranty service. Please contact our customer care center at 1-800-858-TEST (8378) to obtain an RMA number. It is important
that the instrument is packed properly for safe transport. Please contact our customer care center for proper instructions on
packaging. We will not honor damages sustained as a result of improper packaging. You must prepay transportation costs for
the return of the instrument for warranty service. Associated Research will assume the return freight costs when returning your
instrument. The return method will be at the discretion of Associated Research.
Operator Modications
Any non-authorized modications, tampering or physical damage will void this warranty. Elimination of any connections in the
earth grounding system or bypassing any safety systems will void this warranty. This warranty does not cover accessories not of
Associated Research manufacture. Parts used must be parts that are recommended by Associated Research as an acceptable
specied part. Use of non-authorized parts in the repair of this instrument will void the warranty.
Associated Research will not be responsible for any injuries sustained due to unauthorized equipment modications or use
of parts not specied by Associated Research Instruments returned to Associated Research with unsafe modications will be
returned to their original operating condition at your expense.

© Associated Research 2017 5
Table of Contents
Safety Precautions and Warning Symbols for High Voltage Testing...........................................................................................6
Front Panel Controls (7800, 7820 and 7850)................................................................................................................................7
Rear Panel Controls (7800, 7820 and 7850).................................................................................................................................8
Front Panel Controls (7804 and 7854)..........................................................................................................................................9
Rear Panel Controls (7804 and 7854) .........................................................................................................................................11
Setup Instructions.......................................................................................................................................................................13
Getting to Know Your Instrument ..............................................................................................................................................14
Main Menu ..................................................................................................................................................................................16
1. Setup System .............................................................................................................................................................................. 17
2. Setup Tests..................................................................................................................................................................................37
2.1 Setup Continuity Test.......................................................................................................................................................38
2.2 Setup Ground Bond Test .................................................................................................................................................39
2.3 Setup AC Withstand Test................................................................................................................................................. 41
2.4 Setup DC Withstand Test ................................................................................................................................................43
2.5 Setup Insulation Resistance Test ....................................................................................................................................45
3. Perform Test................................................................................................................................................................................ 52
4. Security........................................................................................................................................................................................60
5. FailCHEK......................................................................................................................................................................................62
6. MyMenu.......................................................................................................................................................................................65
Using Remote I/O and PLC Control ........................................................................................................................................... 66
Appendix A - Installation and Test Operator Information .........................................................................................................69
Installation ............................................................................................................................................................................69
1. Unpacking and Inspection ................................................................................................................................................. 69
2. Safe Lifting and Carrying Instructions ............................................................................................................................. 69
3. Contents of the Carton ...................................................................................................................................................... 69
4. Preparation for Use ............................................................................................................................................................ 70
5. Power Cable ........................................................................................................................................................................ 70
Operating Environment........................................................................................................................................................71
Storage and Shipment..........................................................................................................................................................71
Test Operator and Safety Considerations ...........................................................................................................................71
1. Qualifications ...................................................................................................................................................................... 71
2. Safety Procedures...............................................................................................................................................................72
3. Dress..................................................................................................................................................................................... 72
4. Medical Restrictions ...........................................................................................................................................................72
5. Test Station.......................................................................................................................................................................... 72
Appendix B - Instrument Specifications.....................................................................................................................................74
Appendix C - Series Options ......................................................................................................................................................82
Appendix D - Remote Bus Interface: RS-232 ............................................................................................................................ 99
Appendix E - Replacement Parts List ......................................................................................................................................116
Appendix F - Calibration Procedure......................................................................................................................................... 118
NOTE: This is an interactive PDF, if viewing on a computer click on our quick links to jump quickly to that section.
Return to the Table of Contents by simply clicking on the page number with a above it in the bottom right corner.

© Associated Research 2017
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6
Safety Precautions and Warning Symbols for High Voltage Testing
GENERAL: Review this product and its related documentation 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 input
voltage to the instrument is 115VAC±10% or 230VAC±10% and the correct fuse is installed.
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.
S’il vous plaît se référer au manuel d’instructions de mise en garde ou information sur la prudence pour éviter des
blessures ou des dommages au produit
Product will be marked with this symbol when hazardous voltages may be present.
Avertissement des tensions dangereuses qui peuvent être présentes
Product will be marked with this symbol at connections that require earth grounding.
Le produit sera marqué de ce symbole au niveau des connexions qui nécessitent à la terre.
Caution and Warning Symbols
Calls attention to a procedure, practice, or condition that could possibly cause bodily
injury or death.
Appelle l’attention sur une procédure, une pratique ou une condition qui pourrait causer des blessures corporelles ou la mort.
Calls attention to a procedure, practice, or condition that could possibly cause damage
to equipment or permanent loss of data.
Appelle l’attention sur une procédure, une pratique ou une condition qui pourrait causer des blessures corporelles ou la mort.
The HypotULTRA 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.
Le HypotULTRA, des tensions et des courants qui peuvent causer des chocs électriques dangereux ou mortel. Pour éviter toute
blessure ou un décès accidentels, ces procédures de sécurité doivent être strictement respectées lors de la manipulation et
l’utilisation de l’appareil de contrôle.
CAUTION
WARNING
WARNING

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Front Panel Controls (7800, 7820 and 7850)
RESET BUTTON - Resets the instrument. If a failure condition occurs during a test, pressing this button will reset the
system, shut off the alarm and clear the failure condition. You must press the Reset button before performing another test
or changing any of the setup parameters. This button also serves as an abort signal to stop any test in progress.
TEST BUTTON - This is a momentary contact switch used to start a test. Press the green button to turn on the high
voltage output when in test mode. The indicator lamp within the button will light when test expires with pass condition.
TOUCH SCREEN GRAPHIC LCD - Displays all the information and allows full control of the instrument.
MY MENU - Brings up the MyMENU screen.
TOGGLE - This button allows you to toggle between test les if you are wearing high voltage gloves.
CONTINUITY OUTPUT TERMINAL - Connector used to attach the return test lead, adaptor box return lead, or test xture
return lead used during Continuity testing.
RETURN TERMINAL - Connector used to attach the return test lead, adapter box return lead or test xture return lead
to the instrument. This connection provides the return current path.
POWER SWITCH - Powers the test instrument ON or OFF.
BARCODE USB PORT - This USB style port allows for connecting a barcode scanner.
DATA USB PORT - This USB style port allows for connecting a USB ash drive to extract test and system data.
HIGH VOLTAGE INDICATOR - This indicator ashes to warn the operator that high voltage is present at the high voltage
output terminal.
HIGH VOLTAGE OUTPUT TERMINAL - Connector used to attach the high voltage test lead, adapter box high voltage lead
or test xture high voltage lead to the instrument. This connection provides the high voltage used during a Hipot test.

© Associated Research 2017
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Rear Panel Controls (7800, 7820 and 7850)
REMOTE SIGNAL OUTPUT - 9-Pin D-type subminiature female connector for monitoring PASS, FAIL, and PROCESSING
output relay signals.
SCANNER CONNECTOR - For connection of optional external Scanner.
REMOTE SIGNAL INPUT - 9-Pin D-type subminiature male connector for remote control of TEST, RESET, and REMOTE
INTERLOCK DISABLE functions, as well as MEMORY SELECTION.
CALIBRATION BUTTON - To put the instrument into the calibration mode push this button and turn on the power switch
simultaneously.
BUS INTERFACE - Standard connector for interconnection to the USB/RS-232 Bus interface. You can substitute an
Optional IEEE 488 (GPIB) or Ethernet interface for the USB/RS-232.
SCANNER OUTPUTS - Optional internal Scanner matrix that provides 8 HV/Continuity/Return connections. Please refer
to the Options section of this manual for additional connection information.
REAR PANEL HIGH VOLTAGE OUTPUT TERMINAL - 2nd high voltage output connector in parallel with the front panel
connector.
REAR PANEL RETURN TERMINAL - 2nd return output connector in parallel with the front panel connector.
REAR PANEL CONTINUITY OUTPUT TERMINAL - 2nd continuity output connector in parallel with the front panel output.
CHASSIS GROUND (EARTH) CONNECTION - Connect this terminal to a good earth ground before operation.
INPUT POWER RECEPTACLE - Standard IEC 320 connector for connection to a standard NEMA style line power (mains) cord.
FUSE RECEPTACLE - To change the fuse, unplug the power (mains) cord and turn the fuse receptacle counter-clockwise.
This will expose the fuse compartment. Please replace the fuse with one of the proper rating.

© Associated Research 2017
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Front Panel Controls (7804 and 7854)
RESET BUTTON - Resets the instrument. If a failure condition occurs during a test, pressing this button will reset the
system, shut off the alarm and clear the failure condition. You must press the Reset button before performing another
test or changing any of the setup parameters. This button also serves as an abort signal to stop any test in progress.
TEST BUTTON - This is a momentary contact switch used to start a test. Press the green button to turn on the high voltage
output when in test mode. The indicator lamp within the button will light when test expires with pass condition.
TOUCH SCREEN GRAPHIC LCD - Displays all the information and allows full control of the instrument.
MY MENU - Brings up the MyMENU screen.
SENSE+ TERMINAL - Connector used to attach the + sense lead for 4-wire Kelvin current measurement. This connection
provides for accurate current measurement during the Ground Bond test.
CURRENT OUTPUT TERMINAL - Connector used to attach the high current output lead, adapter box high current lead
or test xture high current lead to the instrument. This connection provides the output current for the ground bond and
continuity.
POWER SWITCH - Powers the test instrument ON or OFF.
BARCODE USB PORT - This USB style port allows for connecting a barcode scanner.
DATA USB PORT - This USB style port allows for connecting a USB ash drive to extract test and system data.
TOGGLE - This button allows you to toggle between test les if you are wearing high voltage gloves.
Continued on next page C

© Associated Research 2017
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SENSE- TERMINAL - Connector used to attach the - sense lead for 4-wire Kelvin current measurement. This connection
provides for accurate current measurement during the Ground Bond test.
RETURN TERMINAL - Connector used to attach the return test lead, adapter box return lead or test xture return lead to
the instrument. This connection provides the return current path.
HIGH VOLTAGE OUTPUT TERMINAL - Connector used to attach the high voltage test lead, adapter box high voltage lead
or test xture high voltage lead to the instrument. This connection provides the high voltage used during a Hipot test.
HIGH VOLTAGE INDICATOR - This indicator ashes to warn the operator that high voltage is present at the high voltage
output terminal.

© Associated Research 2017
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Rear Panel Controls (7804 and 7854)
CURRENT OUTPUT TERMINAL - Connector used to attach the high current output lead, adapter box high current lead or
test xture high current lead to the instrument. This connection provides the output current
for the ground bond and continuity.
SENSE+ TERMINAL - Connector used to attach the + sense lead for 4-wire Kelvin current measurement.
This connection provides for accurate current measurement during the Ground Bond test.
SCANNER CONNECTOR - For connection of optional external Scanner.
BUS INTERFACE - Standard connector for interconnection to the USB/RS-232 Bus interface. You can
substitute an Optional IEEE 488 (GPIB) or Ethernet interface for the USB/RS-232.
REAR PANEL HIGH VOLTAGE OUTPUT TERMINAL - 2nd high voltage output connector in parallel with the front panel
connector.
REAR PANEL RETURN TERMINAL - 2nd return output connector in parallel with the front panel connector.
SENSE- TERMINAL - Connector used to attach the - sense lead for 4-wire Kelvin current measurement.
This connection provides for accurate current measurement during the Ground Bond test.
REMOTE SIGNAL OUTPUT - 9-Pin D-type subminiature female connector for monitoring PASS, FAIL,
and PROCESSING output relay signals.
REMOTE SIGNAL INPUT - 9-Pin D-type subminiature male connector for remote control of TEST, RESET,
and REMOTE INTERLOCK DISABLE functions, as well as MEMORY SELECTION.
Continued on next page C

© Associated Research 2017
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CALIBRATION BUTTON - To put the instrument into the calibration mode push this button and turn on
the power switch simultaneously.
CHASSIS GROUND (EARTH) CONNECTION - Connect this terminal to a good earth ground before
operation.
INPUT POWER RECEPTACLE - Standard IEC 320 connector for connection to a standard NEMA style line
power (mains) cord.
FUSE RECEPTACLE - To change the fuse, unplug the power (mains) cord and turn the fuse receptacle counter-clockwise.
This will expose the fuse compartment. Please replace the fuse with one of the proper rating.

© Associated Research 2017
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Setup Instructions
Power Up Sequence
1. 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.
2. Connect the Interlock Disable key to the Remote Input connector on the back panel of the instrument. This is required in order
to run a test. For more information on the interlock, see section for Remote Interlock.
3. Turn on the POWER switch located on the lower left hand side of the front panel. Upon powering the instrument up, a POWER
ON SELF TEST (POST) will automatically be performed. This test will check for the condition of the ram chips, PCB’s and other
critical components. The instrument screen will then default to the main menu.
The default screen is the main menu screen of the instrument. From this screen you can access all the functions and settings of
the instrument:
Only insert the main plug in a socket outlet with a protective ground (earth) contact. This protective
ground must not be defeated by the use of an extension cord without a protective conductor.
La che principale ne doit être insérée dans une prise de courant avec une masse (terre) avec système de protection. Cette terre
de protection ne doit pas être vaincu par l’utilisation d’ une rallonge sans conducteur de protection.
WARNING
Main Menu

© Associated Research 2017
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Getting to Know Your Instrument
Using the Touch Screen
The touch screen display of the HypotULTRA provides full control of the instrument. Use the he touch screen to setup system and
test parameters as well as security setup and calibration. HypotULTRA’s touch screen functions just like any other touch screen.
Soft Keys
The HypotULTRA touch screen has 3 functional keys: Back, Home and Perform Tests:
Use the Home key to return
to the Main Menu.
Use the Perform Tests key to navigate
to the Perform Tests screen.
Use the Back key to return
to a previous menu.

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Touch
The various screens of the HypotULTRA will display icons and
parameters. Touch the appropriate icon or parameter with the
ngertip as shown in the image to the right.
Scroll and Swipe
A scroll bar on the right side of the screen indicates that there are
additional parameters or features. To scroll up and down between
parameters touch the screen anywhere scroll upward or downward.
Swipe left to right in order to change parameters when setting up
test or system values.
Drag and Drop
You can drag and drop test les and steps on certain HypotULTRA
screens. To use this feature simply touch and hold the test le, test
step or parameter. Drag the le to the appropriate location as
shown in the following screen to the right.

© Associated Research 2017
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Main Menu
Upon powering up, the instrument will default to the Main Menu. The Main Menu is also the default home screen.
1
3
5
2
6
4
1
3
5
2
4
6
Main Menu
Setup Tests Screen - Create test les.
Setup System Menu - Instrument
global parameters such as time and
date, calibration and hardware.
Security Menu - Access instrument
lockout and security features.
Perform Test Screen - Navigate to the
Perform Tests screen in order to run a
test sequence.
My Menu Screen - User customized
menu.
FailCHEK Menu - Check the instrument’s
failure detectors
*Note – Details of each system and test parameter are listed in the relevant sections of the manual.

© Associated Research 2017
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1. Setup System
From the default main menu touch the Setup System icon to enter the Setup System sub menu. This is where all System
Parameters can be edited:
12
Main Menu
12
3
5 6
4
Setup System Menu Cont.
Setup System Menu
7
Time and Date Menu Calibration Alert Menu
Continued on next page C

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Setup System Continued
34
56
7
Hardware Menu
Information Screen Import Menu
Export Menu
Results Menu

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Time and Date
Time and Date menu allows the user to edit and save the System Time and Date. This time and date will be used to stamp the
test results data.
1
3
2
4
Time and Date Menu
Setup System Menu
12
3 4
Enter the current date to set System
Date.
Select the Date Format for System Date.
Enter current time to set System Time.
Select the Time Format for System
Time.

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Calibration Alert
The Calibration Alert menu allows the user to setup alerts prior to the Calibration Due date. The user can also edit the Calibration
Due date. It is not recommended that the Calibration Due date be changed once the instrument has been calibrated. Associated
Research recommends annual calibrations for all models.
1 2
3
Calibration Alert Menu
Setup System Menu
1
2 3
Select Calibration Alert ON or OFF.
Enter a Calibration Alert Date.
Enter a Calibration Due date.
The above Calibration Alert screen will
be displayed upon powering up the
instrument, on and after the Calibration
Alert Date. This screen will display the
Calibration Due Date of the instrument.