Th5101d Operational Manual

Transcript

OPERATION MANUAL MO DE L T H5 10 1D / TH 51 0 1E WITHSTANDING VOLTAGE & INSULATION TESTER TToonngghhuuii E Elleeccttrroonniicc C Coo.. ,, LLttdd.. （ TTE （00551199） ）8855113322222222， ，8855111133334422 ELL： ： FFA （ AX X： ： （00551199） ）8855110099997722 E EM MA AIILL： ：ssaalleess@ @ttoonngghhuuii..ccoom m..ccnn H Httttpp::////w ww ww w..ttoonngghhuuii..ccoom m..ccnn Content Chapter 1 Introduction ............................................................................................................... 1 1.1 Introduction.................................................................................................................... 1 1.2 Feature ............................................................................................................................ 1 Chapter 2 Installation and preparation..................................................................................... 3 2.1 Unpacking....................................................................................................................... 3 2.2 Precautions for Installation........................................................................................... 3 2.2.1 Do not use the tester in a flammable atmosphere. ........................................... 3 2.2.2 Avoid locations where the tester is exposed to high temperatures or direct sunlight. ........................................................................................................................ 3 2.2.3 A void humid environments. .............................................................................. 3 2.2.4 Do not place the tester in a corrosive atmosphere............................................ 3 2.2.5 Do not locate the tester in a dusty environment. .............................................. 3 2.2.6 Do not use the tester where ventilation is poor................................................. 3 2.2.7 Do not place the tester on a tilted surface or in a location subject to vibrations...................................................................................................................... 4 2.2.8 Do not use the tester in locations affected by strong magnetic or electric fields. ............................................................................................................................. 4 2.2.9 Do not use the tester in locations near a sensitive measuring ......................... 4 2.2.10 Secure adequate space around the power plug. ............................................. 4 2.3 Power cable..................................................................................................................... 4 2.4 Connection power cable ................................................................................................ 4 2.5 Ground............................................................................................................................ 4 Chapter 3 Warning ...................................................................................................................... 6 3.1 Preparation..................................................................................................................... 6 3.1.1 Wear insulation glove ......................................................................................... 6 3.1.2 Ground................................................................................................................. 6 3.2 Warning and note .......................................................................................................... 6 3.2.1 Before turn on AC input..................................................................................... 6 3.2.2 Connect low terminal test lead .......................................................................... 6 3.2.3 Connect high voltage test line ............................................................................ 6 3.2.4 Before change parameter ................................................................................... 6 3.2.5 Stop testing .......................................................................................................... 6 3.2.6 Dangerious accessary.......................................................................................... 6 3.3 Warning after turning off power .................................................................................. 6 3.3.1 Items need checking after turning off power.................................................... 7 3.3.2 Remaining high voltage ...................................................................................... 7 3.4 Warning of remote control ............................................................................................ 7 3.5 Forbiden ......................................................................................................................... 7 3.5.1 Don’t turn on and off power rapidly and repeatly........................................... 7 3.5.2 Don’t short to ground ......................................................................................... 7 3.6 Operation under emergency ......................................................................................... 8 3.7 Breakdown...................................................................................................................... 8 3.7.1 Don’t use broken tester ...................................................................................... 8 3.7.2 High voltage indicator ........................................................................................ 8 3.8 Power, temperature and other limitation..................................................................... 8 Chapter 4 Description of front and rear panel.......................................................................... 9 4.1Instruction of front panel ............................................................................................. 10 4.2 Instruction .................................................................................................................... 17 4.3 Instruction of rear panel ............................................................................................. 20 Chapter 5 Preparation before testing....................................................................................... 21 5.1 Initiated setting ............................................................................................................ 21 5.2 Check ............................................................................................................................ 21 5.3 Check the instrument before testing .......................................................................... 22 Chapter 6 Test procedure.......................................................................................................... 23 6.1 AC withstanding voltage test ...................................................................................... 23 6.1.1 Select a AC range .............................................................................................. 23 6.1.2 Set high limit cutoff current............................................................................. 23 6.1.3 Set low limit cutoff current .............................................................................. 23 6.1.4 Set test time ....................................................................................................... 24 6.1.5 Set test voltage................................................................................................... 24 6.1.6 Connection of DUT ........................................................................................... 25 6.1.7 Test ..................................................................................................................... 25 6.1.8 Repeat testing .................................................................................................... 26 6.2 Insulation resistance test： ......................................................................................... 27 6.2.1 Select a DC test voltage range.......................................................................... 27 6.2.2 Set low limit reference resistance..................................................................... 27 6.2.3 Set high limit reference resistance ................................................................... 28 6.2.4 Set test time ....................................................................................................... 28 6.2.5 Connection of DUT ........................................................................................... 28 6.2.6 Test ..................................................................................................................... 28 6.2.7 Repeat testing .................................................................................................... 28 6.3 Auto switch test of withstanding voltage to insulation ............................................. 28 6.3.1 Instruction of entering range ........................................................................... 29 6.3.2 Setting of AC-IR parameter............................................................................. 29 6.3.3 Setting of wait time of AC-IR........................................................................... 29 6.3.4 Test procedure ................................................................................................... 29 6.3.5 Test ..................................................................................................................... 29 6.3.6 Repeat testing .................................................................................................... 32 6.4 Auto switch test of insulation resistance to withstanding voltage......................... 32 6.4.1 Instruction of entering range ........................................................................... 32 6.4.2 Setting of IR-AC parameter............................................................................. 32 6.4.3 Setting of wait time of IR - AC......................................................................... 32 6.4.4 Test procedure ................................................................................................... 32 6.4.5 Test ..................................................................................................................... 32 6.4.6 Repeat testing .................................................................................................... 33 6.5 Remote control ............................................................................................................. 33 6.5.1Remote control by connector ............................................................................ 33 6.5.2 Pass signal input/output connector remote control........................................ 33 6.5.3 Interlock function ............................................................................................. 34 6.5.4 Start/stop control............................................................................................... 35 6.5.5 Output signal..................................................................................................... 35 6.6 Special mode setting .................................................................................................... 35 6.6.1 Dual effect mode ............................................................................................... 36 6.6.2 Pass hold mode.................................................................................................. 36 6.6.3 Instant test mode............................................................................................... 36 6.6.4 Fail pass mode ................................................................................................... 36 Chapter 7 RS-232C interface.................................................................................................... 37 7.1 Connection cable.......................................................................................................... 37 7.2 RS-232C specification............................................................................................... 37 7.3 Communication method .............................................................................................. 37 7.4 Communication mode ................................................................................................. 37 7.5 Notes before using RS-232C........................................................................................ 39 7.6 RS-232C command and respondance ..................................................................... 40 Chapter 8 Specification ............................................................................................................. 43 8.1Basic specification of AC withstanding voltage.......................................................... 43 8.2 Basic performance of insulation resistance ............................................................... 44 8.3 Interface and other function ....................................................................................... 45 8.4 Signal input/output ...................................................................................................... 45 8.5 General specification ................................................................................................... 46 8.6 Accessary ...................................................................................................................... 46 Chapter 9 Daily warrenty ......................................................................................................... 47 9.1 Clean ............................................................................................................................. 47 9.2 Check test line and power line .................................................................................... 47 9.3 Warrenty....................................................................................................................... 47 9.4 Calibration ................................................................................................................... 47 Chapter 1 Introduction 1.1 Introduction TH5101D/TH5101E is a kind of instrument for performing withstanding voltage and insulation test in electrical device and component. ！ ： z In this instrument, there are variable safe measures to protect operator to avoid danger. However, when the high voltage is applied in DUT, the electrical shock will be caused in test lead, probe and output terminal if touching the device under test accidently. z Be sure to provide overall protection around instrument and DUT to avoid electrical shock——such as use rope to encompass the test zone to avoid people to approach. 1.2 Feature ⒈ The instrument observes main industrial standard The instrument can perform withstanding voltage (insulation intensity) and insulation resistance test in electrical device and component according to related electrical standard and rule. ⒉ Volume of transformer TH5101D installs a transformer with the volume of 500VA，and TH5101E installs a transformer with the volume of 200VA ⒊ Reasonable planning of key and switch All keys are on the panel for easier operation. In order to set high limit current, low limit current, high limit resistance value, low limit resistance value, test time, set increasing and decreasing key. The reasonable arrangement and VFD display help you operate the instrument correctly. ⒋ VFD There is a VFD displayer for clearly displaying information：test condition，test status，test value，pass/fail judge result .etc. ⒌ A analogy voltage meter and digital voltage meter This instrument installs an analogy voltage meter（±5%FS）and a digital voltage meter（±1.5FS）. The former one can help you control voltage rapidly, but the latter one can read data more conveniently and accurately. ⒍ Digital current meter/digital ohm meter Digital current meter can be used to display the current flowing through DUT. ⒎ Pass/fail judge When the test current flowing through DUT is higher than the high limit value or lower than low limit value, fail judge signal will be generated. Low limit judge check function help improve the reliability. The instrument has independent indicator and signal output for each malfunction which can help us find out the reason. 8. Digital timer Timer allows the test time of high voltage being applied to DUT. Preset range： 0.2—999s. when timer is ON，the time is countdown digit，timer displays the remaining test time. 9. Remote control function The instrument has the operation of remotely-controlled start/stop. There are -1- 5-pin connector on the front panel（selectable remote control box or high voltage test probe），there are 25 core cable lead on the rear panel. Remote control function and status signal function will help you test efficiently. 10．Status signal 25 core cable lead on the rear panel is used to transfer 7 status signal （with remote control signal）. The seven signals are HV-ON，TEST，PASS，U-FAIL， L-FAIL，READY，PROTECTION. 11. Compaction and light Model TH5101D TH5101E Dimension 320mm(W)*132mm(H)*300(D) Weight 13kg 10kg 12. Protection When you turn off the instrument，the test status will be stored in non-volatile memory. When you turn on the instrument again, the instrument will recover the stored information. 13. Safe high voltage output terminal Using lead to insert into high voltage output terminal is much safer. 14. Indicator When the electric charge is in high voltage output terminal, the indicator will light to warn the electrical shock. 15. Interlock function There is interlock function for cutting voltage with external device. When the function is activated, the output will be cut to refuse test. 16. Keylock function This function is to warn operator to use the keyboard incorrectly. 17. Noise rejection circuit The inner circuit design can reject noise well to improve the reliability. 18. RS-232C interface The result is output to computer or printer. -2- Chapter 2 Installation and preparation 2.1 Unpacking Upon receiving the product, confirm that the necessary accessories are included and have not been damaged in transit. Should any damage or shortage be found, please contact TongHui distributor/agent. Accessory： 1 TH90001R withstanding voltage test lead ； 1 TH90001B withstanding voltage ground lead； 1 TH90002 withstanding voltage test rod； 1 TH5100-IL cable(25 core)； 1 Power cable； Manual operation； 2.2 Precautions for Installation Be sure to observe the following precautions when installing the tester. 2.2.1 Do not use the tester in a flammable atmosphere. To prevent explosion or fire, do not use the tester near alcohol, thinner, or other combustible materials, or in an atmosphere containing such vapors. 2.2.2 Avoid locations where the tester is exposed to high temperatures or direct sunlight. Do not locate the tester near a heater or in areas subject to drastic temperature changes. Operating temperature range: 0 °C to +40 °C Storage temperature range: -20 °C to +70 °C 2.2.3 A void humid environments. Do not locate the tester in a high-humidity environment—near a boiler, humidifier, or water supply. Operating humidity range: 20 % to 80 % RH (no dew condensation permitted) Storage humidity range: 90 % RH or less (no dew condensation permitted) Condensation may occur even within the operating humidity range. In that case, do not start using the tester until the location is completely dry. 2.2.4 Do not place the tester in a corrosive atmosphere. Do not install the tester in a corrosive atmosphere or one containing sulfuric acid mist or the like. This may cause corrosion of various conductors and imperfect contact with connectors, leading to malfunction and failure, or in the worst case, a fire. 2.2.5 Do not locate the tester in a dusty environment. Dirt and dust in the tester may cause electrical shock or fire. 2.2.6 Do not use the tester where ventilation is poor. This tester features a forced-air cooling system. Provide sufficient space for the air inlet on the lateral side and the air outlet on the rear side to allow air to flow. -3- 2.2.7 Do not place the tester on a tilted surface or in a location subject to vibrations. If placed on a non-level surface or in a location subject to vibration, the tester may fall, resulting in damage and injury. 2.2.8 Do not use the tester in locations affected by strong magnetic or electric fields. Operation in a location subject to magnetic or electric fields may cause the tester to malfunction, resulting in electrical shock or fire. 2.2.9 Do not use the tester in locations near a sensitive measuring Instrument or receiver. Operation in a location subject, may cause such equipment may be affected by noise generated by the tester. At a test voltage exceeding 3 kV, corona discharge may be generated to produce substantial amounts of RF broadband emissions between grips on the test leadwire. To minimize this effect, secure a sufficient distance between alligator clips. In addition, keep the alligator clips and test leadwire away from the surfaces of conductors (particularly sharp metal ends). 2.2.10 Secure adequate space around the power plug. Do not insert the power plug to an outlet where accessibility to the plug is poor. And, do not place objects near the outlet that would result in poor accessibility to the plug. 2.3 Power cable The requirement of AC power cable is： 250V，50/60HZ，10A 2.4 Connection power cable Note ¾ The instrument must be connected to a reliable AC power. From inner structure to see AC withstanding voltage test，output voltage will be affected by the input of AC power. 2.5 Ground ！ ： z If there is no suitable ground device, it is easy to generate electric shock. z Be sure to connect a ground terminal to a correct ground terminal. There are 2 methods for ground connection： -4- As below： 1. Connect cable line to a 3-core power correctly. 2. Connect ground terminal on the rear panel to the ground. -5- Chapter 3 Warning ！ ： The instrument can transfer 5kV test voltage，maybe cause electric shock. When you operate instrument，please be careful. 3.1 Preparation 3.1.1 Wear insulation glove Please wear insulation glove when you operate the instrument. 3.1.2 Ground Be sure the safe ground or it will release high voltage and cause electric shock. 3.2 Warning and note 3.2.1 Before turn on AC input Be sure voltage adjusting knob is in“0”. 3.2.2 Connect low terminal test lead Before using instrument，be sure there is no damage in low terminal. When DUT is connected to instrument，firstly connect low terminal test line， then high terminal，make sure the low terminal is connected to corresponding terminal of DUT（shell protection ground）. If connect incorrectly, the whole DUT is charged to a danger high voltage. 3.2.3 Connect high voltage test line 1. Press stop switch. 2. Check if the indication of output voltage is in position“0”，and if the indicator is off. 3. Connect high voltage test line to high voltage output terminal, and high voltage test line to DUT. 3.2.4 Before change parameter Press stop key before changing parameter，and make sure voltage adjusting knob is in position“0”. 3.2.5 Stop testing When stopping a test，make sure voltage adjusting knob is in position“0” ，then press stop. 3.2.6 Dangerous accessory The DUT, test line, and those with high voltage are dangerous. 3.3 Warning after turning off power -6- 3.3.1 Items need checking after turning off power If you have to touch DUT, test line, probe, output terminal and other accessories，please make sure 2 points below： z If output voltage indication is“0”. z If danger light is off. There is high test voltage in DUT after turning off power in insulation resistance test. 3.3.2 Remaining high voltage Warning of remaining high voltage When you perform an insulation resistance test, there is high voltage in test line, probe, output terminal and other accessories. Even if you turn off DC voltage output, the voltage is still existed according to working environment, during this time, please don’t touch the referred thing below, or you will be shocked. Before touching high voltage components, make sure the conditions below are provided： （1）output voltage meter indicates“0”. （2）danger indicator is off. Check discharge After output is cut off，there is an inner circuit for releasing remaining high voltage. Don’t remove DUT in testing；if DUT is removed, the remaining high voltage will exist for a long time. 3.4 Warning of remote control Be careful under remote control mode, because high voltage can be turned on and off remotely！ The safe method is as below： 9 Not output voltage when setting test condition. 9 Make sure no one can touch DUT, test line, probe , output terminal and the near zone.（Test status） 3.5 Forbidden 3.5.1 Don’t turn on and off power rapidly and repeatably After turning off power switch, make sure there are several seconds or more time; don’t turn on or off power switch rapidly and repeatably only under special condition. 3.5.2 Don’t short to ground Attention high voltage test line can’t be shorted with nearby AC power or the device connected to ground, if being shorted, the shell may be charged to a dangerous high voltage. Make sure the protective ground is connected to ground！If do it correctly, there is no danger in instrument，even when output terminal of high voltage and low voltage is shorted, the shell can’t be charged to a high voltage. Make sure instrument is grounded for safety！the description of ground can be -7- referred to 2.6“ground”. 3.6 Operation under emergency If there is emergency（for example electrical shock discharge or burning of DUT）， adopt the methods below： Turn off the power switch, and remove the power cable from AC power socket. 3.7 Breakdown 3.7.1 Don’t use broken tester Even you press STOP key，high voltage indicator is on or analogy voltage meter deflexs, it means the instrument has been damaged and at an extremely dangerous status. If it happened, please turn off power switch and remove power line from socket. Please contact us！Please don’t try to fix the instrument by yourself. 3.7.2 High voltage indicator Due to the indicator or other reasons causing indicator not light, the error will be caused if use instrument continuously, please stop using and contact us！ 3.8 Power, temperature and other limitation Use the instrument when the voltage is lower or equal to 5kV The Max.output voltage may be higher than 5kV when there is no load. Due to the wave of AC power voltage, it may be higher. Make sure the instrument is operated within 5kV. ■ Provide stop time Under AC test situation，considering that the heat consumption of high voltage transformer and radiation condition of instrument, the stop time should be same as test time when the high limit cutoff current is higher than 50mA. The Max. allowed test time is 30 min. If the limitation is over passed ， high voltage transformer may be damaged. ■ Use rated line voltage within ±10％ range The AC line voltage must be within ±10％ range, or the instrument can’t be operated normally. Use suitable method to transfer within the range. ■ Capacity of AC power There is a 500VA high voltage output transformer，and it can drive several amps output current under the conditions below： （a）check dozens milliseconds before failure. （b）in dozens milliseconds when setting instrument. ■ -8- Chapter 4 Description of front and rear panel Front panel： 9 10 8 17 TH5101D TONGHUI ELECTRONICS 13 11 16 14 AC/IR WITHSTANDING VOLTAGE TESTER 4 2 6 0 12 kV HV INDICATE LOWER ON FUNCTION UP/ LOW RANGE CUTOFF CURRENT ON OFF TIMER SHIFT MAX 5kV 0 KEYLOCK MAX TEST VOLTAGE HIGH VOLTAGE LOW 6 7 ！ AC ON 30min/OFF 30min DC ON 15s /OFF 150s REMOTE 4 POWER 5 2 3 1 Rear panel： 4 RS-232C 3 1 SIGNAL IN/OUT . ! WARNING . ※ TO AVOID ELECTRIC SHOCK,THE POWER CORD PROTECTIVE GROUNDING CONDUCTOR OR THE PROTECTIVE CONDUCTOR TERMINAL MUST BE CONNECTED TO GROUND. ※ THIS INSTRUMENT CONTAINS NO OPERATOR SERVICEABLE PARTS INSIDE; REFER SERVICING TO SERVICE TRAINED PERSONNEL ONLY. INPUT ~ ! PLEASE READ MANUAL FOR SAFETY -9- 200-240V 47-63Hz 500VA Max 2 15 4.1Instruction of front panel 『1』Power switch When you turn on power，the instrument will restore the stored test condition of last time（for example cutoff current, test time setting）. Press shift when turning on power switch, it will back to initialized test condition，restore to initialized setting （default value），the former stored test condition will be lost. Item Initialized set value High limit cutoff current 0.2mA Low limit cutoff current Low limit reference value High limit reference resistance 0.1mA 2.00MΩ 3.00 MΩ Low limit pass/fail judge（AC） Off Low limit pass/fail judge（IR） Off Test time(AC) 0.5s Test time(IR) 0.5s （Wait Time） Timer function 0.2s On Keylock function Off Communication mode 0 Test mode, range AC，2.5kV Caution ¾ When high limit cutoff current, low limit cutoff current, low limit reference resistance or test time is changed，you must test once or press STOP key，then the set value can be stored. When you turn on power switch ， the instrument will enter ready status automatically（“READY”lights）. However, the indicator won’t light under the following situation. E.g.： （1）In protection status(“PROTECTION”lights） (a) Turn on the keylock pin of signal input\output connector on the rear panel. At this situation，clear interlock signal firstly，then press stop key to clear protection status，then start operation.（more in 6.3.3“interlock function”）。 (b) The test voltage of insulation resistance deflects 30％ range from range voltage，the protection status will be displayed，and test will be over，press STOP to clear protection status. （2） In AC setting，low limit cutoff current is higher than high limit cutoff current, and low limit pass/fail judge function can’t be turned on. Under such situation，low limit cutoff current is lower than high limit cutoff - 10 - current，or turn off low limit pass/fail judge，then operate the instrument. （3）In insulation resistance setting，low limit set resistance is higher than high limit set resistance，and high limit pass/fail judge function is turned on Under such situation，low limit set resistance is lower than high limit set resistance，or turn off low limit pass/fail judge，then operate the instrument. （4）In insulation resistance setting，when range setting is wrong When the range is 100V，Min. set resistance is 0.2k; When the range is 500V，Min. set resistance is 1M, if under such range， READY disappears. When the range is 1000V，Min. set resistance is 2M, if under such range， READY disappears. Under such situation, set to ruled value，READY will appear. （5）In auto test，in AC，or IR setting，turn off TIMER ON Turn to AC/IR interface to turn on timer，then to auto test interface， READY appears. 『2』Start key Press start key when the instrument is at ready status（“READY”indicator lights），it will execute testing according to set parameter. If “remote”is displayed， the start key on the front panel has no function，the start control signal of remote control connector/output connector has function. If test mode switch of signal input/output connector on the rear panel is set as instant mode, only press start key to execute testing，more in 6.6. Note ¾ Don’t remotely control instrument from remote connector and signal input/output connector. If you do like that, there will be danger. More in 6.3， “Remote control”. 『3』Stop key It is used to stop or reset instrument. Press this key, the instrument has these functions below： （1）Clear test status（“TEST”off） (a) Use highest priority to cut off voltage output. (d) Turn off“TEST”message. (c) Set discharge circuit in insulation resistance testing. (d) If there is no remaining test voltage in output circuit, turn off danger indicator. (e) Turn off the test signal flowing into signal input/output connector and high voltage indicator signal. (f) In auto test，when there is no remaining test voltage in output circuit, restore to the setting status in test start. （2）Clear pass status（“PASS”off） (a) Turn off ”PASS” message. - 11 - (b) Turn off the pass signal flowing into signal input/output connector. （3）Clear fail status（“FAIL” off） (a) Turn off“high limit fail” （“U-FAIL”lights）and“low limit fail” （“L-FAIL” lights）message. (b) Turn off the high limit fail and low limit fail signal flowing into signal input/output connector. （4）Clear protection status（“PROTECTION”off） (a) Turn off protection message. (b) Turn off protection signal flowing into signal input/output connector. However, if interlock pin of signal input/output connector is turned on, the instrument won’t clear protection status. Under such situation, clear interlock signal（more in 6.3.3，“interlock function”），then press stop key to clear protection status. （5）Clear ready status（ “READY”lights） (a)Turn off“READY”message. (b)Turn off ready signal flowing into signal input/output connector. Under common situation，after you untwist stop key，the instrument enters ready status（“READY”lights）. However，the instrument can’t enter ready status under such situation. ◎ Protection status can’t be cleared. ◎ Test voltage is still existed. High voltage indicator still lights after“TEST” signal is off. ◎ When pressing start key，stop key is untwisted. Note ¾ If the fail hold mode of test mode switch is set，fail status or protection status can only be cleared by stop key. ¾ More in 6.6， “special test mode setting”. 『4』Remote connector The connector can control start/stop function via a remote box or high voltage test probe. After you connect the jack, the remote controlled circuit is built, and “REMOTE”message appears，the start key has no function. Under such condition, after you remove the jack， “REMOTE”signal disappears，the start key has function. ！ z z ： In AC test mode, the test voltage below 4kV, the high voltage probe can be selected. Don’t use remote connector or signal input/output connector to remotely control instrument. If you do so, there will be unpredicted danger, more in 6.3，“Remote control”. 『5』Test voltage adjusting knob It is used to adjust test voltage. Turn adjusting knob from counter clockwise position “0”to clockwise，test voltage becomes larger. - 12 - Note ¾ When not in operation，make sure voltage adjusting knob is turned to counter clockwise position“0”. ¾ In AC mode，the output voltage may be higher due to the wave of AC power. Make sure operate instrument under low range voltage. 『6』High voltage terminal Transfer output high voltage between high voltage line and low voltage line（shell ground） ！ z ： Don’t touch high voltage output terminal in testing. 『7』Low voltage terminal It is the low voltage line of output; the terminal is directly connected to the shell. 『8』High voltage indicator The red indication means the voltage is transferred，it lights only in output back circuit. ！ ： z When high voltage indicator lights，don’t touch high voltage terminal, probe, DUT or other electrical device. 『9』Pointer meter Pointer meter means the amount of output voltage. It can work in both AC and DC mode. 『10』Null calibration Make sure power switch is turned off before null calibration. 『11』RANGE The key is used to select voltage range and selective test mode. In AC setting, when the key is pressed only，the voltage range can be selected between 2.5KV and 5.0KV；In DC setting, when the key is pressed only，the voltage range can be switched among 100V,500V,1000V；if you press SHIFT and this key meanwhile，then switch among AC,IR,AC-IR.IR-AC. Model Range and mode 2.5kV AC TH5101D/TH5101E 5kV AC 100V DC AC 500V DC 1000V DC IR AC-IR IR-AC When the instrument is in ready status（“READY” lights），the key has function；if instrument is in test status（“TEST”lights）or in transfer pass/fail judge （“PASS”or“FAIL”lights），the key has no function. - 13 - Note ¾ Before changing test voltage range or mode，make sure voltage adjusting knob is in counter clockwise position“0”. 『12』Cutoff current key/set resistance key（▲▼） These keys are used to increase or decrease cutoff current/set resistance（for 用 reference current/resistance of pass/fail judge）. When the instrument has function in Ready status（“READY”lights）and“KEYLOCK”disappearing, these keys have function. if instrument is in test status（“TEST”lights）or in transfer pass/fail judge （“PASS”or“FAIL”lights），the key has no function, and also in AC-IR,IR-AC. In insulation resistance, if low limit sets resistance out of ruled range，LOWER ON will shine，READY disappears，stop testing. As the range below： When the range is 100V，Min.set resistance is 0.2k; When the range is 500V，Min.set resistance is 1M, if below the range，LOWER ON shines，READY disappears When the range is 1000V，Min.set resistance is 2M, if below the range， LOWER ON shines，READY disappears Set resistance value to ruled range ， the status will be disappeared automatically. In AC setting，if you press any key alone，use the following resolution to increase or decrease. If you press SHIFT key meanwhile ， the increasing or decreasing rate is 10 times than before. In insulation resistance setting，if you press any key alone，use the following resolution to increase or decrease. If you press SHIFT key meanwhile ， and resistance value is below 1M，the increasing or decreasing rate is 10 times than before；if resistance value is above 1M，the increasing or decreasing rate is 100 times than before. If you keep pressing the key，it will increase or decrease automatically. ▲ ▼ Increase cutoff current setting/reference resistance setting. The setting is displayed in current/resistance Decrease cutoff current setting/reference resistance setting. The setting is displayed in current/resistance High limit/Low limit cutoff Resolution Displayed format current range 0.1mA-9.9mA 0.1mA X.X mA 10mA-110mA /10mA-45mA 1mA XXX mA Note：TH5101D sets range to 110mA,TH5101E sets range to 145mA。 High limit/Low limit reference resistance range 0.2MΩ-9.99MΩ 10.0 MΩ－99.9 MΩ 100 MΩ-999 MΩ 1.00GΩ-9.99 GΩ 10 GΩ-99.9 GΩ Resolution Displayed format 0.01MΩ 0.1 MΩ 1 MΩ 0.01 GΩ 0.1 GΩ X.XX MΩ XX.X MΩ XXX MΩ X.XX GΩ XX.X GΩ - 14 - Note ¾ Because high and low limit cutoff current / reference resistance can be set without limitation，it is possible that low limit is larger than high limit，and low limit cutoff current/high limit resistance pass/fail judge function can be turned on，indicated unit（“mA”/ “MΩ”/“GΩ”）shines and“READY” message disappears，which means the test condition is not available. 『13』Cutoff current high/low key（UP/LOW） The key is used to select high limit or low limit cutoff current. If when you press SHIFT as well as this key，low limit pass/fail judge function can turned on or off. When the instrument is in ready status（“READY”lights）and“KEYLOCK” message is turned off，if not in auto test status，the key has no function. When in test status （“TEST”lights）or in transfer pass/fail judge（when“PASS”or“FAIL” lights），if in auto test status，the key has no function. （1）when the key is pressed alone： When you press the key，high limit or low limit cutoff current is selected， “ UPPER ” or “ LOWER ” appears. “ UPPER ” means high limit cutoff current/reference resistance is selected，and the value is displayed in current readout/resistance readout，you can use ▲▼to adjust value.“LOWER” means low limit cutoff current/reference resistance is selected，and the value is displayed in current readout/resistance readout，you can use ▲▼to adjust value. （2）when you press SHIFT and UP/LOW： In AC， “LOWER ON”disappears or appears，indicating low limit judge function is valid or invalid； In insulation resistance， “UPPER ON” disappears or appears，indicating low limit judge function is valid or invalid. 『14』Timer（▲▼） These keys are used to increase or decrease test time. When the instrument is in ready status（“READY”lights）and“KEYLOCK”message is turned off, When in test status （“TEST”lights）or in transfer pass/fail judge（when“PASS”or“FAIL” lights），if in auto test status，the key has no function. If you press any key alone，it will increase or decrease with the unit shown as below. If you press SHIFT meanwhile，the increasing or decreasing rate is 10 times than basic unit. If you keep pressing the key, it will increase or decrease automatically. ▲ ▼ The key is used to set increasing test time. The setting is displayed in time The key is used to set decreasing test time. The setting is displayed in time Test time setting range Basic unit - 15 - Displayed format 0.2s-99.9s, off 100s-999s, off 0.1s 1s XX.X s XXX s 『15』Timer（ON/OFF） If you press SHIFT as well，（“KEYLOCK”）is turned on or off. （1）Timer （ON/OFF）is pressed alone： If timer is turned on， “TIMER ON”appears，timer indicates the remaining test time，stop testing when test time is over. If timer function is off， “TIMER ON”disappears，at the status，timer indicates the passed time，test can’t be over. When in ready status（“READY”lights）and“KEYLOCK”is off，Timer （ON/OFF） has function. When in test status （“TEST”lights）or in transfer pass/fail judge（when“PASS”or“FAIL”lights），if in auto test status，the key has no function. （2）when pressing SHIFT as well as timer（ON/OFF）： The key is locked and“KEYLOCK”appears，if you press it again， the key is unlocked，and“KEYLOCK”disappears. When the lock key is confirmed，the following key is locked. (a) Cutoff current ▲▼ (b) Cutoff current high limit/low limit（UP/LOW） (c) Test voltage range/mode（RANGE） (d) Timer▲▼ (e) Timer（ON/OFF） Note ¾ If in AC/IR interface，timer is off， “TIMER ON”disappears，when cutting to auto test，TIMER ON will shine，and corresponding range indication will shine as well，READY disappears. 『16』SHIFT （1）Turn on switch when pressing SHIFT. Initiated test condition. （2）Cut off current▲and▼when pressing SHIFT See the instruction of cutoff current▲and▼. （3）Press SHIFT and voltage/mode（RANGE）。 Switch among（AC），（IR），AC-IR，IR-AC. （4）Press SHIFT and high limit/low limit（UP/LOW）。 Low limit pass/fail judge function can be on or off. （5）Press SHIFT and timer▲ and ▼. See the instruction of timer▲ and ▼ （6）Press SHIFT and timer（ON/OFF）。 Key lock function can be on or off. 『17』VFD） VFD displays indicated test condition，result and other items. More in 4.2， “Displayed item”. - 16 - 4.2 Instruction 『1』Test voltage range information Indicate the selectable range for test voltage. AC，selectable test voltage range is 5kV or 2.5kV. DC，selectable test voltage range is 0.1kV,0.5kV,1.0kV。 Auto test，display corresponding code（as the table below）. AC-IR，the front digit displays range code of AC，the back digit displays range code of IR. IR-AC，the front digit displays range code of IR, the back digit displays range code of AC. Range Code 2.5kV 0 5kV 1 0.1kV 2 0.5kV 3 1.0kV 4 『2』AC/DC test voltage indicated information Selectable test voltage is AC or DC. 『3』Voltage display Voltage display indicates output voltage. It can monitor output voltage lastly. Range and resolution Displayed Range Resolution format 5kVAC 0kV-6.5kV 27.77V X.XX kV 2.5kVAC 0kV-3.25kV 13.88V X.XX kV 0.1kVDC XXX V 0.5kVDC XXX V 1.0kVDC X.XX kV 『4』Current display /resistance display In AC, when instrument is in test status（“TEST”lights），current displays test current；when instrument is not in test status，it displays preset high limit or low limit cutoff current value. In insulation resistance，when instrument is in test status（“TEST”lights）， current displays test current；when instrument is not in test status，it displays preset high limit or low limit reference resistance value. - 17 - 1. Displayed item In ready status In testing “UPPER”lights “LOWER”lights High limit cutoff Low limit cutoff Tested current/resistance current/reference current/reference resistance resistance 2. Range AC test mode DC test mode Model High limit cutoff High limit/low limit current/reference resistance reference resistance value 0.20MΩ-99.9GΩ TH5101D/TH5101E 0.1mA-110mA /0.1mA-45mA 3. Set resolution and displayed format High limit/low limit cutoff Resolution Displayed format current range 0.1mA-9.9mA 0.1mA X.X 10mA-110mA /10mA-45mA 1mA XXX Note：setting range of TH5101D is up to 110mA,TH5101E is up to 45mA。 High limit/low limit reference Resolution Displayed format resistance range 0.2MΩ-9.99MΩ 0.01 MΩ X.XX MΩ 10.0 MΩ－99.9 MΩ 0.1 MΩ XX.X MΩ 100 MΩ-999 MΩ 1 MΩ XXX MΩ 1.00GΩ-9.99 GΩ 0.01 GΩ X.XX GΩ 10 GΩ-99.9 GΩ 0.1 GΩ XX.X GΩ 『5』High limit and low limit message When the instrument is in ready status（“READY”lights）and“KEYLOCK” disappears，use UP/LOW to switch between high limit and low limit cutoff current. When in testing（“TEST”lights）， “UPPER”and“LOWER”disappears，the amp meter displays the test current. 『6』Low /high limit open message When this function is on，the message displays“LOWER ON” （“UPPER ON”） lights；when off，the message disappears，“LOWER ON”(“UPPER ON”) off. When the instrument is in ready status（“READY”lights）and“KEYLOCK” disappears，press SHIFT and UP/LOW to turn on or off the function. In AC test, turn on/off low limit judge function；in insulation resistance test，turn on/off high limit judge function. 『7』Timer When the instrument is in test status，time display indicates the remaining or passed test time. When the instrument is in ready status（“READY”lights）and “KEYLOCK”disappears，use ▲▼ to increase or decrease the preset time. If you press SHIFT and▲or▼，increasing/decreasing rate is 10 times than before. If timer function is on（“TIMER ON”lights），the displayed time will decrease as the test time passed，and the test is over when preset time passed. If timer function is off（“TIMER ON”off），displayed time starts from zero，and increase as the time passed，test won’t be over when preset time passed. The preset setting - 18 - time can be set under the situation below：AC mode；insulation resistance mode； in auto test mode，set waiting time. 1. Displayed time Testing Ready “TIMER ON”appears “TIMER ON”disappears Display preset Remaining time Passed time time 2. Set range，resolution，and displayed format Set range Resolution Displayed format 0.2s-99.9s or off 0.1s XX.X 100s-999s or off 1s XXX 『8』Timer open message When the instrument is in ready status（“READY”lights）and“KEYLOCK” disappears，use on/off to turn on or off timer function. If in AC or insulation resistance，turn off some timer to auto test mode， “TIMER ON”shines，READY disappears，stop testing. 『9』Ready message（“READY”lights） It shows the instrument is ready for testing. When the message is displayed, press START，the instrument will work according to the parameter displayed on displayed board. 『10』Test message It shows the instrument is in testing. Press STOP key to clear the status. 『11』Pass message When pass/fail judge is passed，the message appears. If timer function is off or test is cancelled，there will be no pass message. Under common situation，it lasts for 0.2s. if the mode you set is pass hold mode，the message is held, press STOP to reset instrument from pass hold status. 『12』Fail message High limit fail message：when the result of high limit pass/fail judge is fail，the message（yellow）appears，it shows the current/insulation resistance flowing through DUT is larger than preset high limit cutoff current/high limit reference resistance value. Press STOP to reset instrument. Low limit fail message：when the result of low limit pass/fail judge is fail，the message （yellow）appears，it shows the current/insulation resistance flowing through DUT is smaller than preset high limit cutoff current/high limit reference resistance value. Press STOP to reset instrument. 。 『13』Protection message The instrument enters protection status, the message (yellow) appears, and output voltage is cut off for any accidence below. In order to clear protection status, firstly find out the reason, and then press STOP. 1. Interlock signal inputting pin of signal input/output connector is on - 19 - 2. Test mode or range switch is error. 3. In insulation resistance test，after waiting judge time is passed, test voltage deflects 30％ to range voltage. 4. Remote control function is valid or invalid，there is protection，press STOP to clear the protection. 『14』Keylock message When the keylock function is on，the message appears；when the function is off， the message disappears. Keylock function can make the keys below unavailable： (a)cutoff current ▲▼key (b)cutoff current high limit/low limit key（UP/LOW） (c)Test voltage range/mode key（RANGE） (d)Timer▲▼key (e)Timer（ON/OFF）key Press SHIFT as well as ON/OFF key，turn on or off keylock function at anytime. 『15』Remote control message It shows instrument is remotely controlled by remote control connector or signal input or output connector. When receiving remote command from RS-232C interface，it also appears. When the message appears，start key on the panel has no function. More in 6.3，“Remote control”. 4.3 Instruction of rear panel 『1』Protection ground For connecting instrument to ground safely. More in 2.6， “ground”. 『2』AC power connection Power line connector for AC power input. 『3』Signal input/output connector The connector is 25-core cable for output and test mode of interlock signal, remote signal, and status output signal. More in 6.3.3 “Interlock function”，6.3.2 “signal input /output remote control” ，more in 6.6 节，“special setting mode”. 『4』RS-232C connector The connector is used to connect a RS-232C cable. The test result is output to PC or printer via RS-232C. - 20 - Chapter 5 Preparation before testing 5.1 Initiated setting Table 5.1shows default value of setting data. Item Initiated setting value High limit cutoff current 0.2mA Low limit cutoff current Low limit reference resistance High limit reference resistance 0.1mA 2.00MΩ 3.00 MΩ Low limit pass/fail judge（AC） Off High limit pass/fail judge（IR） Off Test time(AC) 0.5s Test time(IR) 0.5s （Wait Time） 0.2s Timer function On Key lock function Off Communication 0 Mode, range AC，2.5kV Adopt the following steps to restore setting value to default value. 1. Turn on power switch and press“SHIFT”meanwhile. VFD displayer starts to lighting, the displayed power has been turned on. 2. Loose“SHIFT”and power key After several seconds，VFD displays edition number，model，communication mode. If nothing displays on VFD，execute step again. 5.2 Check 1. Be sure power switch is off. 2. If the voltage adjusting knob on the front panel is in the counter clockwise zero position. 3. Check if the 25 core cable jack has been connected to the signal input/output terminal on the rear panel. 4. Check if power line has been connected correctly. 5. When turning on power switch，press“SHIFT”. After several seconds, VFD displays edition number，model and alternation mode. 6. Check if protection status is valid under the situation of keylock. 7. Turn off power. 8. Turn on power，check if the instrument is in ready status（“READY”lights）. - 21 - 5.3 Check the instrument before testing 1. Calibration of anolog voltage meter Before turning on power, check if the analog voltage meter is in position “0”. If not, adjust to position“0”in null adjuster. If you do the adjustment when the power is on, please turn off power firstly. 2. Interlock function Before testing, make sure there is a suitable interlock function is test system. 3. Not in protection status If instrument is in protection status，even you press start key，the instrument won’t start testing and transfer voltage. Clear out the reason causing protection status，then press stop key. The reason is shown below： ① Interlock input signal pin of signal input/output connector is on. ② Test mode or range switch is error. ③ Test voltage of insulation resistance deflects 30％ - 22 - to range voltage. Chapter 6 Test procedure 6.1 AC withstanding voltage test Available parameter range： Test Standard of high voltage limit cutoff current 0.1mA-110mA 0kV-5kV /0.1mA-45mA Standard of low limit cutoff current 0.1mA-110mA or off /0.1mA-45mA or off Test time 0.2s-999s or off 6.1.1 Select an AC range Press “RANGE”，select a AC voltage range（2.5kV or 5kV）. The information of AC testing mode appears，the voltage range information indicates the range you select. Note ¾ ¾ Switch voltage range ， make sure voltage adjusting knob is in counter clockwise position“0”. In testing, “RANGE”is invalid. 6.1.2 Set high limit cutoff current If the current flowing through DUT is over the value，DUT is judged as fail. Procedure： ① Use“UP/LOW”to select high limit cutoff current setting mode.“UPPER” appears，the saved high limit current is displayed by current displaying window. ② Use ▲ and ▼ to adjust the high limit cutoff current value, if you press “SHIFT”meanwhile，the adjusting speed will be increased with base number of 10 times. High limit cutoff setting range：0.1mA-110mA/45mA (TH5101D/TH5101E)。 Resolution and displayed format High limit cutoff setting range Resolution Displayed format 0.1mA-9.9mA 0.1mA X. XmA 10mA-110mA /10mA-45mA 1mA XXXmA Note ¾ When the instrument is in ready status （“ READY ” displays ） and “KEYLOCK”signal is off，the key has function. When the instrument is in test status（“TEST”displays）or transferring pass/fail judge result（“PASS” or“FAIL”appears），the key has no function. 6.1.3 Set low limit cutoff current If the current flowing through DUT is below the value，DUT is judged as fail. You can distinguish the DUT with small current to improve the reliability. You can turn off this mode for convenient use. Procedure： 1. Use UP/LOW to select low limit cutoff current mode.“LOWER”appears， the saved low limit current is displayed by current displaying window. 2. Use ▲ and ▼ to adjust the low limit cutoff current value. if you press - 23 - “SHIFT”meanwhile，the adjusting speed will be increased with base number of 10 times. 3. When you press“SHIFT”and“UP/LOW”，low limit pass/fail judge function can be valid and“LOWER ON”appears. Low limit cutoff current setting rang ： 0.1mA-110mA/45mA or off (TH5101D/TH5101E) Resolution and displayed mode： Low limit cutoff current range Resolution Displayed mode 0.1mA－9.9mA 0.1mA X. XmA 10mA－110mA /10mA-45mA 1mA XXXmA Note ¾ When instrument is in ready status（“READY”displays）and“KEYLOCK” signal is off，the key has function. When instrument is in test status（“TEST” displays）or transferring pass/fail judge result（“PASS”or“FAIL”appears）， the key has no function. ¾ Because high/low limit cutoff current can be set independently，the latter setting can be higher than former，now if low limit cutoff current judge function is on，“mA”shines，“READY”disappears，indicating the test condition is not allowed. 6.1.4 Set test time When there is no any fail judge，as time pass by，the test will be over. You can turn off timer function if you don’t need it. Note ¾ Test and stop time is limited by setting high limit cutoff current. “ON 30min”on the front panel displays an Max.test time， “OFF 30min”displays a shortest stop time. More in 9.1. Procedure： 1．Use ▲ and ▼ to adjust the low limit cutoff current value. if you press “SHIFT” meanwhile，the adjusting speed will be increased with base number of 10 times. 2. Turn on（off）time function，press“ON/OFF”key. Resolution and displayed format Test time Resolution Displayed format 0.2s-99.9s,off 0.1s XX.X 100s-999s,off 1s XXX Note ¾ When the instrument is in ready status （“ READY ” displays ） and “KEYLOCK” signal is off，ON/OFF has function. When in TEST-ON status（“TEST”displays）and transferring pass/fail judge result，they have no function. 6.1.5 Set test voltage The procedure is used to set test voltage for DUT Note ¾ The instrument must use a stable AC power for stable test voltage. In AC - 24 - withstanding voltage，seen from inner circuit structure, output voltage is affected by the wave of AC power. Set procedure： 1. Press“SHIFT”and UP/LOW to turn off low limit pass/fail judge function. “LOWER ON”will disappear. 2. Press ON/OFF to turn off timer function.“TIMER ON”will disappear. 3. Check if the voltage adjusting knob is in position“0” （counter clockwise）and in ready status（“READY”displays, start to press. 4. Readout the actual output voltage in analog voltage meter or digital voltage meter，adjust voltage adjusting knob in clockwise way to output required voltage value. 5. Press stop key to turn off output voltage. 6. Press ON/OFF to turn on timer function.“TIMER ON”will display. 7. If you need low terminal pass/fail function，press“SHIFT”and UP/LOW key, “LOWER ON”displays. 6.1.6 Connection of DUT Procedure： 1. Make sure analog voltage meter is in position“0”，high voltage indicator is off， “READY”appears. 2. Connect low voltage test line to low voltage ground terminal，connect high voltage test line to high voltage ground terminal. 3. Short low voltage test line and high voltage test line for releasing high voltage. 4. Connect low voltage test line to DUT, and high voltage test line to DUT. 6.1.7 Test The test condition： Test voltage range 2.5kVAC Test voltage 1.2kV High limit cutoff range 10mA Low limit pass/fail judge OFF function Test time 1s Note ¾ Set test voltage by actual output voltage. See in 6.1.5，“Set test voltage”. Procedure 1. when instrument is in“READY” status（“READY”appears） ，press start key to set testing. ◆ Danger indicator lights. ◆ HV-ON and TEST signal of input/output connector is on. ◆ “TEST”signal displays. ◆ Test voltage is transferred between high voltage and low voltage test terminal. ◆ Analog voltage meter indicates test voltage. ◆ Digital voltage meter indicates test voltage. ◆ Digital current meter displays tested current. ◆ Time displays the remaining time or passed test time. - 25 - Note ¾ If in protection status, the instrument won’t start testing. ¾ If a stop signal is applied, the instrument won’t start testing. 2. If test result is pass，and preset test time is passed，the instrument will give a pass result, the following action will happen： ◆ End testing and cut off test voltage. ◆ “TEST”signal disappears, TEST signal of input/output connector is off. ◆ Danger indicator is off， HV-ON signal of input/output connector is off. ◆ “ PASS ” is displayed ， beeper alarms ， PASS signal of input/output connector is off. 3. In common status，PASS lasts for 0.2s, then instrument will reset to READY status automatically（READY displays）. ◆ “PASS”disappears，beeper stops alarming. ◆ PASS signal of input/output connector is off. Note ¾ The instrument won’t reset to READY status under the circumstance below — The test mode on the rear panel is set as pass hold mode，under this situation, pass status is held lastly. If reset it，press STOP key — Protection status is existed — Stop key is pressed（including that in remote control box）. — When start key is pressed（including that in remote control box）. 4. If timer is off，“TIMER ON”won’t disappear，the test won’t be stopped automatically. Press stop key to stop testing manually. Under this situation, instrument won’t make pass judgment，and the following actions will happen： ◆ End testing and cut off test voltage. ◆ “TEST”signal disappears, TEST signal of input/output connector is off ◆ Danger indicator is off， HV-ON signal of input/output connector is off. 5. If test result is fail. If in the process of testing, leakage current is over the limitation below, the instrument will make a fail judgment, cut off test voltage and end testing. （A） When test current is larger than high limit cutoff current： “UPPER FAIL” appears. （B）When test current is lower than high limit cutoff current：“LOWER FAIL” appears. When test result is fail： ◆ End testing and cut off test voltage. ◆ “TEST”signal disappears, TEST signal of input/output connector is off ◆ Danger indicator is off， HV-ON signal of input/output connector is off. ◆ “UPPER FAIL” or“LOWER FAIL”displays. ◆ U _FAIL and L _FAIL signal of input/output connector is on, beeper alarms. 6.1.8 Repeat testing PASS lasts for 0.2s, then instrument will reset to READY status automatically， you are allowed to press start key to repeat testing. The application is the same in remote control. - 26 - Note ¾ The instrument won’t reset to READY status under the circumstance below — The test mode on the rear panel is set as pass hold mode，under this situation, pass status is held lastly. If reset it，press STOP key — Protection status is existed — Stop key is pressed（including that in remote control box）. — When start key is pressed（including that in remote control box）. 6.2 Insulation resistance test： Test DUT according to the required parameter. The range of as below： Test High limit reference Low limit reference voltage resistance standard resistance standard 0.2MΩ－800MΩ 0.2MΩ－1.0GΩ 100V 1.0MΩ－4.0GΩ 1.0MΩ－5.0GΩ 500V 2.0MΩ－10GΩ 2.0MΩ－10GΩ 1000V parameter is shown Test time 0.2s-999s or off 0.2s-999s or off 0.2s-999s or off 6.2.1 Select a DC test voltage range Use test voltage range switch key （ RANGE ） to select IR test range （0.1kV,0.5kV,1.0kV），IR mode will appear，test voltage range will indicate the range you select. 6.2.2 Set low limit reference resistance Low limit reference resistance setting range：0.2 MΩ－99.9 GΩ。 Resolution and displayed format： High/low limit reference Resolution resistance range 0.2MΩ-9.99MΩ 0.01MΩ 10.0 MΩ－99.9 MΩ 0.1 MΩ 100 MΩ-999 MΩ 1 MΩ 1.00GΩ-9.99 GΩ 0.01 GΩ 10 GΩ-99.9 GΩ 0.1 GΩ Displayed format X.XXMΩ XX.X MΩ XXX MΩ X.XX GΩ XX.X GΩ In insulation resistance，if you set resistance value out of ruled range，LOWER ON will shine，READY disappears，forbidden starting testing. The setting range below： - 27 - When the range is 100V，Min.setting resistance is 0.2k; When the range is 500V，Min.setting resistance is 1M, if below this range， LOWER ON will shine，READY disappear. When the range is 1000V，Min.setting resistance is 2M, if over this range， LOWER ON will shine，READY disappear. 6.2.3 Set high limit reference resistance High limit reference resistance setting range：0.2 MΩ－99.9 GΩ or off Resolution and displayed format： Same as the table below. 6.2.4 Set test time Set test time of test status，in 6.1.4 6.2.5 Connection of DUT Setting procedure in 6.1.6。 6.2.6 Test Test condition： Test voltage range Low limit reference resistance setting High limit pass/fail judge function Test time 500V 10MΩ OFF 5s 6.2.7 Repeat testing In 6.1.8 6.3 Auto switch test of withstanding voltage to insulation AC withstanding voltage insulation resistance test. Press SHIFT+RANGE to enter this testing，the status after IR. - 28 - 6.3.1 Instruction of entering range After entering this test，enter AC Ready status（range is displayed with code；preset time is not the AC preset time，but the waiting time of withstanding voltage to insulation resistance）. Note：range is displayed with code，more in 4.2.AC-IR, the former displays AC range code，the latter displays IR range code. Range 2.5kV 5kV 0.1kV 0.5kV 1.0kV Code 0 1 2 3 4 E.g.：RANGE 02 indicate the test of AC to IR Range of withstanding voltage： 2.5kV。 Range of IR：0.1kV。 6.3.2 Setting of AC-IR parameter After AC-IR，each parameter can’t be set. If set，press SHIFT+RANGE to back to single AC，or single insulation resistance setting. After setting，enter AC-IR to perform test. Note ¾ Now，key has no function（except SHIFT+RANGE, SHIFT+TIMER ON） 6.3.3 Setting of wait time of AC-IR Default value：0.2s. Test range：0.2s-999s. Press timer ▲and▼ to modify the middle waiting time. In 6.1.4. Note：now，TIMER ON/OFF of timer is invalid，has no function. Note ◇ Wait time，the wait time of AC-IR and IR-AC is the same. 6.3.4 Test procedure ① In AC，actual current is displayed，and timer displays the remaining time of AC test，pass/fail judge，same as single AC part. ② When AC test ends, in middle wait time，voltage is off， current part is displayed in black，HV ON indicator lights，TEST lights. ③ To IR, actual resistance is displayed，and timer displays the remaining time of IR test，pass/fail judge，same as single IR part. ④ Test ends，instrument resets to the start status. 6.3.5 Test Test condition： Voltage range 2.5kV - 29 - Voltage 1.0kV High limit cutoff 10mA AC current Low limit pass/fail OFF judge function Test time 5.0s 2.0s （WaitTime） Voltage range 0.5kV Low limit reference 100MΩ IR resistance value High limit 10.0GΩ reference resistance value High limit pass/fail ON judge function Test time 10s Note：Turn on timer in AC and IR！ Note ¾ In AC，use actual output voltage to set test voltage. In 6.1.5， “Set test voltage”. Test procedure When in“READY”status（“READY”appears） ，press start to set up test. ◆ Danger indicator lights. ◆ HV-ON and TEST signal of input/output connector is on. ◆ “TEST”signal displays. ◆ Test voltage is transferred between high voltage and low voltage test terminal. ◆ Analog voltage meter indicates test voltage. ◆ Digital voltage meter displays test voltage. ◆ Digital current meter displays the tested current. ◆ Time displays the remaining or passed test time. Note ¾ ¾ If instrument is in protection status，the instrument won’t start testing. If a stop signal is applied，the instrument won’t start testing. If leakage current is over the limitation below，the instrument will give a fail judge and cutoff test voltage and end testing. （A） Test current ＞high limit cutoff current：“UPPER FAIL”will appear. （B）Test current ＜high limit cutoff current：： “LOWER FAIL” will appear. Test result is fail： ◆ Test ends and cut off voltage. ◆ “TEST”disappears, TEST signal of input/output connector is off. ◆ Danger indicator is off. HV-ON signal of input/output connector is off. ◆ “UPPER FAIL” or“LOWER FAIL”is displayed. ◆ U _FAIL and L _FAIL signal of input/output connector is on，beeper alarms. - 30 - Preset time is passed，no fail judge，enter middle wait time. Now： ◆ Cut off test voltage，voltage displays as 0.00kV. ◆ Current display is black, indicating in middle wait time status，time displays remaining wait time. After wait time is passed，turn to insulation resistance test，and set up test. ◆ Test voltage is transferred between high voltage and low voltage test terminal. ◆ Digital voltage meter displays test voltage. ◆ Digital current meter displays the tested current. ◆ Digital ohm meter displays tested resistance. ◆ Time displays the remaining or passed test time. If test result is pass，preset test time is passed，the instrument will give a pass judge. If test result is pass： ◆ Test ends and cut off voltage. ◆ “TEST”disappears, TEST signal of input/output connector is off. ◆ Danger indicator is off. HV-ON signal of input/output connector is off. ◆ “ PASS ” is displayed ， beeper alarms ， PASS signal of input/output connector is on. Under common status，PASS lasts for 0.2, then the instrument will reset to READY status automatically（READY is displayed）， ◆ “PASS”disappears，beeper stops alarming. ◆ PASS signal of input/output connector is off. Note ¾ Instrument will reset to READY status — Test mode on the rear panel is pass hold mode，and pass status will be held constantly. If you reset it，press STOP key. — Protection status is existed — Stop key is pressed（including that in remote control box）. — When start key is pressed（including that in remote control box）. If test result is fail. If insulation resistance is over the limitation below，the instrument will give a fail judge and cutoff test voltage and end testing.。 （A）Test resistance＜high limit cutoff resistance： “LOWER FAIL” will appear. （B）Test resistance＞high limit cutoff resistance：“UPPER FAIL” will appear. If test result is fail. ◆ Test ends and cut off voltage. ◆ “TEST”disappears, TEST signal of input/output connector is off. ◆ Danger indicator is off. HV-ON signal of input/output connector is off. ◆ “UPPER FAIL” or “LOWER FAIL”is displayed. ◆ U _FAIL and L _FAIL signal of input/output connector is on，beeper alarms. - 31 - Note ◇ In testing，press STOP key，then the instrument will reset to test start. 6.3.6 Repeat testing In 6.1.8。 6.4 Auto switch test of insulation resistance to withstanding voltage AC withstanding voltage insulation resistance test. Press SHIFT+RANGE to enter this testing，the status after AC-IR. 6.4.1 Instruction of entering range After entering this test，enter IR Ready status（range is displayed with code；preset time is not the AC preset time，but the waiting time of withstanding voltage to insulation resistance）. Note：range is displayed with code，more in 4.2.AC-IR, the former displays IR range code，the latter displays AC range code. Range 2.5kV 5kV 0.1kV 0.5kV 1.0kV Code 0 1 2 3 4 E.g.：RANGE 20 indicate the test of IR to AC Range of withstanding voltage： 2.5kV Range of IR：0.1kV 6.4.2 Setting of IR-AC parameter Note ◇ If the parameter is not set correctly in single test mode，when entering IR-AC，IR is error， IR shines in corresponding range .AC only shines in corresponding range. Quit，enter single test mode，after each parameter is set correctly, enter IR-AC mode again. 6.4.3 Setting of wait time of IR - AC Default value：0.2s. Test range：0.2s-999s. Press timer▲ and ▼to modify middle wait time in 6.1.4。 Note：now，TIMER ON/OFFof timer is invalid，has no function. Note ◇ Wait time，the wait time of AC-IR and IR-AC is the same. 6.4.4 Test procedure See in 6.3.4 AC-IR 6.4.5 Test - 32 - See in 6.3.4 AC-IR 6.4.6 Repeat testing See the requirement in 6.1.8 6.5 Remote control ！ ： z Be careful to operate the instrument in remote control mode，because dangerous high voltage is controlled by remote control switch. 6.5.1Remote control by connector a. Procedure： 1. Turn off power 2. Use a specified cable（5 core）to connect remote control to selected device. 3. Turn on power. “REMOTE”is displayed，the start key from selective device is valid，but the one on the front panel has no function. However，you can stop the voltage by the stop key on the panel and selective device. b. Restore panel operation： 1. Turn off power. 2. Remove the specified cable of remote connector on the front panel（5 core）. 3. Turn on power. “REMOTE”disappears and start switch on the panel has function. Note ¾ ¾ Don’t use remote control connector and signal input/output connector to remotely control instrument. If test mode is set as fail hold mode，fail and protection status can’t be reset by applying a remote stop signal. They should use stop key to reset partly. 6.5.2 Pass signal input/output connector remote control Signal input/output connector has 3 functions below，providing 25-core cable connector. (1)Test mode setting（1，2，3，4，5） 。 (2)External device remote control（13，20，22，23，24，25） 。 (3)Output status（6，7，8，9，10，11，12，15，16，17，18，19）。 Table 6-1 Instruction of signal input/output Item Specification High level input voltage 7V-15V Input Low level input voltage 0V-1V signal Input time width No less than 5ms High level output voltage 11V-15V Output Low level out put voltage 0V-1V signal High level Max. output current 5 mA/channel Figure 6-1 Pin arrangement of signal input/output connector - 33 - Table 6-2 Pin arrangement of signal input/output connector Pin No. Status Output condition and signal description 1 VCC1 +5V DOUBLE-ACTI 2 Dual effect mode ON Input 3 PASS-HOLD Pass hold mode 4 MOMENTARY Instant test mode 5 FAIL-MODE Fail hold mode 6 HV-ON 7 TEST 8 PASS 9 U-FAIL 10 L-FAIL 11 READY 12 PROTECTION 15,16,17 18，19 VCC2 COM Output 13 INTERLOCK 20 COM 22 STOP 23 START 24 ENABLE 25 VCC2 Input Output Turn on when in testing or there is high voltage in output terminal（high level is valid） Turn on during testing（high level is valid） Turn on for 0.2s in pass；and constantly in pass hold（high level is valid） Turn on when high limit fail produces （high level is valid） Turn on when low limit fail produces （high level is valid） Turn on in ready（high level is valid） Turn on when protection function is available（high level is valid） Power（+15V） Common ground of circuit Interlock signal input terminal （ high level is valid） Common ground of circuit Stop signal input terminal（high level is valid） Start signal input terminal（high level is valid） Enable signal input terminal（high level is valid） Power （+15V） 6.5.3 Interlock function When interlock function is on ， instrument enters protection status （“PROTECTION”appears）. Now，instrument cuts off test voltage，which can’t neither respond the start signal from start key or remote control connector，nor stop - 34 - signal from stop key or remote control connector. Interlock function：pin 13 and 25 of signal input/output connector is the input terminal of interlock signal. When pin 13 and 25 is off, interlock function has function；when pin 13 and 25 is shortly connected, function releases. ！ ： If you turn on the power, interlock function will activated, the instrument won’t work. A 25 core cable jack is provided as accessory. When instrument is installed by actual ground，use interlock function as possible， Provide a safe working environment. The method is as below： ①Provide case for DUT to prevent electrical shock. ②Open case，cut off output. 6.5.4 Start/stop control Pin 22，23，24 of signal input/output connector is used for remote control start/stop. Procedure： a) Short pin 24（ENABLE）to pin 20（COM），pin 24 is low level. The start key is invalid. Use stop key of pin 22（STOP）to stop testing. b) When pin 11（READY signal）is open，short pin 23 to pin 20 to set pin 23 as low level. c) Short pin 22 to pin 20 to set stop signal（STOP），instrument stops testing. d) Set remote enable signal as high level for unlocking control. “REMOTE” disappears，start key has function，start signal of input/output connector has no function. Start/stop reference circuit：when using relay and switch to connect instrument，you can adopt transistor, field effect transistor，coupling to replace or drive these contact device. 6.5.5 Output signal The status can be output from pin 6 to 12 of 25-core input/output connector. The Max.output current of high level is 5 mA/channel，please attention in designing driving circuit. 6.6 Special mode setting Set 4 test modes by pin 1，2，3，4，5 of 25-core input/output connector. You can choose 2 kinds or more groups. When the power is on, instrument reads open setting. - 35 - When you change setting, turn off power switch and then turn on power again. 6.6.1 Dual effect mode Short pin 2 to pin 1 to set dual effect mode，only after you release stop key for 0.5s, the operation can be performed. Or operation can’t be available. Although this procedure is complicated, it improves the testing safety. The function can be available in remote control. 6.6.2 Pass hold mode Short pin 3 to pin 1 to set pass hold mode，don’t reset start status after 0.2s of pass judge. Press stop key or apply stop signal of remote control circuit to reset ready status. 6.6.3 Instant test mode Short pin 4 to pin 1 to set instant test mode. Only when pressing the start key, the test starts，loose start key, test ends. By doing so, it improves the testing safety. The function can be available in remote control. 6.6.4 Fail pass mode Short pin 5 to pin 1 set fail hold mode，for stop signal from remote control circuit, the instrument can’t reset to fail pass judge or protection status. If reset the instrument, you should press the stop key on the panel. - 36 - Chapter 7 RS-232C interface 7.1 Connection cable a) Turn off power of instrument and DUT. b) Connect a crossed RS-232C cable to 9-core RS-232C connector. 7.2 RS-232C specification Table 7-1：RS-232C specification Item Specification On-off sync，half dual Transfer rule Transfer rate 9600bps Data length 8 digit Odd and even None Stop 1 Intonation None Send：CR+LF Separated character Receive：CR,LF, CR+LF Note ¾ When turning on the instrument，some characters of bite can be sent. After power being on, turn on the power of PC or printer. 7.3 Communication method Use signal from PC and respond to perform communication. After a command, a responding is back. Command can’t be sent constantly. Confirm responding before next order. 7.4 Communication mode - 37 - 4 communication modes of RS-232C Table 7-2 communication mode Mode Description Only respond the mode from PC command（default intensity 0 setting） Auto responding mode of test starts and ends. Back to instrument status 1 Test starts Test ends ,,,, Auto responding mode of test starts and ends. Back to instrument status， set, and test value. (AC) high limit cutoff current， （low limit cutoff current ◎1）， （preset test time◎2），,AC， （Wait time◎3）。 (IR) low limit reference resistance， （high limit reference resistance◎1），（preset test time◎2） ，,IR (AC-IR) high limit cutoff current，（low limit cutoff current◎1） ， （preset test time◎2），AC，wait time Test starts Low limit reference resistance，（ high limit reference resistance◎1） ， 2 （preset IR test time◎2） ，,IR (IR-AC) low limit reference resistance ，（ high limit reference resistance◎1） ， （preset IR test time◎2），IR， wait time high limit cutoff current，（low limit cutoff current◎1） ， （preset AC test time◎2） ，，AC， Max. test voltage，Max. test current/Min.test resistance， current test time ， and responding of test ends in Test ends communication mode 1. In AC-IR/IR-AC，display the first test result，and latter one on the next line. Operation is the same as mode 2，except a LF character is added when 3 test ends. ◎1 when low limit pass/fail judge has function（“LOWER ON”lights），low limit cutoff current is back. ◎2 when timer function has function（ “TIMER ON”lights），preset test time is back. The process of PC in communication mode1-3 is decreased，because the command from PC doesn’t need sending. Otherwise，connect a printer to instrument，these modes allow test to be printed. Example： Talk-model-1 Talk-model-2 Talk-model-3 08.0mA,2.5SAC 08.0mA,2.5SAC 930V,0.3mA,2.5S 930V,0.3mA,2.5S 100MΩ,15SIR - 38 - 500V,50MΩ,10S 100MΩ,15SIR 08.0mA,2.5SAC WaitTime0.2s 500V,50MΩ,10S 100MΩ,15SIR 930V,0.3mA,2.5S 08.0mA,2.5S,AC WaitTime0.2s 500V,50MΩ,10S 100MΩ,15SIR 930V,0.3mA,2.5S 500V,50MΩ,10S Set communication mode Procedure： 1. Check if power switch is off. 2. Turn on power according to the required communication mode, and the indicated key in table 7-3. Table 7-3 setting key Communication Power+key on front panel mode 0 Power+timer on/off 1 Power+cutoff current▼ 2 Power+cutoff current▲ 3 Power+cutoff current▼and ▲ VFD displayer starts lighting. 3. Loose key and switch After several seconds，VFD displayer will display edition number，mode and communication mode. If there is no display, execute the procedure from start. 4. Check if the appointed communication mode in step 2 has been displayed. 7.5 Notes before using RS-232C (1)when instrument is set as special setting： ○ When the switch of signal input/output connector is set as dual effect mode， even a start command is sent, test won’t start. Turn off dual effect test mode. (2)release protection status： ○ protection status is not released in stop command ， check the brief description of released protection status. (3)operation and remote control message： ○ Table 7-4 indicates enable control source for each group of remote control source. ○ Commonly，when starting instrument by RS-232C，as Table 7-4 “d” ，the sending condition of remote command. Table 7-4 Remote control source G r Remote Input/output RS-232C o connec connector on u tor on therear panel p front (enable signal - 39 - Start function Panel Control Enable remote source Display remote info panelre remote connec tor on front panel is in low level） a b Can Can’t ◎ c d e ◎ ◎ f g h Can’t ◎ ◎ ◎ Can’t ◎ ◎ ◎ Can’t ◎ Can’t ◎ Can’t ◎ Can’t Off Remote connector has function Input/output control has function RS-232C has function Remote， or Input/output control has function Input/output control has function Remote connector has function Remote， or Input/output control has function On On On On On On On 7.6 RS-232C command and responding ● Command error responding：ERROR。 ● The command in parentheses is the abbreviated format. *IDN? Query the format name and ROM edition number. E.g.: TH5101D back: “TONGHUI（CHANGZHOU）ELECTRONIC CO.，LTD，TH5101D，1.02” *RST Communication mode is set as default value（0）。 Back：OK。 STATUS?(STAT?) Query the status. Respond the following： - 40 - PROTECTION，TEST，READY，PASS，U_FAIL，L_FAIL，ELSE （ELSE indicates a status differing from PROTECTION,TEST,READY,PASS,U_FAIL,or L_FAIL） MODE? Query timer setting，low limit cutoff current setting，voltage mode，and voltage range. E.g.：in AC，responding: TIMERON,LOWERON,VOLTAC,RANGE2.5 In IR，responding：TIMERON,UPPEROFF,VOLTIR,RANGE 500 In AC-IR，responding：TIMERON,LOWERON,VOLTAC,RANGE2.5 TIMERON,UPPEROFF,VOLTIR,RANGE 500 In IR-AC，responding：TIMERON,UPPEROFF,VOLTIR,RANGE 500 TIMERON,LOWERON,VOLTAC,RANGE2.5 MEASURE?(MEAS?) Query the test value. Responding back：  In testing Return to test voltage，test current and actual test time.   Wait time of auto test Return to test mode（AC/IR），test voltage，remaining wait time No testing Return to the former test result according： Return to Max.test current，current/Min. test resistance，actual test time and status. Status includes： ,,,,, （：after power is on, respond MEASURE? instantly）. TMODE(TMOD) Set communication mode. e.g.：TMOD 0——Set communication mode 0. TMOD 1——Set communication mode 1. TMOD 2——Set communication mode 2. Responding，back：OK。 TMODE? (TMOD?) Query mode setting. Query： TMODE0，TMODE1，TMODE2，TMODE3 REMOTE Use START to be useful by RS-232C.“REMOTE”message is displayed on the front panel. Responding，back：OK。 - 41 - LOCAL Use START to be usefuk by RS-232C. “REMOTE”message is off on the front panel. Responding，back：OK。 START Start testing。 Respondence： ◎ Be functional in START command，back：OK。 ◎ Be not functional in START command，back：ERROR。 STOP Responding，back：OK. - 42 - Chapter 8 Specification 8.1Basic specification of AC withstanding voltage Item：voltage V o l t a g e AC ： output rated value AC：waveform AC：stability AC：switch AC：display AC：accuracy Item：current c u r r e n t AC：accuracy AC：display AC：calibration TH5101 D /TH5101E AC：0kV-2.5kV /0kV-5kV TH5101D: 500VA/5kV,100mA(rated power voltage) TH5101E: 200VA/5kV,40mA (rated power voltage) Power voltage waveform ≤10％（Max. rated load is changed to empty load） Null switch 200ms， RMS is displayed Analog meter（2.5 class）：≤5% F.S. Digit is displayed： ≤1.5% F.S. TH5101D /TH5101E TH5101D: AC：0mA-110mA TH5101E: AC：0mA-45mA High limit cutoff current±(5%+20uA) 200ms，RMS is displayed Use load with pure resistance to calibrate RMS of current Note 1．In AC，make use the instrument within the given range below. Temperature t Cutoff current Max.allowed constant Stop time （℃） I(mA) time 50