Cirris CH2 User manual

Cirris CH2
User Manual

Table of Contents
THE CH2 TESTER .................................................................................................................... 1
INTRODUCTION ..............................................................................................................................................................1
High Voltage Warning............................................................................................................................................1
Medical Warning ...................................................................................................................................................1
HIGH VOLTAGE SAFETY....................................................................................................................................................2
PARTS LIST ....................................................................................................................................................................3
ADD-ON SCANNER PARTS LIST ..........................................................................................................................................3
GENERAL INFORMATION ....................................................................................................... 4
MAINTENANCE...............................................................................................................................................................4
TESTER SYMBOLS............................................................................................................................................................5
CONDITIONS FOR OPERATION ...........................................................................................................................................5
HELP...................................................................................................................................... 6
ACCESSING THE ONLINE MANUAL/HELP SYSTEM..................................................................................................................6
EASY-WIRE SOFTWARE .......................................................................................................... 8
REQUIREMENTS FOR A STATION OR NETWORK SERVER...........................................................................................................8
SETTING UP THE TESTER ........................................................................................................ 9
INSTALLING ADD-ON SCANNERS ........................................................................................................................................9
ELECTRICAL ASSEMBLY...................................................................................................................................................10
CHECKING THE SYSTEM ....................................................................................................... 12
TROUBLESHOOTING A RED STATUS INDICATOR ...................................................................................................................14
CHECKING THE SOUND...................................................................................................................................................15
ADDING OR REMOVING SCANNER MODULES....................................................................... 17
TRADITIONAL FIXTURING..................................................................................................... 22
BUILDING TRADITIONAL FIXTURING ..................................................................................................................................22
TWO-WIRE FIXTURING...................................................................................................................................................22
BUILDING FIXTURING FOR FAST ATTACH............................................................................................................................23
REQUIREMENTS FOR USING FAST ATTACH..........................................................................................................................24
FOUR-WIRE FIXTURING..................................................................................................................................................25
Kelvin points in four-wire fixturing.......................................................................................................................25
Requirements for Kelvin Points............................................................................................................................26
Visible and Hidden Point Mates...........................................................................................................................26
OPTIONAL CAPABILITIES...................................................................................................... 28
ADVANCED INSTRUCTIONS..............................................................................................................................................28
EXTERNAL INSTRUMENTS................................................................................................................................................29
REQUIRED PARTS FOR MEASURING DEVICES ......................................................................................................................30
SETTING UP AND ATTACHING EXTERNAL INSTRUMENTS ........................................................................................................30
ENERGIZATION BOX............................................................................................................. 31
INTRODUCTION ............................................................................................................................................................31
SELECTING A POWER SUPPLY ..........................................................................................................................................31
REQUIRED PARTS..........................................................................................................................................................32

SET UP.......................................................................................................................................................................32
E-BOX INSTRUCTIONS....................................................................................................................................................34
ENERGIZATION BOX PERFORMANCE VERIFICATION..............................................................................................................38
ITEMS NEEDED FOR THE PERFORMANCE VERIFICATION TEST..................................................................................................38
SELECTING POWER RESISTORS.........................................................................................................................................38
WARRANTY ......................................................................................................................... 52

Introduction 1
THE CH2 TESTER
Introduction
Use this guide to install the Cirris Easy-Wire™software, setup the CH2 tester, connect the
CH2 tester to a network and get an overview of the test system.
If you need assistance at any time, call your Cirris Customer Support representative. In the
United States, Cirris Sales and Customer Support may be reached at [phone].
High Voltage Warning!
Possible electric shock!
CH2 (when NOT equipped with xHV or xHVC power supply)
The CH2 test system provides the capability to perform high voltage Dielectric Withstand (DW)
and Insulation Resistance (IR) testing. By design and purpose, the output of high voltage test
equipment presents a risk of electric shock. The extent of the risk is a function of the voltage,
current and high voltage energy or charge. In order to mitigate the risk, the high voltage energy
limit of the CH2 is 35 mJ and the high voltage charge limit is 45μC. These limits prevent
circuits energized during high voltage testing from meeting the definition of hazardous or
dangerous live points found in international standards.
•IEC 61010-1, section 6.3.1, which specifies general safety requirements for electrical test
and measurement equipment, states that in a dry environment 60 volts DC or 30 Volts
RMS (or greater) are deemed to be “HAZARDOUS LIVE” if the current exceeds 0.5 mA
RMS or 5 mA DC and the level of capacitive charge or energy exceeds 45μC at the same
time. The maximum 45μC charge limit of the CH2 means the high voltage output of the
CH2 is not considered HAZARDOUS LIVE.
•European standard EN 50191 defines requirements for the erection and operation of
electrical test equipment and focuses on measures to ensure operator safety. It states that
compliance with the standard is not necessary if contact with live parts presents no danger,
which it goes on to say is the case if the discharge energy does not exceed 350 mJ. The
requirements of the standard are not mandatory for the CH2 due to the unit’s 35 mJ high
voltage energy limit.
CH2 Equipped with xHV or xHVC Power Supply
It’s essential to recognize that when the CH2 test system is equipped with the xHV or xHVC
power supply, the voltage, current, energy limit and charge limit during high voltage testing can
exceed the thresholds of what IEC 61010-1 and EN 50191 define as hazardous or dangerous
making it necessary to use safety interlocks and additional measures to protect operators from
high voltage electric shock. Please see the CH2 xHVC User Manual for additional information.
Medical Warning
Individuals with medical conditions wearing electronically controlled devices
such as a cardiac pacemaker or insulin pump should NOT perform hipot testing.
CR Tester

Introduction 2
High Voltage Safety
The restricted high voltage energy and charge limits of the CH2 do not mean that performing
hipot testing with the system is entirely without risk as operators can still receive a startling or
even painful shock. Therefore, it’s necessary and prudent to protect operators. Consider the
following while recognizing it is not an exhaustive list.
Training
Operators should only use the test equipment after they have been properly trained.
•Operators should understand the hazards of electricity and that electric current will take
any path to ground including through a person.
•Operators should know how to use the test equipment and how to recognize when high
voltage testing is being performed.
•Operators should understand not to touch the product being tested or any test fixture
hardware during high voltage testing.
•Operators should understand test processes and their importance.
•Operators should understand that untrained workers should not be allowed to use the test
equipment.
Test Station
Training alone is not as effective as eliminating access to hazards.
•Protection from energized points can be accomplished by insulation, covers, enclosures,
obstacles or safe distance. A remote start button and/or safety interlock can be used as
part of a protection strategy. The CH2 supports the use of either or both.
•Use a non-conductive surface for testing. Do not use an Electrostatic Discharge (ESD)
station for testing. Conductive materials can create a connection path between exposed
connections or connector shells and the operator.
•Do no use the tester in a wet environment or in the presence of flammable/explosive
gases.
•Verify that the power outlet provides a properly wired, low impedance earth ground. The
connection to earth ground is integral to the power cord supplied with the tester.
•Isolate high voltage testing from untrained employees and post high voltage warning signs
at the test station boundary.
See the Cirris web site for more Ideas on Improving Hipot Safety.

Introduction 3
Parts List
Each CH2 order comes with the following parts:
Add-on Scanner Parts List
A CH2 add-on scanner system is optional and includes the following parts:
You may want to add these optional accessories
You can purchase the listed accessories at computer and office supply stores. Each accessory
is easy to integrate with your computer and CH2 test system to fit your requirements.
CR Tester
❑Base Unit
One required per system.
Provides up to 800 points
in 160-point increments.
❑Hand Held Probe
❑easy-wire Software USB
flash drive
❑USB Cable
❑Add-on Scanner Chassis
Provides up to 800 points in
160-point increments.
❑Box-to-Box Cable
One for every Scanner
Chassis.
❑Power Cable
❑Power Cable
Varies according to
the country of receipt.
❑Sheet Printer
For printing test reports
and fixturing information
❑Label Printer
For printing labels to
apply to the device-
under-test
❑PC Network Card
For sharing test
information between
CH2 testers (requires
purchase of easy-wire
networking software)
❑Barcode Scanner
For replacing the mouse
on the production floor
❑HV Interlock
Override

Introduction 4
GENERAL INFORMATION
Maintenance
Tester Maintenance
The CH2 tester requires no maintenance. If desired, you may clean the outside surfaces of the
CH2 tester. Since some cleaning agents leave a conductive residue, take special care to not
allow the cleaning agents contact the test point connectors or the circuitry inside the casework.
Fixture Maintenance
The fixturing contacts that mate to the device-under-test may wear due to repeated insertion
cycles. Contact wear can result in higher connection resistances which increases the
measured resistances for the device-under-test. For this reason, Cirris recommends that
customers evaluate the number of mating cycles and the cycle life of fixture contacts to
determine maintenance intervals for testing and/or replacing fixturing contacts. A good way to
check fixture contact resistance is to construct and use a shorting block. For more information
on creating shorting blocks, see http://www.cirris.com/adapters/test-adapt.html.
Service
Cirris Testers are modular in design for easy servicing. If your Cirris tester requires service, as
directed by Cirris support personnel, you may need to send the affected module or the entire
tester back to Cirris for repair. If needed during the repair period, a loaner tester can be sent to
you. You should not attempt to service any circuit board at the component level. All
component-level service should be performed by Cirris technicians.
Calibration
With your CH2 tester you should have received a Certificate of Verification. Before leaving the
factory every CH2 tester is calibrated in compliance with ANSI/NCSL Z540-1-1994 and MIL-
STD-45662A to standards traceable to the NIST in the United States. The calibration of the
tester should thereafter be verified annually.
To verify calibration and functionality, you can purchase the CH2 Performance Check Kit. In
addition to the performance check kit, you need a calibrated volt meter and high voltage probe
capable of measuring up to 1500 VDC.
Note: In the event a Cirris tester is found to be out of calibration, there are no adjustable
controls; the tester, or the affected portions of the tester, must be sent back to a Cirris facility
for repair.

Introduction 5
Tester Symbols
The yellow lightning bolt symbols on the CH2 tester inform operators that high voltage is
involved with the scanner modules and that there is risk of electric shock. The yellow
exclamation mark means to use caution and see the manual for more information. See more
details below.
Caution: See
manual for more
Information
Risk of shock
When performing a high voltage test, the CH2 tester
limits the Total Current to 2.5 milliamps and the applied
charge to 45 micro coulombs. If you are using an xHV
supply, the applied current limit is 22 milliamps. For
these reasons, Cirris recommends that you keep the
Real Current setting as low as possible (1 milliamp or
smaller) and avoid touching the cable during the hipot
test. Using a DC voltage for high voltage testing also
provides an added level of operator safety. See the
Cirris website for more hipot safety information.
See manual for more
Information
The symbols with a white exclamation mark on the back
of the tester, inform operators that more information
about the Digital I/O, Auxiliary HV input, and Auxiliary
Input Supply Connections can be found in the CH2
User Manual and in the Easy-Wire on-line manual/help
system.
The Digital I/O Connector allows the tester to respond
to inputs and create outputs without the use of a PLC.
Easy-Wire software version 8.80 or higher has Digital
I/O capability. See the Easy-Wire help system for more
information.
The Auxiliary HV Input and Auxiliary Supply
Connections are for non-standard features. You can call
Cirris for more information on the intended function of
these features.
Conditions for Operation
Your CH2 Tester is intended to be used indoors at a temperature of 50 to 104 degrees
Fahrenheit (10 to 40 degrees Celsius). Best performance can be obtained at a relative
humidity less than 70%. Insulation Resistance Measurements will degrade at over 70% relative
humidity. The unit can be mounted in a ventilated compartment. Be sure not to block the vents
on the sides and back of the tester.
Never apply live voltages to the test points or probe input of your Cirris tester. Power supplies
and other accessories not approved by Cirris may cause damage or present a hazard. If you
use a Cirris product in a manner not specified in this manual and the accompanying help
system, the protection provided by the product may be impaired.

Help 6
HELP
Accessing the Online Manual/Help System
In addition to this user manual, the complete Easy-Wire manual is available in the Easy-Wire
help system. Sections of the online manual may be printed if desired.
1. In the Easy-Wire software, click
the Help button at the bottom of
any window.
The help information for that
window will appear on the screen.
2. To view the entire online manual
by chapter, click Contents.

Help 7
3. Click any link to view the help for
that specific topic. Scroll down if
necessary.
In every Help page, you can do the
following:
•Click Contents to view the
Easy-Wire manual by chapter.
•Click Search to find information
using key words.
•Click Contact to view the contact
information for Cirris.
•Click Website to view the Cirris
website if you have an internet
connection.

Easy-Wire Software 8
EASY-WIRE SOFTWARE
Requirements for a Station or Network Server
•2.0 GHz min. processor speed
•Windows 10® or later (for server - Windows 10®, Windows Server 2012® or Windows Server
2016®)
•15 GB hard drive space
•4 GB RAM
•256 MB min. video memory
•1024 x 768 min display resolution
•Sound (for audible feedback –not required on server)
•USB 2.0 or 3.0 port (not required on server)
•Internet connection: Not required, but if available, can facilitate support issues.
For Easy-Wire station installation instructions, please see the Cirris Easy-Wire Software
Manual –CH2 & CR.
For Easy-Wire Server Installation Instructions, please see the Cirris Server Software
Install guide.
For assistance:
•Call Cirris [phone] or email [e-mail].
•Outside the US, contact the Cirris office nearest you.

Setting Up the CH2 Tester 9
Setting Up the Tester
Before setting up the tester, select a test area where you can keep 2 feet (60 cm) between the
test system and noise emitting electronics.
Some examples of electrically noisy
devices include:
•CRT video monitors
•Florescent lights
•Equipment motors
Keep such devices at least 2 feet from the
test system, test fixturing, and
device-under-test. Otherwise, measurement
accuracy may be compromised.
•
Installing Add-on Scanners
Close together: Stacking the add-on scanners onto the base unit is the standard configuration. The
system is less susceptible to electrical noise in the environment, and therefore generally more accurate.
This configuration supports the supplied box-to box cable(s).
Spaced apart: The units can be spaced apart to allow for a shorter interface cable to the device-under-
test. For this type of configuration, you must order custom box-to-box cables from Cirris. The maximum
total length of a box-to-box cable is 200 ft (60m).
1. Connect the box-to-box cable from
the OUT connector on the base unit
to the IN connector on the next unit.
You may also connect a box-to-box cable
from a BRANCH connector to the IN
connector of another unit.
Minimum
2 ft.(60cm)
OUT
Connector
IN
Connector
BRANCH
Connector

Setting Up the CH2 Tester 10
2. Plug the power cord into the additional scanner. A power connection is needed for each
scanner chassis.
Electrical Assembly
1. Insert one end of the USB cable into the USB
port on the back of the Base Unit. Insert the
other end into a USB port on your computer.
Note: For more reliable tester operation, connect the tester’s USB port directly to the PC’s
USB connect and not a USB Hub.
2. Connect the HV Interlock Override to the
Digital I/O Connector on the Base Unit.
Note: CH2 testers made after March of 2007, have HV interlock capability. An interlock helps
protect operators from high voltage during the high voltage test. For more information on
interlocks, search the word “interlock” in the Easy-Wire help system.
3. Plug the power cord into the Base Unit’s power
connector. Make sure the back-panel power
switch is in the ON position.
Power switch
(not found on
every tester)
Digital I/O
connector
Power
connector
USB port

Setting Up the CH2 Tester 11
4. Plug the other end of the power cord into the
same grounded outlet or plug strip that is used
for the computer. IF your tester has a power
switch on the back panel, make sure it is in the
ON position.
The power supply auto adjusts to line voltages
of either 120 VAC 60 hertz or 240 VAC 50
hertz.
For optimum measurement accuracy, the CH2
must have a consistent earth ground to the
entire system. Make sure to use a grounded (3-
prong) outlet or plug strip.
5. On the front of the tester, insert the probe into
the probe port. Probes can be plugged into any
or all testers in a multi-tester system.
Probe port
Grounded
outlet

Connecting to a Network 12
CHECKING THE SYSTEM
The tester goes through a series of self-tests upon boot up. These tests check to ensure that
the hardware and software are working properly. In the Easy-Wire main menu, you can tell if
the tests pass or fail by checking the status indicator. You can also check the sound from the
Easy-Wire main menu.
If you disconnected the USB cable
while updating the software,
reconnect it.
1. On your desktop, double-click on
the Easy-Wire icon.
Note: If you don’t see the icon on the desktop, from the Windows task bar, click Start>All
Programs>Cirris Systems Corporation, Easy-Wire>Easy-Wire.
2. If this is your first time opening
Easy-Wire, the “Select Default
Tester and Frequency” window
will appear on your screen.
a) Enter the station name or
server name (the station
name will be used on reports
generated by this station).
b) Select Easy-Wire CH2 as tester
that will be attached to this
station.
Important! Make sure you
select the correct tester. If you
select the incorrect tester and
click OK, call Cirris for
assistance.
c) Select your line
frequency.
d) Click OK.

Connecting to a Network 13
3. The Easy-Wire software will load.
In the “User Login” window,
click OK.
Note: Initially, no password is required for the "Master Login" user. To learn how to create
login user names and passwords, click the Help button in the “User Login” window.
4. If the “Hardware Status Update”
window opens, read the message
and click OK.
Note: Each time you run the software, the Hardware Status Update window will display if the
system has been changed or disconnected. Click the Help button in this window for more
information.
The Easy-Wire main menu will
open. If you are updating an
existing installation, ensure that
your test programs are in the
test program list.
5. In the Easy-Wire main menu,
verify that the status indicator is
green.
If the status indicator says
ready, the tester is working.
Skip to page 12 to check the
sound.
If the status indicator says
error, the tester has a problem.
See “Troubleshooting a Red
Status Indicator” on the next
page.
For other unresolved problems, see “Startup and Verify” in the help system, or call Cirris Technical
Support at 1-800-441-9910.

Connecting to a Network 14
Troubleshooting a Red Status Indicator
If you have a red status indicator on the main menu of the software, do the following:
1. Verify that there is power to the Base
Scanner and any Booster Scanners.
2. Verify that the USB cable is
connected between the computer
and the Base Scanner.
3. Reboot the tester. If the problem
persists, write down the error
messages that appear after launching
the software, and call Cirris for
assistance.

Connecting to a Network 15
Checking the Sound
The Easy-Wire software relies on sound prompts to provide test feedback to the operator.
1. In the Easy-Wire main menu,
click the green status indicator.
You should hear two trumpet
sounds coming from the tester.
2. If you hear the sounds, skip
to “Error! Reference source not
found.”
on page 14.
If you do not hear the sounds,
continue with the steps below.
3. From the Easy-Wire main
menu, click Utilities.
4. Click Setup System Options.
5. Open the “Computer” tab and
click Change Volume.

Connecting to a Network 16
6. Adjust the volume slider and
click Test to try out the setting.
7. When the volume is at the desired
level, click Done.
8. The “Setup System Options” window
will be open. Click OK.
9. The “System Utilities” window will
be open. Click Done to return to the
main menu.
10. If you are still having sound problems, try the following:
•Verify that speakers are connected to the PC and have power.
•Verify that the speakers are on and that the volume is turned up.
•Verify that the volume on your PC is turned up (the PC volume
control can be found on your Windows task bar).
If the sound problem persists, call Cirris for assistance.

General Information 17
ADDING OR REMOVING SCANNER MODULES
Units can hold up to five 160 point Scanner Modules.
Accessing Scanner Modules
1. Disconnect all cables from the back
panel of the unit.
2. Remove the four screws (two on each
side) from the chassis. Lift the chassis top
straight up and off the unit.
Pictured here are the parts of the CH2
system. There is a Base Box Assembly
only in the Base Unit. However every unit
has a Power Supply, Node Module, and
one to five Scanner Modules.
3. Lift the scanner and node modules
partially out of the chassis to expose the
wiring.
Screws
Node
module
Scanner modules
Power
supply
Base box
assembly