Associated Research SC6540 Operation manual

Associated Research
28105 North Keith Drive - Lake Forest, IL 60045 USA
T. 1-847-367-4077 F. 1-847-367-4080
[email protected] www.arisafety.com
OPERATION AND SERVICE MANUAL
MODEL SC6540
High Voltage and High Current Scanning Matrix
SERIAL NUMBER
Item 38616, Ver 3.14
Printed January 4th, 2021

DECLARATION OF CONFORMITY
Manufacturer: Associated Research, Inc.
Address: 28105 North Keith Dr.
Lake Forest, IL 60045 USA
Product Name: SC6540® High Voltage and High Current Scanning
Matrix
Model Number: SC6540
Conforms to the following Standards:
Safety: UL 61010-1:2012
CAN/CSA-C22.2 NO. 61010-1-12
IEC 61010-1:2010, IEC 61010-2-030:2010
IEC 61010-031:2002+A1
EN 61010-1:2010, EN 61010-2-030:2010
EN 61010-031:2002+A1
EMC: EN 61326-1:2013
EN 55011 :2009+A1
Supplementary Information:
The product herewith complies with the requirements of the Low
Voltage Directive 2014/35/EU, 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 affixed:05
The technical file and other documentation are on file with
Associated Research, Inc.
______________________________
Joseph Guerriero, President
Associated Research, Inc.
Lake Forest, Illinois USA
August 20, 2020

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TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................1
1.1. Warranty Policies .............................................................................................1
1.2. Safety Symbols.................................................................................................3
1.2.1. Product Marking Symbols....................................................................3
1.2.2. Caution and Warning Symbols............................................................3
1.3. Glossary of Terms............................................................................................3
1.4. Safety.................................................................................................................5
1.4.1. Service and Maintenance.....................................................................5
1.4.2. Test Station............................................................................................6
1.4.3. Test Operator.........................................................................................7
1.5. Key Features and Benefits: SC6540.............................................................9
2. GETTING STARTED........................................................................................10
2.1. Unpacking and Inspection.............................................................................10
2.1.1. Packaging.............................................................................................10
2.1.2. Contents of Carton..............................................................................10
2.2. Installation .......................................................................................................14
2.2.1. Work Area.............................................................................................14
2.2.2. Power Requirements..........................................................................14
2.2.3. Basic Connections...............................................................................15
2.2.4. Environmental Conditions..................................................................15
3. SPECIFICATIONS AND CONTROLS..............................................................17
3.1. SC6540 Functional Specifications...............................................................17
3.2. Instrument Controls........................................................................................18
3.2.1. Front Panel Controls...........................................................................18
3.2.2. Rear Panel Controls............................................................................19
4. OPERATING INSTRUCTIONS.........................................................................21
4.1. Scanner Configurations.................................................................................21
4.2. Operation of the SC6540 with HypotULTRA III/ HypotULTRA...................
4.2.1. Cables and Connections Description...............................................22
4.2.2. Connection Diagrams.........................................................................23
4.2.3. Setup.....................................................................................................25
4.2.4. Operation..............................................................................................27
4.3. Operation of the SC6540 with OMNIA 8100/8200 Series .......................29
4.3.1. Cables and Connections Description...............................................29
4.3.2. Connection Diagrams.........................................................................30
4.3.3. Setup.....................................................................................................33
4.3.4. Operation..............................................................................................35
4.4. Interfacing Multiple SC6540s.......................................................................36
4.4.1. Scanner Interconnection ....................................................................36

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4.4.2. Connection Diagram...........................................................................37
4.4.3. Scanner Addressing............................................................................39
5. BUS REMOTE INTERFACE GPIB / USB / RS-232 / ETHERNET...................44
5.1. USB/RS-232 Interface...................................................................................44
5.1.1. RS-232 Connector...............................................................................44
5.1.2. Communications Port Configuration.................................................45
5.1.3. Sending and Receiving Commands.................................................45
5.2. GPIB Interface................................................................................................45
5.3. GPIB Address Setup......................................................................................47
5.4. Interface Functions ........................................................................................47
5.5. Ethernet Interface...........................................................................................48
5.6. Autoware IP Track..........................................................................................51
5.7. GPIB / USB / RS-232 / Ethernet Interface Command List ......................55
5.7.1. Rules for Sending Commands to the Instrument...........................55
5.7.2. Scanner Channel Configuration Commands..................................55
5.7.3. Query Commands...............................................................................57
5.7.4. IEEE 488.2 Common Commands.....................................................58
5.7.5. Ethernet Card Setting Commands and Companion Queries.......60
5.7.6. Status Reporting..................................................................................60
5.7.7. GPIB Service Request........................................................................61
6. REPLACEMENT PARTS LIST.........................................................................63

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1. INTRODUCTION
1.1. Warranty Policies
Ikonix USA, certifies that the tester listed in this manual meets or exceeds published
manufacturing specifications. This tester was calibrated using standards that are
traceable to the National Institute of Standards and Technology (NIST).
Your new tester is warranted to be free from defects in workmanship and material for
a period of (5) years from date of shipment. We aim to provide an amazing experience
and quality testers that last a long time. If you’re not satisfied with your tester, return it
within 45 days for a full refund. Calibrate annually with us, or one of our authorized
partners, and we’ll extend your warranty an additional year for the service life of your
tester, and at least five years after discontinuation. If it breaks during that time, we
promise to fix it for free (unless abuse or excessive damage is present). When your
tester reaches the end of its service life, we’ll responsibly recycle it and give you a
discount on a replacement. Annual calibration and inspection must be made in each
successive year starting one year after the original purchase date in order to remain
eligible for extended warranty coverage beyond the standard warranty period (five
years).
Ikonix USA recommends that your tester be calibrated on a twelve-month cycle. A
return material authorization (RMA) must be obtained from Ikonix USA. To obtain an
RMA please contact our Customer Support team at 1-847-367-4077 or visit
arisafety.com. Damages sustained as a result of improper packaging will not be
honored. Transportation costs for the return of the tester for warranty service must be
prepaid by the customer. Ikonix USA will assume the return freight costs when
returning the tester to the customer. The return method will be at the discretion of
Ikonix USA.
Except as provided, herein Ikonix USA makes no warranties to the purchaser of this
tester and all other warranties, expressed 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 accessories
not of Ikonix USA manufacture. Parts used must be parts that are recommended by
Ikonix USA as an acceptable specified part. Use of non-authorized parts in the repair
of this tester will void the warranty.
*5 year warranty is valid on any model purchased in 2021 or after.

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**This Page Intentionally Left Blank**

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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
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.
1.3. Glossary of Terms
(As used in this manual)
Alternating Current, AC: Current that reverses direction on a regular basis. Utility power is
usually generated in the form of a sinusoid at a frequency of 60 times per second in the United States
and 50 times per second in other countries.
Arc: A partial momentary breakdown due to the force of a strong electric field on closely spaced
conductors, sometimes evidenced by corona or a luminous flashover.
Breakdown: The failure of insulation to effectively prevent the flow of current. If the test voltage is
gradually raised, breakdown will begin suddenly at a certain voltage level and current flow will not be
directly proportional to voltage. Once a breakdown occurs, especially for a period of time, the next
gradual application of voltage will often cause a breakdown to begin at a lower voltage.
Conductor: A solid or liquid material which permits the flow of electrons. A material which has a
volume resistivity of no more than 103 Ω-cm.
Current: The movement of electrons through a conductor. Current is measured in amperes (A),
milliamperes (mA), microamperes (uA). 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.

4
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.
Frequency: The number of cycles an AC waveform repeats over time. Usually given in Hertz (Hz).
Ground: Refers to the point of low potential in a circuit to which all other voltages are referenced.
May or may not be tied to the earth. Also referred to as Earth.
Hot: Used to refer to the test lead or output side of an instrument that is at high potential.
Impedance: The property of capacitive or inductive items to limit certain frequencies.
Insulation: Gas, liquid or solid material which has a volume resistivity of at least 1012 Ω-cm and is
used for the purpose of restricting current flow between conductors.
Leakage: AC or DC current flow through insulation and over its surfaces. Current flow is directly
proportional to voltage. The insulation is thought of as a constant impedance unless breakdown
occurs.
Neutral: The point of low potential in a circuit to which all other voltages are referenced. Also known
as Common.
Peak Current: The maximum amplitude of an AC current waveform. For a sinusoid, 1.414 x the
RMS value.
Power: The amount of work performed by an energy source over time, given in Watts (W).
PF (Power factor): Power Factor = W/VA where W =Watts (Real Power) and VA =Volts x Amps
(apparent power). It is important to note that the closer the power factor is to "1" the more resistive the
DUT is. The closer the power factor is to 0 the more reactive (inductive or capacitive) the DUT is.
Reactive Current: The current component due to the reactive impedance of a load. Also called
imaginary current.
Real Current: The current component due to the resistance of a load.
Resistance: The 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 (Ω). Symbol = R
Return: The path by which current returns to a source.
RMS: The Root Mean Squared value of a voltage or current waveform. An RMS waveform delivers
the same amount of energy to a load as a DC waveform of the same value. For a sinusoid, the RMS
value is .707 x the peak value.
Total Current: The vector sum of the real current component and the reactive current component
produced by an applied voltage.
VA: A rating of instantaneous power found by multiplying an instrument’s maximum output current by
its maximum output voltage.
Voltage: The force which causes current through an electrical conductor, given in volts (V).
Symbol = V

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The SC6540 has the
capability of relaying
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.
PHONE: [phone]
1 (800) 858-TEST (8378)
FAX: [phone]
E-MAIL: [email protected]
This instrument
meets UL
requirements for
audible and visual
failure indication.
SAFETY
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
(115 or 230) and the correct fuse is
installed.
This product carries an NRTL (Nationally
Recognized Testing Laboratory) and
comes equipped with an audible and visual failure indicator.
1.4.1. Service and Maintenance
User Service
To prevent electric shock do not remove the
instrument cover. There are no internal user
serviceable parts. Routine maintenance or
cleaning of internal parts is not necessary. Avoid
the use of cleaning agents or chemicals on the
instrument, as 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. Refer servicing and certification to an Associated Research, Inc.
authorized service center.
Service Interval
Associated Research, Inc. will not be held liable for injuries suffered if the instrument
is not properly maintained and safety checked annually. See section 1.1. Warranty
Policies for more information.
ASSOCIATED RESEARCH, INC.
13860 WEST LAUREL DRIVE
LAKE FOREST, IL 60045-4546 U.S.A.

6
ESD TESTING
1.4.2. Test Station
Location
Select an area away from the mainstream of activity where employees do not walk
while 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 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
When possible, use the instrument on a non-conducting table or workbench. 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”.
Keep the area clean and uncluttered. All test equipment and unnecessary test leads
should be removed from the test bench and put
away. It should be apparent to both the operator
and to any observers which product is under test,
which product is waiting to be tested and which
product has already been tested.
Power
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 should be able to cut off the
power before entering the test area to offer
assistance.
More Information
For more information on setting up a safe work station, please visit the Events and
Training section of our website at http://www.asresearch.com/events-
training/Default.aspx
Electrical safety tests
should not be
performed in or around
ESD testing areas.
ESD methods should
not be employed during
electrical safety testing,
as this could cause a
hazardous condition for
equipment and test
operators.

7
KEY SAFETY POINTS TO
REMEMBER
1.4.3. Test Operator
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.
Do not touch the device under test, high voltage test
lead, alligator clip, or clip insulator once the test has
been started.
Do not touch the front panel when testing or after a
malfunction has occurred.
Rules
Operators should be thoroughly trained to follow all national safety standard
guidelines for electrical safety testing in the workplace. Defeating any safety
system should be considered a serious offense with severe penalties. Allowing
unauthorized personnel in the area during a test should also be dealt with as a
serious offense. Test operators should be familiar with methods to properly
discharge a device under test in case test leads become disconnected during
testing.
Refer to the following standards for more information:
NFPA 70E
OSHA 1910 subpart (S)
EN50191
Dress
Operators should not wear jewelry that could accidentally complete a circuit.
ESD protocols
should not be
observed while
performing electrical safety tests.
Intentionally grounding the test
operator could lead to a harmful or
fatal electric shock.
Medical Restrictions
Personnel with heart ailments or
devices such as pacemakers should
be informed that the voltages and
Keep unqualified and
unauthorized personnel away
from the test area.
Arrange the test station in a safe
and orderly manner.
In case of any problem, turn off
the high voltage first.

8
currents generated by the instrument are very dangerous. If contacted, the
instrument may cause heart-related problems. Please have the test operator
consult a physician for recommendations.

9
1.5. Key Features of the SC6540
CONFIGURABLE
SCANNING MATRIX
The SC6540 can be purchased as a “main” scanning
matrix with its own power source, or as a “secondary”
scanning matrix controlled through an automated
Associated Research instrument. Each main Scanner can
control up-to four additional secondary Scanners,
allowing a total of 80 test points.
UP TO 16 HIGH
VOLTAGE
SWITCHING
OUTPUTS
High voltage outputs are rated for up to 5 kVAC and 6
kVDC to handle a wide range of safety agency
specifications.
UP TO 16 HIGH
CURRENT
SWITCHING
OUTPUTS
High current channels allow ground bond testing to be
incorporated into automated testing applications. Outputs
are rated for up to 40 Amps.
AUTOMATED
MULTI-POINT OR
MULTI-PRODUCT
TESTING
CAPABILITIES
When used in conjunction with OMNIA®or
HypotULTRA®, the SC6540 reduces test setup time and
eliminates operator error to ensure consistent test results.
AUTOMATION
INTERFACES FOR
SOFTWARE
CONTROL
Main Scanners are available with USB/RS-232, GPIB and
Ethernet automation interfaces.
FRONT PANEL
INDICATORS
LED’s indicate the status of each channel. The operator
can clearly see which output is active.
POINT TO POINT
CONTINUITY TESTS
High voltage channels can also be used for point-to-point
Continuity tests.
COMPACT 2U RACK
MOUNT DESIGN
This space saving design allows the SC6540 to be
quickly and easily installed into a rack mount system.

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2. GETTING STARTED
Introduction
This section contains information for the unpacking, inspection, preparation 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. If the shipping
carton is damaged, inspect the contents for visible damage such as dents,
scratches or a broken display. If the instrument is damaged, notify the carrier and
Associated Research, Inc.’s customer support department. Please save the
shipping carton and packing material for the carrier’s 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-TEST
(8378).
2.1.2. Contents of the Carton
Inside the carton should be the following:
DESCRIPTION
AR PART NUMBER
SC6540 SECONDARY
SC6540 Scanner
SC6540
25-Pin Scanner Bus Cable
38592
High Voltage Interconnect
240-013
Bracket Rack Mount 2U (Qty 2)
38793
Handle Rack Mount 2U (Qty 2)
38794
Screw M4 x 12mm FHMS (Qty 4)
38549 For Rack Mount
Handle
SC6540 MAIN
SC6540 Scanner
SC6540
Line Cord1
33189
Fuse (2A, 20mm, Fast-Blow)
38603
USB Cable AB-Type 1.8m
39066
Bracket Rack Mount 2U (Qty 2)
38793
Handle Rack Mount 2U (Qty 2)
38794
Screw M4 x 12mm FHMS (Qty 4)
38549 For Rack Mount
Handle
W/ HIGH VOLTAGE MODULE

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DESCRIPTION
AR PART NUMBER
100’ White 18AWG Wire
37534
High Voltage Cable Kit
HS-8-13
W/ GROUND BOND MODULE2
20 Hook-Style Crimp Lugs
38599
W/ HYPOTULTRA 3 INTERCONNECT
High Voltage Cable
HS-8-12
2 Return Cables
HS-8-11
W/ HYPOTULTRA INTERCONNECT
High Voltage Cable
HS-8-12
2 Return Cables
HS-8-11
W/ OMNIA 8200 SERIES
INTERCONNECT
High Voltage Cable
HS-8-12
Ground Bond Output Cable
38555
Ground Bond Return Cable
38556
Probe Hi/Probe Lo Cable
388792
1The Line Cord is listed as American. Other Line Cord styles are available upon
request.
2 Part #38879 included only with the 8206, 8256, 8207 and 8257
3 Part # 240-01 is only needed for multiple secondary connection
Only accessories which meet the manufacturer’s
specification shall be used.
NOTE: The items listed are per module. If two of a particular module have
been purchased, then double the amounts listed will be supplied.

12
SC6540 Contents of the Carton
Additional Carton Contents for use with OMNIA 80xx
Additional Carton Contents for use with OMNIA 81xx and OMNIA 8204/8254

13
Additional Carton Contents for use with OMNIA 8206, 8256, 8207, 8257
Additional Carton Contents for use with HypotULTRA

14
2.2. Installation
2.2.1. Work Area
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 setup in section 1.4. Safety.
Make sure the work area you choose has a three-prong grounded outlet capable
of supplying the necessary input current to the power source. Be sure the outlet
has been tested for proper wiring before connecting the instrument to it.
The mains plug is used as the disconnecting device and
shall remain readily operable. The socket-outlet shall be
installed. Near the equipment and shall be easily
accessible.
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. Before applying
power verify that the instrument is set to the correct line voltage (115 or 230 volts).
Adjust the voltage select switch to 115 for use with a 115 volt input. Adjust the
voltage select switch to 230 for use with a 230 volt input. See section 3.2.2. Rear
Panel Controls for an image of the rear panel.
Do not replace the power supply cord with an improperly
rated cord. For North American: A UL listed and CSA
labeled power cord must be used with the instrument in the
United States and
Canada. The power cord must include a NEMA5-15 style male plug, SVT or SJT
cord sets, and be rated for at least 125VAC, 10A, number 16 gauge (or 125VAC,
15A, number 14 gauge) wire or larger, and the length of the cord does not exceed
2 m must be used. For European: A certified power supply cord not lighter than
light PVC sheathed flexible cord according to IEC 60227, designation H03 VV-F or
H03 VVH2-F (for equipment mass not exceeding 3 kg), or H05 VV-F or H05
VVH2-F2 (for equipment mass exceeding 3 kg), and be rated for at least 3G 0.75
mm² (for rated current up to 10 A) or 3G 1.0mm² (for rated current over 10 A up to
16 A) wire or larger, and the length of the cord does not exceed 2 m must be used.
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.
The SC6540 must be connected to a good ground. Be
certain that the power wiring is properly polarized and that

15
the proper low resistance bonding to ground is in place.
2.2.3. Basic Connections
Power Cable
The instrument is shipped with a line cord containing a protective earth ground.
When the line cord is connected to an appropriate AC power source the cable will
connect the chassis to earth ground.
The main plug shall only be inserted 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.
Return Connection
When the instrument’s 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 high voltage to the chassis of the instrument). These currents are inherent
and will cause errors when trying to monitor very low leakage currents in the
microamp range.
The output power supplies of this instrument are referenced directly to earth
ground. Any conductor that completes a path between the high voltage and earth
ground will form a completed circuit.
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….................. 41° - 104° F (5° - 40°C)
Relative humidity…........... 0 – 80%
Altitude…......................... 6560 feet (2,000 meters)
Keep the ventilation slits uncovered during operation.
Failure to do so could cause the instrument to overheat and
may damage internal components.
Storage and Shipping Environment
This instrument may be stored or shipped in environments with the following limits:
Temperature….................. -40° - 167° F (-40° - 75°C)
Altitude…......................... 50,000 feet (15,240 meters)
The instrument should also be protected against temperature extremes that may
cause condensation within the instrument.

16
Failure to operate this instrument within the specified conditions could result in
damage.
If the instrument is used in a manner not specified by the manufacturer, the
protection provided by the instrument may be impaired.
More Information
For more information on test operator and workstation safety please visit the
Events and Training section of our website at http://www.asresearch.com/events-
training/Default.aspx