QuadTech Guardian 2500 Series User manual

Guardian 2500 Series
AC/DC/IR Hipot Tester
Instruction Manual
Form 150319/A8
QuadTech, Inc., 1999
Domestic Sales 800-253-1230
For additional contact information please visit our website
www.quadtech.com
The material in this manual is for informational purposes only and is subject to change, without notice.
QuadTech assumes no responsibility for any error or for consequential damages that may result from the
misinterpretation of any procedures in this publication.
WARNING
Potentially dangerous voltages may be present on front and rear panel terminals. Follow all warnings in
this manual when operating or servicing this instrument. Dangerous levels of energy may be stored in
capacitive devices tested by this unit.
Always make sure the high voltage indicator is not on when connecting or disconnecting the device under
test.
Product will be marked with this symbol (ISO#3684) when it is necessary for the user to refer to
the instruction manual in order to prevent injury or equipment damage.
Product marked with this symbol (IEC417) indicates presence of direct current.
Product will be marked with this symbol (ISO#3684) when voltages in excess of 1000V are
present.

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Contents
Warranty ............................................................................................................7
Specifications............................................................................................................9
Accessories ............................................................................................................13
Safety Precautions....................................................................................................17
Condensed Operating ..............................................................................................19
Installation and Power Up
Selecting Test Conditions
Recalling Setups/Preprogrammed Test Conditions
Modifying/Programming Test Conditions
Implementing Measure Offset
Connection Using Test Leads
Connection Using Corded Product Adapter
Connection to S50 Using Corded Product Adapter
Initiating Tests
Introduction - Section 1
1.1 Unpacking/Inspection ....................................................................................29
1.2 Product Overview ..........................................................................................29
1.3 Front Panel Description .................................................................................30
1.4 Rear Panel Description ..................................................................................34
1.5 Installation......................................................................................................35
1.5.1 Instrument Positioning.......................................................................35
1.5.2 Cleaning .............................................................................................36
1.5.3 Power Requirements ..........................................................................36
1.5.4 Safety Inspection................................................................................36
1.5.5 Fuse Replacement ..............................................................................37
Operation/Programming - Section 2
2.1 Power Up .......................................................................................................39
2.2 Program/Setup Procedure ..............................................................................39
1. Mode ..........................................................................................................41
2. Voltage.......................................................................................................41
3. Hi Limit......................................................................................................42
4. Lo Limit .....................................................................................................42
5. Arc Limit....................................................................................................43
6. Ramp Time.................................................................................................43
7. Hi Limit Ramp ...........................................................................................43
8. Lo Limit Ramp...........................................................................................44
9. Dwell Time ................................................................................................44
10. Test Time .................................................................................................44
11. Fall Time..................................................................................................45
12. Frequency (AC Hipot only, Model 2510/2530).......................................45
13. Ground Continuity ...................................................................................45

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Contents (continued)
2.3 Programming Sequence Tests........................................................................46
1. Sequence Test #1 .......................................................................................46
2. Sequence Test #2 .......................................................................................47
3. Sequence Test #3 .......................................................................................48
4. Calculate Measurement Function ..............................................................49
2.4 Utility Functions ............................................................................................50
2.4.1 General...............................................................................................50
2.4.2 Measure Offset...................................................................................51
2.4.3 Keypad Lockout.................................................................................51
2.4.4 Test Location .....................................................................................53
2.4.5 Buzzer On Fail ...................................................................................54
2.4.6 Beep On Key Hit................................................................................55
2.4.7 RS-232 Interface (Optional) ..............................................................55
2.4.8 IEEE-488 Interface (Optional)...........................................................55
2.4.9 Enhanced Features .............................................................................56
1. Test Low Limit ..............................................................................56
2. Delay Time.....................................................................................57
3. Continue Voltage On Fail ..............................................................58
4. Continue Steps On Fail ..................................................................58
5. Stop Test On Pass ..........................................................................59
6. Step And Increment .......................................................................60
7. Clear All Tests ...............................................................................60
8. Test To View..................................................................................62
9. Perform Calibration .......................................................................62
10. Ground Fault Stop........................................................................63
11. Arc pulse Width .......................................................................................64
12. Adaptive DC Ramp......................................................................64
13. Autoranging .................................................................................65
2.5 Default Test Conditions .................................................................................67
2.5.1 General...............................................................................................67
2.5.2 Setups.................................................................................................67
2.6 Error Messages...............................................................................................68

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Contents (continued)
Interface - Section 3
3.1 General...........................................................................................................73
3.2 Remote I/O.....................................................................................................73
3.3 RS-232 ...........................................................................................................74
3.4 Enhanced Remote I/O Interface.....................................................................76
3.5 IEEE-488.2 Interface .....................................................................................78
3.5.1 General...............................................................................................78
3.5.2 IEEE-488 & Rs-232 Commands........................................................79
3.5.3 Remote Calibration ............................................................................87
3.5.4 Formats ..............................................................................................88
3.5.5 IEEE-488 Sample Program (Quick Basic) ........................................89
Maintenance & Calibration - Section 4
4.1 General...........................................................................................................91
4.2 Instrument Return ..........................................................................................91
4.3 Calibration......................................................................................................91

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Warranty
QuadTech warrants that Products are free from defects in material and workmanship and, when
properly used, will perform in accordance with QuadTech's applicable published specifications.
If within one (1) year after original shipment it is found not to meet this standard, it will be
repaired, or at the option of QuadTech, replaced at no charge when returned to a QuadTech
service facility.
Changes in the Product not approved by QuadTech shall void this warranty.
QuadTech shall not be liable for any indirect, special or consequential damages, even if
notice has been given of the possibility of such damages.
This warranty is in lieu of all other warranties, expressed or implied, including, but not
limited to any implied warranty or merchantability or fitness for a particular purpose.
SERVICE POLICY
QuadTech policy is to maintain product repair capability for a period of at least five (5) years
after original shipment and to make this capability available at the then prevailing schedule of
charges.

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Specifications
Guardian 2510/2520/2530
AC Output Voltage: Range: 0.1 to 5KV AC, in 2V steps
Regulation: +/-(1% of setting +5V)
Frequency: 50/60Hz selectable, 100ppm accuracy
Waveform: Sinusoidal, crest factor 1.4
Voltage Display: Accuracy: +/-(1% of reading +5V)
Resolution: 1V steps
AC Current Display: Real, Imaginary or Total current (user selectable)
Range: 1µA to 15mA AC, in 1µA steps
Accuracy: +/-(0.5% of set high limit + 1µA) *
Guardian 2520/2530
DC Output Voltage: Range: 0.1 to 6KV DC, in 2V steps
Voltage Display: Accuracy: +/-(1% of reading +5V)
Resolution: 1V steps
DC Current Display: Range: 0.1µA to 1.0mA DC, in 0.1µA steps
1.0mA to 7.5mA DC, in 1µA steps
Accuracy: +/-(0.5% of set high limit + 0.1µA or 1µA) *
*Accuracy is degraded by a factor of 2 in DUT
Grounded mode
Guardian 2530
Insulation Resistance: Voltage: 50 - 1000V DC in 1V steps
Accuracy: +/-(2% of setting + 5V)
Range: 10kΩ- 2TΩ, voltage dependent
(range limited to V/50µA in DUT Grounded mode)
Accuracy: +/-(2% + 1 count) for V/R ≥10nA
+/-(5% + 1 count) for V/R < 10nA
(Accuracy above V/10nA is degraded with
Ground Continuity (GC) function in use)
Charging Current: 7.5mA maximum
1000V
500V
50V
10K
50V
150K
5G
100G
2T
2% Accuracy
5% Accuracy
Voltage
Resistance

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Specifications (continued)
Common Features
Ground Continuity: Test Current: 100 mA DC +/- 10%
Range: 10mΩto 10Ω, in 1mΩsteps
Accuracy: +/- (5% of reading + 20mΩ)
Limits: Programmable Hi/Lo during Test Time
(Lo can be set to Off : Hipot & GC, Hi can be set to Off for IR)
Programmable Hi/Lo during Ramp Time (AC/DC Hipot only)
(Both limits can be set to Off)
Ground Fault Shutdown within 2msec for current imbalance > 250µA (AC)
Interrupt: > 400µA (DC)
Arc Detection: Arc Level AC: 0.5mA - 15mA in 0.5mA increments
Arc Level DC: 0.5mA - 15mA in 0.5mA increments
Arc Time: 1 to 50 µsec programmable
Indication: Pass/fail display, lights, audible sound
Buzzer Level: Low, High, Off
Time: AC Hipot: Ramp, Test, Fall: 0.1 to 999sec (+/-50ms)
DC Hipot: Ramp, Dwell, Test, Fall: 0.1 to 999sec (+/-50ms)
IR: Ramp, Dwell, Test, Fall: 0.1 to 999sec (+/-50ms)
GC: Test: 0.1 to 999sec (+/-55ms)
(Test can be set to Continuous. Ramp, Dwell, & Fall can be set to Off)
Standard Interfaces: RS-232
Remote:
Inputs: Start, Stop
Characteristics: TTL active low, Pulse width >1ms
Outputs: Pass, Fail, Under Test
Characteristics: Dry contact relay, Closed if true
36V, 100mA max
Connector: 9 pin male D-series (compatible w/Sentry Series)
Test Setups: 25 User Defined (shipped with some factory settings)
9 Multi-step (3 steps)
Connectors: Front and Rear Connection
High Voltage: Locking, Amp Part # 861610-2
Return: BNC female (Selectable for ground or virtual ground)
Continuity: Standard Banana Socket
Front Panel Lockout: 6 Digit Password with or without setup recall
Miscellaneous: Continue Step on Fail Stop Test on Pass
Continuous Voltage on Fail Step and Increment

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Specifications (continued)
Optional Interfaces: IEEE-488
Enhanced Remote:
Inputs: Start, Stop, Test Selection
Characteristics: TTL active low, Pulse width >1ms
Outputs: Under Test, Pass, Fail, Fail Hi, Fail Lo, Fail Arc, Fail Cont
Characteristics: Dry contact relay, Closed if true
36V, 100mA max
Connector: 25 pin male D-series (compatible w/Sentry Series via a adaptor)
Mechanical: Bench Mount (optional rack mount flanges available, 2000-16)
Dimensions:(w x h x d): 17x5.25x16in (432x133x406mm)
Weight: 29 lbs (13kg) net, 36 lbs (16kg) shipping
Environmental: Meets MIL-T-28800E, Type 3, Class 5
Operating: 0 to 40oC
Storage: -10 to 60oC
Humidity: Maximum RH of 80% for temperatures up to 31oC
and decreasing linearly to 50% at 40oC
Warm-up Time: 1 minute
Indoor Use: Altitude up to 2000m
Pollution Degree 1, Installation Category II
Power: •100 - 240V AC +/-10% •50 – 60 Hz •300W max
Supplied: •Instruction Manual •Power Cable
•Calibration Certificate •Test Leads (3)
Ordering Description Catalog No.
Information: AC Hipot Tester Guardian 2510
AC/DC Hipot Tester Guardian 2520
AC/DC/IR Hipot Tester Guardian 2530

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Accessories
Accessories Included
Table 1
Item Part Number
Instruction Manual 150319
High Voltage Lead Set (consisting of 3 cables) 2000-02
High Voltage Cable (labeled w/QuadTech part # 630113, 10KV rating)
Ground Continuity Cable (labeled w/QuadTech part # 630114)
Ground Return Cable (labeled w/QuadTech part # 630115)
Power Cable 4200-0300
Calibration Certificate Traceable to NIST
Accessories/Options Available
Table 2
Item Part Number
High Voltage Lead Set (consisting of 3 cables) 2000-02
High Voltage Cable (labeled w/QuadTech part # 630113, 10KV rating)
Ground Continuity Cable (labeled w/QuadTech part # 630114)
Ground Return Cable (labeled w/QuadTech part # 630115)
High Voltage Lead Set, 2 Meters (consisting of 3 cables) 2000-04
High Voltage Cable (labeled w/QuadTech part # 630133, 10KV rating)
Ground Continuity Cable (labeled w/QuadTech part # 630134)
Ground Return Cable (labeled w/QuadTech part # 630135)
Foot Switch 2000-05
High Voltage Probe 2000-06
Power Entry Adapter Cable 2000-07
Gun Probe 2000-08
High Voltage Lead Set, 2 meters, unterminated 2000-10
Corded Product Adapter (115V) 2000-13
Rack Mount Flanges (require rail support hardware) 2000-16
Corded product Adapter (240V) 2000-25
IEEE-488 Interface (includes Remote I/O Interface) 2000-40
Enhanced Remote I/O Interface 2000-42
2TΩEnhanced Option (2530 only, factory installed) 2000-43

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Accessories (continued)
2000-02 High Voltage Lead Set
2000-02 High Voltage Lead Set
2000-16 Rack Mount Flanges
2000-16 Rack Mount Flanges
The 2000-16 Rack Mount Flanges (quantity 2, left and right) are used as dress panels to adapt the
2500 to the standard 19 inch rack width. THESE FLANGES SHOULD NOT BE USED AS
SOLE MOUNTING SUPPORT OF THE 2500 in rack mount applications. Chassis guides or
other mechanical support is required to support the instrument. Chassis guides are available
from:
Amco Engineering Company
3801 North Rose Street
Schiller Park, Illinois 60176-2190
Telephone [phone]

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Accessories (continued)
2000-40 and 2000-42 Interfaces
2000-40 2000-42
IEEE-488 Interface Option Enhanced Remote Interface
(Rear Panel Configuration) (Rear Panel Configuration)
2000-43 2TΩEnhanced Option
The 2000-43 is an option for use with the Guardian 2530 only. This option provides enhanced
measurement capability of devices with high resistance and substantial parallel capacitance
(devices such as wire wound heaters, ac inlet filters, sensors, etc.). When this option is installed
additional ramp and dwell time will be required in DC Hipot and fall/discharge time will be
increased for DC test voltages greater than 3000 V. AC Hipot functions are not effected by this
option. This option generally serves no purpose if insulation resistance measurements are<200
MΩ.
REMOTE I/O
IEEE-488
RS232
ENHANCED
REMOTE I/O
RS232

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Safety Precautions
The Guardian 2500 Hipot Tester can provide an output voltage as high as 6000VDC (5000VAC)
to the external device under test (DUT). Although the Guardian unit is designed with full
attention to operator safety, serious hazards could occur if the instrument is used improperly and
these safety instructions are not followed.
1. The Guardian 2500 unit is designed to be operated with its chassis connected to earth
ground. The instrument is shipped with a three-prong power cord to provide this
connection to ground. This power cord should only be plugged into a receptacle which
provides earth ground. Serious injury can result if the Guardian 2500 is not connected to
earth ground.
2. When connecting test leads to the instrument make sure the RETURN lead is secured
tightly with the BNC connector locked in the cw direction, and the HIGH VOLTAGE
lead secured tightly with the threaded connector in a cw direction.
3. Never touch the test leads, test fixture or DUT in any manner (this includes insulation on
all wires and clips) when the high voltage is applied and the HIGH VOLTAGE light is
on.
4. Before turning on the Guardian unit, make sure there is no device (DUT) or fixture
connected to the test leads.
5. After each test, press the STOP (red) button for safety. This terminates the high voltage
being applied to the output terminals.
6. When the HIGH VOLTAGE light is flashing (or constantly lit on some later units),
NEVER touch the device under test, the lead wires or the output terminals.
7. Before touching the test lead wires or output terminals make sure :
a) The red STOP button has been pressed.
b) The HIGH VOLTAGE light is not flashing (or not lit).
8. Do NOT short the output terminal to the ground line or AC power line. The instrument
could then be charged up to a dangerously high voltage.
9. In the case of an emergency, turn OFF the POWER switch using the eraser tip of a
pencil or “hot stick” and disconnect the AC power cord from the wall. DO NOT TOUCH
THE INSTRUMENT.
10. If the HIGH VOLTAGE light does not go off when the STOP button is pressed,
immediately stop using the tester and power the instrument down.
11. When the Guardian 2500 instrument is used in remote control mode, be extremely
careful. The High Voltage Output is being turned on and off with an external signal.
WARNING
Should the HIGH VOLTAGE light ever malfunction, a changing time display, shown in seconds (lower right
corner of front panel LCD display), is also an indication that high voltage is being applied to the output
terminals.
CAUTION
When programming the Guardian 2500 for high test voltages it is recommended to program a voltage ramp time
(typically > 1 sec). This is intended to prevent any possible high voltage transients across the output resulting from
inductive kickback of the instrument’s high voltage transformer.

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Condensed Operating Instructions
Installation and Power Up
1. Use of this Condensed Operating procedure assumes the operator is somewhat familiar with
electrical safety testing and the safety precautions associated with it.
2. The Guardian 2500 should be unpacked from its shipping container. The original carton and
packing material should be retained in case it becomes necessary to return the instrument
back to the factory for service or calibration at a later date.
3. Install the 2500 in an isolated work area appropriately marked for High Voltage Testing.
4. Connect the power cord (female end) to the AC inlet module on the rear panel of the
instrument. Connect the other end (male end) to the power receptacle. The instrument is to
be used only with three wire grounded outlets.
5. Apply power to the Guardian 2500 by pressing the front panel POWER switch to ON (1
position).
6. The instrument performs a self test and will momentarily display the instrument model
number and software version, for example:
7. The display will then indicate the power up default test, which is the last test performed
before the instrument was powered down. Note the message “Idle” in the upper right
display, this area always indicates the instrument status.
Selecting Test Conditions
The Guardian 2500 contains memory for storing predefined test conditions. 1 thru 25 are user
defined setups, (see paragraph 2.5.2 for factory settings) and S1 thru S9 are sequential test
setups. A sequential test can consist of any combination (up to 3) of user setups. A quick start up
is usually performed by recalling or programming modification of setup, see examples in the
next paragraphs.
1 AC:0.500KV Idle
Hi:15.00mA 7.0sec
QuadTech Guardian 2530
Version 1.00

Page 20 of 20
Condensed Operating Instructions (continued)
Recalling Setups/Preprogrammed Test Conditions
1. Press the TEST NUMBER key to sequence up through the test setups, those with no
program stored will show the message “No Test Programmed”. Continue to press the key
repeatedly to select any setup desired (user test 1-25, or sequence S1-S9). Typical display
below shows setup #1 programmed for AC Hipot at 500 volts, high current limit of 15 mA
and test time of 7 seconds. Note the message “Idle” in the upper right display, this area
always indicates the instrument status. (Pressing the up/down arrow key will also
sequence through the test setups, up or down)
2. Once the desired test # has been selected (remains displayed) it is possible to view all test
parameters by pressing the left/right arrow keys as follows:
Press arrow for
VIEW mode
Press arrow to
view next parameter
Press arrow to
view next parameter
Press to continue VIEW or
Press to reverse direction
1 AC:0.500KV Idle
Hi:15.00mA 7.0sec
1 View
Mode: AC Total Current
1 View
Volt: 0.500KV
1 View
Hi Limit: 15.000mA
1 AC:0.500KV Idle
Hi:15.00mA 7.0sec