Hypot II Manual Ver. 1.02

Hypot II Manual Ver. 1.02
OPERATION AND SERVICE MANUAL
Model 2503, 2510, 2525, 2550
MODEL 2503 (DC ONLY HIPOT WITH OPTIONAL GROUND CONTINUITY CHECK)
MODEL 2510 (AC ONLY HIPOT WITH OPTIONAL GROUND CONTINUITY CHECK)
MODEL 2525 (500VA AC HIPOT TESTER)
MODEL 2550 (AC/DC HIPOT WITH OPTIONAL GROUND CONTINUITY CHECK)
SERIAL NUMBER
Models
2503/2510/2525/
2550
Item 99-10683-01
Ver 1.03
© Slaughter Company, Inc., 2015
28105 N. Keith Drive
Lake Forest, Illinois, 60045-4546
U.S.A.
Printed April 18, 2016
DECLARATION OF CONFORMITY
Manufacturer:
Slaughter Company, Inc.
Address:
28105 N. Keith Dr.
Lake Forest, IL 60045
USA
Product Name:
Model 2525 500VA AC Hipot Tester
Model Number:
2525
Conforms to the following Standards:
Safety:
UL 61010-1:2012, UL 61010-2-030:2012
CAN/CSA-C22.2 NO. 61010-1-12
CAN/CSA-C22.2 NO. 61010-2-030-12
EN 61010-1:2010, EN 61010-2-030:2010 EN
61010-031:2002+A1
IEC 61010-1:2010, IEC 61010-2-030:2010
IEC 61010-31:2002+A1
EMC:
EN 61326-1:2006 (EN 55011:1998/A2:2002
Class A, EN 61000-3-2:2006, EN 61000-33:1995/A1:2001/A2:2005, IEC 61000-42:1995/A2:2000, IEC 61000-4-3:2002, IEC
61000-4-4:2004, IEC 61000-4-5:1995/A1:2000,
IEC 61000-4-6:2003, IEC 61000-48:1993/A1:2000, IEC 61000-4-11:2004)
Supplementary Information
The product herewith complies with the requirements of the Low Voltage
Directive 2014/35/EU and the EMC Directive 2014/30/EU.
Last two digits of the year in which the CE marking was affixed: 11
The technical file and other documentation are on file with Slaughter
Company, Inc.
______________________________
Joseph Guerriero
President / General Manager
Slaughter Company, Inc.
Lake Forest, Illinois USA
April 18, 2016
Warranty Policy
Slaughter Company, certifies that the instrument listed in this manual meets or exceeds
published manufacturing specifications. This instrument was calibrated using standards
that are traceable to the National Institute of Standards and Technology (NIST).
Your new instrument is warranted to be free from defects in workmanship and material
for a period of (1) year from date of shipment. You must return the “Owners Registration
Card” provided within (15) days from receipt of your instrument.
Slaughter Company recommends that your instrument be calibrated on a twelve-month
cycle. A return material authorization (RMA) must be obtained from Slaughter
Company. Please contact our Customer Support Center at 1-800-504-0055 to obtain an
RMA number. Damages sustained as a result of improper packaging will not be honored.
Transportation costs for the return of the instrument for warranty service must be prepaid
by the customer. Slaughter Company will assume the return freight costs when returning
the instrument to the customer. The return method will be at the discretion of Slaughter
Company.
Except as provided herein, Slaughter Company makes no warranties to the purchaser of
this instrument and all other warranties, express or implied (including, without limitation,
merchantability or fitness for a particular purpose) are hereby excluded, disclaimed and
waived.
Any non-authorized modifications, tampering or physical damage will void your
warranty. Elimination of any connections in the earth grounding system or bypassing any
safety systems will void this warranty. This warranty does not cover batteries or
accessories not of Slaughter Company manufacture. Parts used must be parts that are
recommended by Slaughter Company as an acceptable specified part. Use of nonauthorized parts in the repair of this instrument will void the warranty.
TABLE OF CONTENTS
GLOSSARY OF TERMS ....................................................................................... 1
CONTROLS .......................................................................................................... 6
POWER CABLE ................................................................................................. 16
QUICK START ................................................................................................... 18
SETUP INSTRUCTIONS FOR MODELS 2503/2510/2550 ................................ 19
FIELD INSTALLATION OF OPTIONS ............................................................... 23
OPERATING INSTRUCTIONS FOR MODELS 2503/2510/2550 ....................... 24
SETUP INSTRUCTIONS FOR MODEL 2525 ..................................................... 26
OPERATION INSTRUCTIONS FOR MODEL 2525 ........................................... 30
REMOTE INTERFACE FOR MODELS 2503/2510/2550 ................................... 34
REMOTE INTERFACE FOR MODEL 2525 ........................................................ 35
MODELS 2503/2510/2550 OPTIONS ................................................................ 37
CALIBRATION PROCEDURE MODELS 2503/2510/2550 ................................ 38
CALIBRATION PROCEDURE MODEL 2525 ..................................................... 40
REPLACEMENT PARTS LIST ........................................................................... 42
SAFETY
SAFETY PRECAUTIONS REQUIRED FOR HIGH
VOLTAGE TESTING!
GENERAL:
This product and its related documentation must be reviewed for familiarization with
safety markings and instructions before operation. This product is a Safety Class I
instrument (provided with a protective earth terminal).
Before applying power verify that the instrument is set to the correct line voltage (115 or
230) and the correct fuse is installed.
INSTRUCTION MANUAL SYMBOL. PLEASE REFER TO THE
INSTRUCTION MANUAL FOR SPECIFIC WARNING OR CAUTION
INFORMATION TO AVOID PERSONAL INJURY OR DAMAGE TO THE
PRODUCT.
INDICATES HAZARDOUS VOLTAGES MAY BE PRESENT.
CHASSIS GROUND SYMBOL.
CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR
CONDITION, THAT COULD POSSIBLY CAUSE BODILY
INJURY OR DEATH.
CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR
CONDITION, THAT COULD POSSIBLY CAUSE DAMAGE
TO EQUIPMENT OR PERMANENT LOSS OF DATA.
A Hipot produces voltages and currents which can cause harmful
or fatal electric shock. To prevent accidental injury or death,
these safety procedures must be strictly observed when handling
and using the test instrument.
5
INTRODUCTION
SERVICE AND MAINTENANCE
User Service
To prevent electric shock do not remove the instrument cover. There are no user
serviceable parts inside. Routine maintenance or cleaning of internal parts is not
necessary. Any external cleaning should be done with a clean dry or slightly damp cloth.
Avoid the use of cleaning agents or chemicals to prevent any foreign liquid from entering
the cabinet through ventilation holes or damaging controls and switches, also some
chemicals may damage plastic parts or lettering. Schematics, when provided, are for
reference only. Any replacement cables and high voltage components should be acquired
directly from Slaughter Company, Inc. Refer servicing to a Slaughter Company, Inc.
authorized service center.
SLAUGHTER COMPANY, INC.
28105 N. KEITH DRIVE
LAKE FOREST, IL 60045-4546 U.S.A.
PHONE: 1 (847) 932-3662
1 (800) 504-0055
FAX: 1 (847) 932-3665
E-MAIL : [email protected]
www.hipot.com
Service Interval
The instrument and its power cord, test leads, and accessories must be returned at least
once a year to a Slaughter Company authorized service center for calibration and
inspection of safety related components. Slaughter Company will not be held liable for
injuries suffered if the instrument is not returned for its annual safety check and
maintained properly.
User Modifications
Unauthorized user modifications will void your warranty. Slaughter Company will not be
responsible for any injuries sustained due to unauthorized equipment modifications or use
of parts not specified by Slaughter Company. Instruments returned to Slaughter
Company with unsafe modifications will be returned to their original operating condition
at your expense.
TEST STATION
Location
Select an area away from the main stream of activity which employees do not walk
through in performing their normal duties. If this is not practical because of production
line flow, then the area should be roped off and marked for HIGH VOLTAGE
TESTING. No employees other than the test operators should be allowed inside.
If benches are placed back-to-back, be especially careful about the use of the bench
opposite the test station. Signs should be posted: "DANGER - HIGH VOLTAGE
TEST IN PROGRESS - UNAUTHORIZED PERSONNEL KEEP AWAY."
2
INTRODUCTION
Power
Dielectric Voltage-Withstand Test Equipment must be connected to a good ground. Be
certain that the power wiring to the test bench is properly polarized and that the proper
low resistance bonding to ground is in place.
Power to the test station should be arranged so that it can be shut off by one prominently
marked switch located at the entrance to the test area. In the event of an emergency,
anyone can cut off the power before entering the test area to offer assistance.
The mains plug is used as the disconnecting device and shall
remain readily operable. The socket-outlet shall be installed near
the equipment and shall be easily accessible.
Do not replace the power supply cord with an improperly rated
cord. For North American: A UL listed and CSA labeled power
cord must be used with the instrument in the United States and
Canada. The power cord must include a NEMA5-15 style male plug, SVT or SJT cord
sets, and be rated for at least 125VAC, 10A, number 16 gauge (or 125VAC, 15A, number
14 gauge) wire or larger, and the length of the cord does not exceed 2 m must be used.
For European: A certified power supply cord not lighter than light PVC sheathed flexible
cord according to IEC 60227, designation H03 VV-F or H03 VVH2-F (for equipment
mass not exceeding 3 kg), or H05 VV-F or H05 VVH2-F2 (for equipment mass
exceeding 3 kg), and be rated for at least 3G 0.75 mm² (for rated current up to 10 A) or
3G 1.0mm² (for rated current over 10 A up to 16 A) wire or larger, and the length of the
cord does not exceed 2 m must be used.
Work Area
Perform the tests on a non-conducting table or workbench, if possible.
There should not be any metal in the work area between the operator and the location
where products being tested will be positioned.
Position the tester so the operator does not have to reach over the product under test to
activate or adjust the tester. If the product or component being tested is small, it may be
possible to construct guards or an enclosure, made of a non-conducting material such as
clear acrylic, such that the item being tested is within the guards or enclosure during the
test, and fit them with switches so that the tester will not operate unless the guards are in
place or the enclosure closed.
Keep the area clean and uncluttered. All test equipment and test leads not absolutely
necessary for the test should be removed from the test bench and put away. It should be
clear to both the operator and to any observers which product is being tested, and which
ones are waiting to be tested or have already been tested.
3
INTRODUCTION
Do not perform Hipot tests in a combustible atmosphere or in any area where combustible
materials are present.
TEST OPERATOR
Qualifications
This instrument generates voltages and currents which can cause harmful or fatal
electric shock and must only be operated by a skilled worker trained in its use.
The operator should understand the electrical fundamentals of voltage, current, and
resistance.
Safety Procedures
Operators should be thoroughly trained to follow these and all other applicable safety
rules and procedures before they begin a test. Defeating any safety system should be
treated as a serious offense and should result in severe penalties, such as removal from
the Hipot testing job. Allowing unauthorized personnel in the area during a test should
also be dealt with as a serious offense.
Dress
Operators should not wear jewelry which could accidentally complete a circuit.
Medical Restrictions
This instrument should not be operated by personnel with heart ailments or devices such
as pacemakers.
TEST PROCEDURES
NEVER PERFORM A HIPOT TEST ON ENERGIZED
CIRCUITRY OR EQUIPMENT!
If the instrument has an external safety-ground connection be sure that this is connected.
Then connect the return lead first for any test regardless of whether the item under test is a
sample of insulating material tested with electrodes, a component tested with the high
voltage test lead, or a cord-connected device with a two or three-prong plug.
Plug in the high voltage test lead only when it is being used. Handle its clip only by the
insulator---never touch the clip directly. Be certain that the operator has control over
any remote test switches connected to the Hipot. Double-check the return and high
voltage connections to be certain that they are proper and secure.
NEVER TOUCH THE ITEM UNDER TEST OR
ANYTHING CONNECTED TO IT WHILE HIGH
VOLTAGE IS PRESENT DURING THE HIPOT TEST.
4
INTRODUCTION
DO NOT TOUCH THE FRONT PANEL WHEN TESTING
OR AFTER A MALFUNCTION HAS OCCURRED.
When testing with DC, always discharge the capacitance of the item under test and
anything the high voltage may have contacted--such as test fixtures--before handling it or
disconnecting the test leads.
HOT STICK probes can be used to discharge any capacitance in the item under test as a
further safety precaution. A hot stick is a non-conducting rod about two feet long with a
metal probe at the end which is connected to a wire. To discharge the device under test,
two hot sticks are required. First connect both probe wires to a good earth ground. Then
touch one probe tip to the same place the return lead was connected. While holding the
first probe in place, touch the second probe tip to the same place where the high voltage
lead was connected.
KEY SAFETY POINTS TO REMEMBER:





Keep unqualified and unauthorized personnel away from the test area.
Arrange the test station in a safe and orderly manner.
Never touch the product or connections during a test.
In case of any problem, turn off the high voltage first.
Properly discharge any item tested with DC before touching connections.
5
INTRODUCTION
GLOSSARY OF TERMS
Alternating Current, AC: Current which reverses direction on a regular basis, commonly in the
U.S.A. 60 times per second, in other countries 50 times per second.
Breakdown: The failure of insulation to effectively prevent the flow of current, sometimes evident by
arcing. If voltage is gradually raised, breakdown will begin suddenly at a certain voltage level. Current
flow is not directly proportional to voltage. Once breakdown current has flown, especially for a period of
time, a repeated application of voltage will often show breakdown beginning at a lower voltage than
initially.
Conductive: Having a volume resistivity of no more than 103 ohm-cm or a surface resistivity of no
more than 105 ohms per square.
Conductor: A solid or liquid material which has the ability to let current pass through it, and which has
a volume resistivity of no more than 103 ohm-cm.
Current: The movement of electrons through a conductor. Current is measured in amperes,
milliamperes, microamperes, nanoamperes, or picoamperes. Symbol = I
Dielectric: An insulating material which is positioned between two conductive materials in such a way
that a charge or voltage may appear across the two conductive materials.
Direct Current, DC: Current which flows in one direction only. The source of direct current is said
to be polarized and has one terminal which is always at a higher potential than the other.
Hipot Tester: Common term for dielectric-withstand test equipment.
Insulation: Gas, liquid or solid material which has a volume resistivity of at least 1012 ohm-cm and is
used for the purpose of resisting current flow between conductors.
Insulation Resistance Tester: An instrument or a function of an instrument capable of measuring
resistance's in excess of 200 megohms. Usually employs a higher voltage power supply than used in
ohmmeters measuring up to 200 megohms.
Leakage: AC or DC current flow through insulation and over its surfaces, and AC current flow through a
capacitance. Current flow is directly proportional to voltage. The insulation and/or capacitance is thought
of as a constant impedance, unless breakdown occurs.
Resistance: That property of a substance which impedes current and results in the dissipation of power
in the form of heat. The practical unit of resistance is the ohm. Symbol = R
Trip Point: The minimum current flow required to cause an indication of unacceptable performance
during a dielectric voltage-withstand test.
Voltage: Electrical pressure, the force which causes current through an electrical conductor.
Symbol = V
1
SPECIFICATIONS
Models 2503 & 2550 DC Mode Functional Specifications
Unless otherwise stated, accuracy’s are relative to a laboratory standard measurement.
Descriptions
INPUT VOLTAGE
FUSE
OUTPUT
VOLTAGE SETTING
RIPPLE
DWELL TIME
SETTING
RAMP TIMER
FAILURE SETTING
METERING
Soft key used to toggle
between Voltmeter and
Ammeter
TIMER DISPLAY
Discharge Time
Maximum Capacitive
Load
OPTIONAL
Ground Continuity
Check
REMOTE CONTROL
AND SIGNAL
OUTPUT
LINE CORD
TERMINATIONS
MECHANICAL
Specifications
115 / 230 V selectable,  15  variation; 47 – 63 Hz
115 VAC, 230 VAC – 2 A fast acting 250 VAC
Rating
: 5.00 kV DC, 3 mA
Regulation:  (1  of output  5 V) from no load to full load
0.00kV – 5.00 kV, 10 volts/step
Accuracy:  (2  of Setting  5 V) (relative to displayed output).
Can be adjusted during operation via Up & Down Arrow keys.
< 5 % at 5 kV DC / 3 mA
0.0, 1.0 s or 60.0 s
“0.0” for continuous running
0.0 and 0.2 – 999.9 seconds, 0.1 second / step
0.0 ramp setting = 0.1 seconds fixed ramp
High limit
: 0.00 – 3.00 mA, 0.01 mA / step
Accuracy
:  (2  of setting  0.02 mA)
Voltmeter (4 digits)
Range
: 0.00 – 5.00 kV
Resolution
: 0.01 kV
Accuracy
:  (2  of reading  10 V)
Ammeter (4 digits)
Range
: 0.00 – 3.00 mA
Resolution
: 0.01 mA
Accuracy
:  (2% of reading + 0.02 mA)
Range
: 0.0 – 999.9 seconds
Resolution : 0.1 second
Accuracy :  (0.1% of reading + 0.05 seconds)
 300 ms
1 uF
 1 kV
0.08 uF  4 kV
0.75 uF  2 kV
0.04 uF  5 kV
0.5 uF  3 kV
Current: DC 0.1 A  0.01 A, fixed
Max ground resistance: 1 Ohm  0.1 Ohm, fixed
The following input and output signals are provided through the 9 pin
D type connector;
1. Remote control: test, reset and interlock
2. Outputs: pass, fail and test in process
Detachable 7 ft. (2.13 m) power cable terminated in a three prong
grounding plug.
6 ft. (1.82 m) high voltage safety retracting probe, 6 ft. (1.82 m) high
voltage clip probe and 6 ft. (1.82 m) return clip lead.
Dimensions: (WxHxD) (4.75x5.75x14.50 in.) (120x146x370 mm)
Weight: 16.5 lbs (7.5 kgs)
2
SPECIFICATIONS
Models 2510 & 2550 AC Mode Functional Specifications
Descriptions
Specifications
INPUT VOLTAGE
115 / 230 V selectable,  15  variation; 47 – 63 Hz
FUSE
115 VAC, 230 VAC – 2 A fast acting 250 VAC
OUTPUT
Rating
: 5.00 kV AC, 10 mA
Regulation:  (1  of output  5 V) from no load to full load
Frequency: 60 Hz fixed
VOLTAGE SETTING 0.00kV – 5.00 kV, 10 volts/step
Accuracy:  (2  of setting  5 V) (relative to displayed output).
Can be adjusted during operation via Up & Down
Arrow keys.
DWELL TIME
SETTING
RAMP TIMER
0.0, 1.0 s or 60.0 s
“0.0” for continuous running
0.0 and 0.2 – 999.9 seconds, 0.1 second / step
0.0 ramp setting = 0.1 seconds fixed ramp
FAILURE SETTING
High limit
: 0.00 – 10.00 mA, 0.01 mA / step
Accuracy
:  (2  of setting  0.02 mA)
METERING
Voltmeter (4 digits)
Soft key used to toggle
Range
: 0.00 – 5.00 kV
between Voltmeter
Resolution : 0.01 kV
and Ammeter
Accuracy :  (2  of reading  10 V)
Ammeter (4 digits)
Range
: 0.00 – 10.00 mA
Resolution : 0.01 mA
Accuracy :  (2% of reading + 0.02 mA)
TIMER DISPLAY
Range
: 0.0 – 999.9 seconds
Resolution : 0.1 second
Accuracy :  (0.1% of reading + 0.05 seconds)
OPTIONAL
Current : DC 0.1 A  0.01 A, fixed
Ground Continuity
Max ground resistance : 1 Ohm  0.1 Ohm, fixed
Check
REMOTE CONTROL The following input and output signals are provided through the 9
AND SIGNAL
pin D type connector;
OUTPUT
1. Remote control: test, reset and interlock
2. Outputs: pass, fail and test in process
LINE CORD
Detachable 7 ft. (2.13 m) power cable terminated in a three prong
grounding plug.
TERMINATIONS
6 ft. (1.82 m) high voltage safety retracting probe, 6 ft. (1.82 m)
high voltage clip probe and 6 ft. (1.82 m) return clip lead.
MECHANICAL
Dimensions: (WxHxD) (4.75x5.75x14.50 in.) (120x146x370
mm)
Weight: 16.5 lbs (7.5 kgs)
3
SPECIFICATIONS
Model 2525 Functional Specifications
DIELECTRIC WITHSTAND TEST MODE
Descriptions
Specifications
INPUT VOLTAGE
115 / 230V selectable,  10  variation
50/60 Hz  5%
FUSE
115 VAC, 230VAC – 15A fast acting 250VAC
OUTPUT
Rating AC 0 – 5000V, 10V / step, 100mA
Regulation :  (1  of output  5V)
VOLTAGE SETTING 0V – Max output rating, 10 volts/step
Accuracy:  (2  of Setting  5V) (relative to displayed output)
Can be adjusted during operation via UP and DOWN arrow
keys.
OUTPUT
50 / 60 Hz selectable
FREQUENCY
WAVE FORM
Sinewave, 1.3 < Crest Factor < 1.5
DWELL TIME
0 and 0.2 – 999.9 seconds, 0.1 second / step
SETTING
“0” for continuous running
RAMP TIME
0 and 0.2 – 999.9 seconds, 0.1 second / step
SETTING
0 ramp setting = 0.1 seconds fixed ramp
FAILURE SETTINGS AC mode
High limit : 0.00 – 99.99 mA, 0.01 mA / step
Low limit : 0.00 – 99.99 mA, 0.01 mA / step (0= OFF)
Accuracy :  (2  of setting  0.02 mA)
METERING
Voltmeter (4 digits)
Range
: AC 0.00 – 5.00 KV
Resolution : 0.01 KV
Accuracy :  (2  of reading  10 V)
Ammeter (4 digits)
Range
: AC 0.00 - 99.99 mA
Resolution : 0.01 mA
Accuracy :  (2  of reading  0.02 mA)
TIMER DISPLAY
Range
: 0.0 – 999.9 seconds
Resolution : 0.1 seconds
Accuracy :  (0.1% of reading + 0.05 sec)
4
SPECIFICATIONS
GROUND
Current : DC 0.1 A  0.01A, fixed
CONTINUITY
Max. ground resistance : 1   0.1, fixed
CHECK
GENERAL SPECIFICATIONS
Remote Control and
The following input and output signals are provided through two
Signal Output
9 pin D type connectors;
1. Remote control: test, reset, interlock
2. Outputs: pass, fail, test in process
Program Memory
5 sets
Security
Lockout capability to avoid unauthorized access to test set-up
program.
Line Cord
Detachable 7ft. (2.13m) power cable terminated in a three prong
grounding plug.
Terminations
5ft. (1.52m) high voltage and return leads (2) with clips and a
standard U.S. style (NEMA 5-15) remote receptacle box for
testing items terminated with a line cord. International
receptacles also available.
Mechanical
Tilt-up front feet
Dimensions (W x H x D) 17 x 5.8 x 12 in. (432 x 147 x 305mm)
Weight: 56.70 Lbs. (25.92 kgs)
Environmental
Operating Temperatures: 32-104F (0-40C)
Relative Humidity : 0 to 80%
Calibration
Traceable to National Institute of Standards and Technology
(NIST). Calibration controlled by software. Adjustments are
made through front panel keypad in a restricted access
calibration mode. Calibration information stored in non-volatile
memory.
5
CONTROLS
CONTROLS
FRONT PANEL CONTROLS 2503, 2510, 2550
1.
RESET BUTTON: This is a momentary contact button. If a failure is detected
during the hipot test, the red Failure lamp within the button will light. To reset the
system for the next test, press and release this button. This button may also be used
to abort a test in progress.
2.
TEST BUTTON: This is a momentary contact button. Press the green button to
energize the high voltage output. When the Dwell function is “0.0”, high voltage
will remain ON until a reject occurs or the RESET button is pushed. If the Dwell
function is “1.0” or “60.0,” the high voltage will be present only for the programmed
time.
3.
SET KEY: Use this key to advance forward through the setup menus.
4.
DISPLAY: The Display is the main readout for the operator and programmer of the
test settings and test results. Scalar values are indicated via a digital display.
5.
AC INDICATOR: This indicator is illuminated during testing to indicate the
instrument is in the AC mode (2550 only).
6.
HIGH VOLTAGE LED INDICATOR: This indicator flashes to warn the operator
that high voltage is present at the high voltage output terminal.
7.
DC INDICATOR: This indicator is illuminated during testing to indicate the
instrument is in the DC mode (2550 only).
6
CONTROLS
FRONT PANEL CONTROLS 2503, 2510, 2550
8.
EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test.
Also the key is used to toggle VOLTAGE, CURRENT, or DWELL screens before a
test is initiated or during the test in process (2503/2510/2550 only).
9.
POWER SWITCH: Rocker-style switch with international ON (  ) and OFF (0)
markings.
10. UP ARROW () & DOWN ARROW (): Use these keys to increment or
decrement numeric values in the setup mode. These keys are also used to toggle
between AC/DC modes (2550 only) and toggle the DWELL function parameters.
These keys are used to toggle between VOLTAGE, CURRENT, and DWELL in
Results mode. It also may be used to increase or decrease output voltage during a test
in 10 volt increments.
11. HIGH VOLTAGE OUTPUT JACK: For the connection of the detachable 6 foot
(1.82 m) red high voltage test lead. The jack is recessed for safety when this lead is
not being used.
12. RETURN OUTPUT JACK: For the connection of the detachable 6 foot (1.82 m)
black return test lead. This lead is always used when performing a test.
7
CONTROLS
REAR PANEL CONTROLS 2503, 2510, 2550
1.
CONTINUITY RETURN JACK (OPTIONAL): For connection of the detachable
black return test lead when performing a continuity test.
2.
GROUND CONTINUITY SENSING CIRCUIT (OPTIONAL): Used with the
optional Remote Receptacle Box to verify continuity of the ground wire in line cord
connected devices.
3.
VENTILATION: To cool the instrument.
4.
INPUT VOLTAGE SWITCH: Line voltage selection is set by the position of the
switch. In the down position it is set for 115 volt operation, in the up position it is
set for 230 volt operation.
5.
REMOTE INPUT: 9 pin D subminiature male connector for remote interfacing.
6.
CALIBRATION ENABLE KEY: To enter the calibration mode press this key
while the instrument is being powered ON.
7.
FUSE RECEPTACLE: To change the fuse unplug the power (mains) cord and turn
the fuse cap counter clockwise to remove the fuse.
8.
CHASSIS GROUND (EARTH) TERMINAL: This safety terminal should be
connected to a good earth ground before operation.
8
CONTROLS
9.
9
INPUT POWER RECEPTACLE: Standard IEC 320 connector for connection to a
standard NEMA style line power (mains) cord.
CONTROLS
2525 FRONT PANEL CONTROLS
1.
RESET SWITCH: This is a momentary contact switch. If an out-of-range reading is
detected during a hipot test or an IR test or if continuity failure occurs, the red failure
lamp within the switch will light. To reset the system for the next test, press and release
this switch. This switch may also be used to abort a test in progress.
2.
TEST SWITCH: This is a momentary contact switch. Press the green switch to turn
on the high voltage output when in test mode. The indicator lamp within the switch will
light when continuity is “good”, if continuity mode is enabled.
3.
LCD DISPLAY: The Liquid Crystal Display is the main readout for the operator and
programmer of the test settings and test results.
4.
CONTINUITY CHECK OUTPUT JACK: For the connection of the detachable 5
foot (1.52 m) black return test lead or three prong receptacle adapter box. This jack is
always used when performing a continuity test. Please refer to page 33 for details on
connecting the adapter box between the 2525 and the device under test.
5.
POWER SWITCH: Rocker-style switch with international ON (  ) and OFF (0)
markings.
6.
SET KEY: Use this key to advance forward through the setup menus.
10
CONTROLS
2525 FRONT PANEL CONTROLS
7.
UP ARROW () & DOWN ARROW (): Use these keys to increment or decrement
numeric values in the setup mode. This key is also used to toggle ON/OFF functions.
Also may be used to increase output voltage during a test in 10 volt increments.
8.
EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test.
9.
HIGH VOLTAGE OUTPUT JACK: For the connection of the detachable 5 foot
(1.52 m) red high voltage test lead. The silicone rubber insulation is flexible for easy
handling and is rated at 30KVDC. The jack is recessed for safety when this lead is not
being used.
10. HIGH VOLTAGE ARROW (LED INDICATOR): This indicator flashes to warn
the operator that high voltage is present at the high voltage output terminal.
11. RETURN OUTPUT JACK: For the connection of the detachable 5 foot (1.52 m)
black return test lead. This lead is always used when performing a test.
11
CONTROLS
2525 REAR PANEL CONTROLS
1.
REMOTE INTERFACE SIGNAL OUTPUT: 9 pin D subminiature female connector
which provides; Pass, Fail and Test in process signals
2.
REMOTE INTERFACE SIGNAL INPUT: 9 pin D subminiature male connector
which provides remote control access over Test, Reset and Interlock.
3.
CALIBRATION ENABLE KEY: To enter the calibration mode press this key while
the instrument is being powered ON.
4.
THERMAL FAN: To cool the instrument.
5.
REAR PANEL OUTPUT (OPTIONAL): The Rear Outputs option gives the user the
capability to access the High Voltage, Current and Return from the rear panel. These
outputs are in parallel with the front panel output.
6.
INPUT POWER SWITCH: Line voltage selection is set by the position of the switch.
In the down position it is set for 115 volt operation, in the up position it is set for 230
volt operation.
7.
INPUT POWER RECEPTACLE: Standard IEC 320 connector for connection to a
standard NEMA style line power (mains) cord.
8.
CHASSIS GROUND (EARTH) TERMINAL: This safety terminal should be
connected to a good earth ground before operation
12
INTRODUCTION
Introduction
This section contains information for the unpacking, inspection, preparation for use and
storage of your Slaughter Company, Inc., product.
Unpacking and Inspection
Your instrument was shipped in a custom foam insulated container that complies with
ASTM D4169-92a Assurance Level II Distribution Cycle 13 Performance Test Sequence.
If the shipping carton is damaged, inspect the contents for visible damage such as dents,
scratches, or broken meters. If the instrument is damaged, notify the carrier and the
Slaughter Company customer support department immediately. Please save the shipping
carton and packing material for the carrier’s inspection. Our customer support department
will assist you in the repair or replacement of your instrument. Please do not return your
product without first notifying us and receiving an RMA (return materials authorization)
number.
Safe Lifting and Carrying Instructions
Proper methods of lifting and carrying can help to protect against injury. Follow the
recommendations below to ensure that instruments are handled in a safe manner.
13

Determine if the instrument can be lifted by one individual or requires additional
support.

Make sure that your balance is centered and your feet are properly spaced, shoulder
width apart behind the instrument.

Bend at the knees and make sure your back is straight.

Grip the instrument with your fingers and palms and do not lift unless your back is
straight.

Lift up with your legs, not your back.

Keep the instrument close to your body while carrying.

Lower the instrument by bending your knees. Keep you back straight.
INTRODUCTION
Contents of the Carton
Inside the carton should be the following:
Description
SLA Part Number
2525 Instrument
2525 500VA Hipot Tester
High Voltage Cable
102-050-913
Return Cable
102-069-904
High Voltage Clip
102-055-913
Fuse
99-10168-01, 15 Amp, fast
acting 250VAC
Interlock Connector
99-10040-01
Line Cord*
125-013-001 Standard
Description
SLA Series Instrument
High Voltage Cable
Return Cable
Fuse
SLA Part Number
2503/2510/2550
102-055-913
102-069-904
99-10097-01, 3.15 Amp, fast
acting 250VAC
Interlock Connector
99-10040-01
Line Cord*
125-013-001 Standard
*The Line Cord listed is American. Other combinations of the Line Cord are available upon
request.
Only accessories which meet the manufacturer’s specification shall
be used.
Preparation for Use
Power Requirements and Line Voltage Selection
This instrument requires a power source of either 115 volts AC ±
10%, 47-63 Hz single phase or 230 volts AC ±10%, 47-63 Hz
single phase. Please check the rear panel to be sure the proper
switch setting is selected for your line voltage requirements before turning your instrument
on (model 4320 only). In addition, please be sure the correct fuse is selected and installed
while the instrument is in the off position.
Do not switch the line voltage selector switch located on the rear panel while the instrument
is on or operating (model 4320 only). This may cause internal damage and represents a
safety risk to the operator.
14
INTRODUCTION
NOTE
For operation at 115 Volts AC and 230 Volts AC use a 15A fast acting fuse.
15
INTRODUCTION
Power Cable
BEFORE CONNECTING POWER TO THIS INSTRUMENT, THE
PROTECTIVE GROUND (EARTH) TERMINALS OF THIS
INSTRUMENT MUST BE CONNECTED TO THE PROTECTIVE
CONDUCTOR OF THE LINE (MAINS) POWER CORD. THE MAIN PLUG SHALL
ONLY BE INSERTED IN A SOCKET OUTLET (RECEPTACLE) PROVIDED WITH A
PROTECTIVE GROUND (EARTH) CONTACT. THIS PROTECTIVE GROUND (EARTH)
MUST NOT BE DEFEATED BY THE USE OF AN EXTENSION CORD (POWER CABLE)
WITHOUT A PROTECTIVE CONDUCTOR (GROUNDING).
This instrument is shipped with a three-wire power cable. When this cable is connected to
an appropriate AC power source, this cable connects the chassis to earth ground. The type
of power cable shipped with each instruments depends on the country of destination.
Operating Environment
This equipment is intended for indoor use only. The equipment has been evaluated
according to Installation Category II and Pollution Degree 2 as specified in IEC 664.
This instrument may be operated within the following environmental conditions:
Temperature………….41° - 104° F (5° - 40° C)
Relative humidity …….0 - 80%
Altitude ………………6,560 feet (2,000 meters)
Do not block any ventilation openings to prevent over heating of the
equipment. Keep the ventilation slits uncovered during operation.
Failure to do so could cause the instrument to overheat and may
damage internal components.
If the instrument is used in a matter not specified by the manufacturer, the protection
provided by the instrument may be impaired.
STORAGE AND SHIPMENT
Environment
This instrument may be stored or shipped in environments with the following limits:
Temperature.................-40° - 167° F (-40° - 75°C)
Altitude............................ 50,000 feet (15,240 meters)
16
INTRODUCTION
The instrument should also be protected against temperature extremes which may cause
condensation within the instrument.
Field Installation Options
There are no field installable options on the model 2525.
17
QUICK START
QUICK START
This quick start guide presumes the operator has some familiarity with hipot testing and
desires to use the “default” settings on the instrument. The default settings shown will
remain in memory unless you choose to override them with your own test program. The
instrument default settings are as follows:

DEFAULTS

Input Voltage:
115 or 230 volts AC, country specific
(rear-panel switch selectable)

Lock:
OFF (2525)

Voltage Output:
1.50 kV DC (2503/2550 DC mode)
1.24 kV AC (2510/2525/2550 AC mode)

Current Trip:
HI-LMT: 10.00 mA (2525)
HI-LMT: 5.00 mA (2510/2550 AC mode)
HI-LMT: 3.00 mA (2503/2550 DC mode)

Dwell:
1.0 (1 second)

Ramp:
0.0 (0.1 second)

AC Output Frequency:
60Hz
1. Unpack this instrument from its special shipping container.
2. Locate a suitable testing area and be sure you have read all safety instructions for the
operation of the instrument and suggestions on the test area set-up in the SAFETY
section of this manual. Locate a three prong grounded outlet. Be sure the outlet has
been tested for proper wiring before connecting the instrument to it.
3. Check to be sure the correct input line voltage has been selected on the rear panel (either
115 volts AC or 230 volts AC). Connect the power input
plug into its socket on the rear panel of the instrument.
Connect the male end of the plug to the outlet receptacle.
4.
Turn on the POWER switch located on the lower left hand side of the front
panel. Upon powering the instrument up a POWER ON SELF TEST (POST) will
automatically be performed. This test will check for the condition of all critical
components. You will see the model number and then firmware version number briefly
appear on the LED readout and then clear itself.
18
QUICK START
5. If the instrument DEFAULTS are acceptable, then be sure to connect the appropriate
test leads to the device under test (DUT) or test fixture. Be sure to connect this safety
ground to a suitable known good ground before energizing this instrument, then connect
the return lead first (black) to the test fixture or item followed by the high voltage output
lead (red).
6. Models 2503/2510/2550 and 2525 are equipped with a featured referred to as “Remote
Interlock”. Remote Interlock is a feature that utilizes a set of closed contacts to enable
the instruments output. In other words, if the Interlock contacts are open, the output of
the instrument will be disabled. Remote Interlock could also be referred to as a remote
system lockout, utilizing “Fail When Open” logic. If the Interlock contacts are open,
the instrument will not conduct a test if the TEST button is pressed.
If the Interlock contacts are opened during a test, the test will abort. The hardware has been
configured to provide the interlock connections on pins 4 and 5 of the 9-pin, d-sub input
connector located on the back of the unit. The instrument can still be used without the
external interlock device as long as the Interlock Connector (99-10040-01 provided with
unit) is plugged into the input connector. If there is nothing connected to the input port to
provide a connection to the interlock, the instrument will not perform tests.
7. Please check your connections to be sure they are making good contact and that the test
station or area is clear of debris and other personnel.
DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE
TEST HAS BEEN STARTED.
To initiate the test press the green TEST button on the front panel. The instrument will then
cycle ON and begin the automated test using the defaults. If a failure occurs you will HEAR
an audible alarm go off. To stop the alarm you must depress the RED button marked
RESET. This will silence the alarm and reset the instrument to begin another test. This
RESET button must also be used when the Dwell mode is set to “ON” or “0.0” to ABORT a
test and cut off the HIGH VOLTAGE.
When HIGH VOLTAGE is present a RED flashing indicator located to the right of the
display will remain flashing until the HIGH VOLTAGE is OFF. If the device under test
PASSED the test then short beep will sound. In the case of a FAIL condition the instrument
will provide a visual and audible alarm. Depressing the RESET button will reset the
instrument alarm.
SETUP INSTRUCTIONS FOR MODELS 2503/2510/2550
19
SETUP
Check to be sure the correct input line voltage has been selected
on the rear panel (either 115 volts AC or 230 volts AC). Connect
the power input plug into its socket on the rear panel of the
instrument. Connect the male end of the plug to the outlet receptacle.
Please be sure that the safety ground on the power line cord is not defeated and that you
are connected to a grounded power source. Also connect the rear panel chassis ground
for additional safety.
Turn on the POWER switch located on the lower left hand side of the front panel. Upon
powering the instrument up a POWER ON SELF TEST (POST) will be automatically
performed. This test will check for the condition of all critical components. In addition
the display will briefly flash the actual model number and then firmware version number.
For example, for the model 2550 the model number will indicate as follow:
Then the instrument will recall the last setup that was active. The digital display will
show 0.00. The Voltage LED, or Current LED, or Dwell LED will be illuminated
depending upon the setting, and the AC or DC LED (2550 only) will be illuminated
depending upon the programmed setting. On Model 2550, to view the last settings, press
the SET key once and the AC or DC LED will flash and AC or DC will be displayed on
the digital display. Pressing the SET key again will cause the Voltage LED to flash and
the display will show the programmed voltage. On Models 2503 and 2510 the voltage
LED will flash and the display will show the programmed voltage on the initial pressing
of the SET key. Pressing the SET key again will cause the Current LED to flash and the
display will show the programmed trip current. Press the EXIT key to ready the
instrument for testing.
1. To set the AC or DC Testing Mode (Model 2550 only)
Press the SET key and the AC or the DC LED will illuminate and flash.
OR
20
SETUP
Use the Up/Down Arrow keys to toggle between the AC mode and the DC mode. The
LED indicator will flash and the digital display will display AC or DC.
Note: When switching between AC and DC modes, always check ALL setting for
voltage, current, ramp and dwell. The instrument DOES NOT retain separate settings for
the AC mode and the DC mode.
2. To set the Output Test Voltage
Press the SET key until the Voltage LED is illuminated and flashing
Please use the Up/Down Arrow keys to enter the desired test voltage, then press the EXIT
key to exit to the test mode or toggle to another setting using the SET key. The maximum
voltage, which may be entered, is 5.00kV.
3. To set the High Leakage Current Limit
Press the SET key until the Current LED is illuminated and flashing.
Use the Up/Down Arrow keys to enter the leakage current high limit setting, then press
the EXIT key to exit to the test mode or toggle to another setting using the SET key. The
unit of measure is in milliamperes with the maximum setting of 10.00 mA AC for the
model 2510 and 2550 and 3mA DC for the model 2503 and DC mode of the model 2550.
4. To set the Dwell function
Press the SET key until the Dwell LED is illuminated and flashing. Dwell time is the
length of time the instrument will apply the programmed test voltage.
21
SETUP
Use the Up/Down Arrow keys to set the dwell time, then press the EXIT key to exit to the
test mode or toggle to another setting using the SET key. If the Dwell is set to 0.0, the
instrument will operate in a continuous ON mode when the TEST button is pressed and
released. It will stop when the DUT (Device Under Test) goes into failure or the manual
RESET button is pressed. If the Dwell is set to 1.0, the instrument will test for one
second when the TEST button is pressed and released. If the Dwell is set to 60.0, the
instrument will test for sixty seconds when the TEST button is pressed and released. The
instrument will ‘beep’ at the end of a timed test. Pressing the red RESET button will
terminate the test in progress.
5. To set the Ramp function
Press the SET key until the Ramp LED is illuminated and flashing. The ramp time is the
time the instrument will take to reach the full programmed test voltage.
Use the Up/Down Arrow keys to increase or decrease the Ramp time, then press the
EXIT key to exit to the test mode or toggle to another setting using the SET key. When
set to 0.0, the ramp time is fixed at 0.1 seconds to reach full test voltage. Ramp time may
be set up to 999.9 seconds. The red RESET button may be used to terminate the test at
any time.
SETUP for 120KΩ Testing Requirements (AC ONLY)
Set Dwell for 1.0 or 60.0 seconds.
1. First clip Ground Lead to the DUT, and then clip the High Voltage clip lead to
the DUT.
2. Press TEST button and release.
SETUP for Optional Ground Continuity Testing (2503/2510/2550)
1. Switch the instrument to Off.
22
SETUP
2. Plug the black ground-lead’s banana plug into the CONT. CHECK socket on
the back panel and switch the CONT. TEST switch to ON.
3. Plug the leads from the Remote Receptacle Box into the H.V. socket and the
RETURN socket on the front panel of the instrument.
FIELD INSTALLATION OF OPTIONS
Ground Continuity Sensing
1. Installation is simple and requires only a number 1 Phillips screwdriver.
2. Switch the instrument OFF and unplug the line-cord from the wall outlet.
3. Remove the test probes and the line cord from the instrument.
4. Remove and save the two (2) screws holding the blanking plate onto the rear of
the instrument.
5. Please observe the upper and lower card guides inside the opening.
6. Grasp the handle on the continuity board assembly and align the PC board into the
card guides. Slide the card straight in until resistance is felt approximately 1/8
inch before the metal plate on the continuity assembly reaches the back panel. A
firm push will seat the card. The screw holes should be aligned.
7. Install the screws from the blanking plate.
The installation is complete.
23
OPERATION
OPERATING INSTRUCTIONS FOR MODELS 2503/2510/2550
1. After the instrument’s test parameters are programmed, connect the appropriate test
leads to the device under test (DUT) or test fixture. Connect the safety ground (on the
rear panel) to a suitable known good ground before energizing this instrument. Then
connect the return lead first to the test fixture or the DUT followed by the high voltage
lead.
Check your connections to be sure they are making good contact and that the test station
or area is clear of debris or other personnel.
DO NOT TOUCH THE DEVICE UNDER TEST ONCE
THE TEST HAS BEEN STARTED.
2. To initiate a test, press the TEST button on the front panel. The red High Voltage
LED indicator will flash and the display will show the test voltage, or current, or time,
dependent upon the setting. If the Ramp function is set and voltage meter is selected, the
voltage will begin at 0 and step up to the programmed voltage. The rate at which the
voltage increases is dependent upon the ramp time.
3. If Dwell is set to 0.0, the instrument will continue to output voltage indefinitely or
until a failure occurs or the manual RESET button is pressed. If Dwell is set to 1.0 or
60.0, the voltage will continue only until the dwell time has elapsed, then shut off.
4. If the DUT passed the test a short audible beep will be activated. The instrument is
now ready to perform another test.
5. If there is a failure in the DUT during the test, the voltage will shut off, the red
indicator light will illuminate on the RESET button and an alarm will sound.
The red light will illuminate and alarm will sound when the failure occurs and will be
reset automatically when the test restarts. That process may repeat many times until the
dwell time has elapsed. An operator can elect to abort the test at any time by pressing the
RESET button.
6. To stop the alarm, please press the RESET button once. The alarm will stop. The
instrument is now ready for the next test. If the RESET button is pressed again, the data
on the display screen will be cleared.
24
OPERATION
7. To see the results parameters after the test has expired, please press the Up/Down
Arrow keys. Results of Voltage, Current, and Dwell parameters will be toggled when Up
or Down key are pressed. Results data will be lost only when TEST button is pressed to
initiate next test.
8. To select the desired parameter that the display will indicate during the next test,
please press the EXIT key. The EXIT key will toggle the display between the voltmeter,
current meter, and timer. The EXIT key is active also during the test, so the desired
parameters can be changed at any time while the test in process.
CONTINUITY
The continuity test is a passive test.
Set the CONT. TEST switch on the rear panel to ON position.
Plug the DUT’s line cord into the remote receptacle box and connect the Continuity
Check lead from the rear panel to the exposed ‘dead metal’ parts of the DUT.
If ground continuity is made, the green light in the TEST button will illuminate. Pressing
the TEST button will initiate the high voltage test. If continuity is not made or is lost
during the test, a reject will occur and the display will show “cont.”.
Press the RESET button to ready the instrument for another test.
25
SETUP
SETUP INSTRUCTIONS FOR MODEL 2525
Check that the correct input line voltage has been selected on
the rear panel, either 115 volts AC or 230 volts AC. Plug the
line cord into its socket on the rear panel of the instrument.
Connect the male end of the plug to the outlet receptacle.
Please be sure that the safety ground on the power line cord is not defeated and that
you are connecting to a grounded power source. Also, connect the rear panel chassis
ground for additional safety.
Turn on the POWER switch located on the lower left-hand side of the front panel.
Upon powering the instrument up a POWER ON SELF TEST (POST) will be
automatically performed. This test will check for the condition of the ram chips,
PCB’s and other critical components. In addition, the display will show the following
message with the model and version number.
The instrument will recall the last setup that was active and the display will show the
parameters that were programmed into the unit. The instrument is now ready for
2525
Slaughter
VER: X.X
Current software version
displayed here
operation.
1. To Select the Memory location
Please press the SET key until the display shows
Memory =
X
Use the Up/Down arrow keys to select memory locations 1 through 5. After selecting
the memory, press the SET key to view the settings that have been recalled from
memory or to make any changes to these settings.
To store any changes to the settings press the Exit key. The parameters are
automatically updated into the memory location that was selected, when exiting to the
test mode.
2. To set the Output Test Voltage
Please press the SET key until the display shows:
26
SETUP
Voltage= X.XX KV
Please use the Up/Down Arrow keys to enter the desired test voltage, then press the
EXIT key to exit to the test mode or toggle to another setting using the SET key. The
maximum voltage, which may be entered, is 5000 volts AC.
3. To set the High Leakage Current Limit
Please press the SET key until the display shows:
HI-LMT =XX.XX mA
Use the Up/Down Arrow keys to enter the leakage current high limit setting, then
press the EXIT key to exit to the test mode or toggle to another setting using the SET
key. The unit of measure is in AC milliamperes with 0.10 milliamperes as the
minimum setting.
4. To set the Low Leakage Current Limit
Please press the SET key until the display shows:
LO-LMT = X.XX mA
Use the Up/Down Arrow keys to enter the leakage current low limit setting, then
press the EXIT key to exit to the test mode or toggle to another setting using the SET
key. The unit of measure is in AC milliamperes with 0.00 milliamperes as the
minimum setting.
5. To set the Ramp Time
Please press the SET key until the display shows:
Ramp-T = X.X s
Use the Up/Down Arrow keys to enter the ramp time setting then press the EXIT key
to exit to the test mode or toggle to another setting using the SET key. If the ramp
time is set to “0”, the instrument will raise the voltage up to the test voltage in a fixed
ramp time of 0.1 seconds and then begin the dwell cycle. The minimum ramp time
setting is 0.2 seconds with 0.1 second resolution.
6. To set the Dwell Time
Please press the SET key until the display shows:
27
SETUP
Timer
=
X.X s
Use the Up/Down Arrow keys to enter the dwell time setting, then press the EXIT
key to exit to the test mode or toggle to another setting using the SET key. If the
dwell time is set to “0”, the instrument will operate in a continuous ON mode when
the test button is depressed and released. It will stop when the DUT (Device Under
Test) goes into failure or the manual reset button is pressed. The minimum dwell
time setting is 0.2 seconds with 0.1 second resolution.
7. To setup the Ground Continuity Check
Please press the SET key until the display shows:
Continuity=ON
Continuity=OFF
or
Press the Up/Down Arrow key to select the “ON” or “OFF” function of the Ground
Continuity Check mode, the display will show the set status immediately.
Press the EXIT key to exit to the test mode or toggle to another setting using the SET
key.
If the Continuity Function is set to “ON,” the Ground Continuity cable has to be
connected between the “Cont. Check” connector on the instrument panel and the
chassis of the DUT. The instrument will test the ground connection of the DUT
automatically. If continuity is present a green indicator will be illuminated on the
TEST switch and the operator may proceed with the hipot test. The 2525 will
continue to test the ground connection of the DUT during other tests. If no continuity
is present while the operator tries to initiate a test, the instrument will signal a
continuity failure.
8. To set the Frequency 50/60 Hz
Please press the SET key until the display shows:
Freq
=60
HZ
Freq
=50
HZ
or
Press the Up or Down Arrow keys to toggle the frequency selection; 50 or 60 hertz,
then press the EXIT key to exit to the test mode or toggle to another setting using the
SET key.
9. To lock or unlock the front panel keyboard
The 2525 is equipped with a lockout mode. Within this mode, you can lockout all
front panel control functions except TEST and RESET.
28
SETUP
You can toggle this selection only from a power OFF state. Please turn the power
switch to the off position then press and hold the SET key, then turn the power ON.
Momentarily, you will see one of the following screens to indicate if the keys are
locked or unlocked:
Key Lockout
Key Unlock
or
To change the key lock function power down the instrument and repeat the process.
29
OPERATION
OPERATION INSTRUCTIONS FOR MODEL 2525
If the instruments defaults are acceptable then be sure to connect the appropriate test
leads to the device under test (DUT) or test fixture. Be sure to connect the safety
ground (on the rear panel) to a suitable known good ground before energizing this
instrument. First, connect the return lead to the test fixture or DUT, then connect the
high voltage lead.
Check your connections to be sure they are making good contact. Clear the area of
any debris that may create a hazardous situation and ask any unnecessary personnel to
leave the area.
DO NOT TOUCH THE DEVICE UNDER TEST
ONCE THE TEST HAS BEEN STARTED.
Please follow the setup procedures to set the parameters. The display will show the
Dwell or Delay Timer value, the Test Voltage value, and the High Limit Setting and
memory location.
Set
MX
X.XXKVAC
XXX.Xs
XX.XxmA
1. Ground Continuity Check
If you are performing a Ground Continuity Check, the Ground Continuity must be set
to the “ON (Enabled)” position. The ground check cable has to be connected properly
to the chassis of the DUT and the green indicator on the TEST switch should be
illuminated before activating the Test switch. Otherwise, the instrument will signal a
continuity failure when the test switch is activated. Please refer to page 33 for the
proper test connections using the adapter box, to test items terminated in a threeprong plug.
The display will show:
CONT. MX XXX.Xs
- .- - KVAC - -.- - mA
If you are not performing a Ground Continuity Check, the Ground Continuity must be
set to the “OFF” (Disabled) position. It is not necessary to connect the “Cont. Check”
cable since this test will not be performed if the circuit is disabled. The instrument
will proceed with the Hipot Test when the “Test” switch is activated.
30
OPERATION
2. Initiating a Test
To initiate a test, press the TEST switch on the front panel. The red High Voltage
Arrow indicator will flash and the display will immediately show:
Ramp
MX XXX.Xs
X.XXKVAC XX.XxmA
o
r
Dwell
MX XXX.Xs
X.XXKVAC XX.XxmA
The instrument will continue to output the desired voltage for the duration of the
selected dwell time.
3. Short Circuit
If there is a short circuit in the DUT during the test, the red indicator light will
illuminate on the RESET switch and an alarm will sound. The display will show:
HI-LMT MX XXX.Xs
X.XXKVAC OFL mA
4. Flash Over
If a flash over occurs in the DUT during the test, which results in an OFL condition
due to the current exceeding the maximum metering range, Breakdown will be
indicated as follows. The red indicator light will illuminate on the RESET switch and
an alarm will sound. The display will show:
HI-LMT MX XXX.Xs
X.XXKVAC OFL mA
5. Leakage Current Exceeding the Metering Range
If the leakage current exceeds the metering range and neither a short circuit nor flash
over occurred, the red indicator light will illuminate on the RESET switch and an
alarm will sound. The display will show:
HI-LMT MX XXX.Xs
X.XXKVAC OFL mA
6. High Limit
If the leakage current exceeds the high limit setting, but does not exceed the metering
range, the red indicator light will illuminate on the RESET switch and an alarm will
sound. The display will show:
HI-LMT MX XXX.Xs
X.XXKVAC XX.XxmA
31
OPERATION
7. Low Limit
If the leakage current does not exceed the low limit setting, the red indicator light will
illuminate on the RESET switch and an alarm will sound. The display will show:
LO-LMT MX XXX.Xs
X.XXKVAC XX.XxmA
8. Resetting the Alarm
To stop the alarm, please press the RESET switch once. The alarm will stop and the
display will retain the failure information. If the RESET switch is pressed again, the
data on the display screen will be cleared and the display will indicate the setting data
from the last test. The instrument is now ready for the next test.
9. Pass
If the DUT passed the test, the instrument will output a short audible beep tone to
indicate the DUT has passed the test. The display will show:
Pass
MX XXX.Xs
X.XXKVAC XX.XxmA
The instrument is now ready to perform another test.
10. Aborting a Test
If the operator elects to abort a test in process, this can be accomplished by pressing
the RESET switch at anytime. The instrument will stop the test process immediately
and the display will show:
Abort
MX XXX.Xs
X.XXKVAC XX.XxmA
Press the TEST button to initiate another test.
32
OPERATION
ADAPTER BOX CONNECTION MODEL 2525
The following diagram shows how to connect the adapter box to the model 2525 and to
the device under test.
102-069-904
Connect 102-069-904
for two-prong linecord
Remove for
two-prong linecord
CHASSIS
99-10001-01
LINECORD
9 9 -1 0 0 0 5 -0 1
DUT I.E. AC FAN
The adapter box allows you an easy way to connect an item that is terminated in a two or
three-prong line cord. If you are testing a product which is terminated in a three-prong
plug, you are also required to perform a continuity or ground bond test on the ground
conductor of the DUT to the chassis or dead metal of the product. With the 2525, you
can perform both the hipot and continuity tests at the same time by activating the
continuity function on the instrument.
When the 2525 tests the ground conductor of the line cord, if the resistance of the ground
conductor exceeds 1, the hipot will signal a continuity failure. If continuity is present,
high voltage is applied to both conductors of the line cord to insure that all current
carrying conductors in the primary circuit are tested. When testing products with two
prong plugs, do not activate the continuity circuit.
33
REMOTE I/O
REMOTE INTERFACE FOR MODELS 2503/2510/2550
All inputs are connected through the 9-pin “D” type connector mounted on the back panel
of the unit. This connector mates with the standard 9-pin “D” type subminiature
connector included with the unit. For best performance, a shielded cable should be used.
To avoid ground loops, the shield should not be grounded at both ends of the cable.
The remote interface includes a SAFETY INTERLOCK. This interlock must be closed to
allow a test to start. The SAFETY INTERLOCK is wired between pins 4 and 5 of the
interface connector. For manual operation, the provided 9-pin “D” type connector has a
jumper between pins 4 and 5. This mating connector must be in place for manual
operation. For remote operation, the interlock can be appropriately connected to test
station guarding.
The interface allows remote operation of the TEST and RESET functions. A normally
open momentary switch across pins 3 and 5 allows remote operation of the TEST
function. A normally open momentary switch can also be wired across pins 2 and 5 to
allow remote operation of the RESET function. The TEST and RESET buttons on the
front panel remain active during remote operation.
The remote interface also provides signals to remotely monitor the PASS, FAIL, and
PROCESSING conditions. These signals are provided by three normally open internal
relays that switch on to indicate the current condition of the tester. These are normally
open, free contacts and do not provide any voltage or current. The ratings of these
contacts are 1Amp/120VAC (1Amp/24VDC).
The outputs are as follows:
Pins 1 and 6 provide the PROCESSING signal.
Pins 6 and 7 provide the PASS signal.
Pins 8 and 9 provide the FAIL signal.
A description of the output relay operation
follows:
PROCESSING – The relay contact closes the
connection between pin 1 and pin 6 while the instrument is performing a test. The
connection is opened at the end of a test.
PASS – The relay contact closes the connection between pin 6 and pin 7 after detecting
that the device under test passed the test. The connection is opened when the next test is
initiated or the reset function is activated.
FAIL – The relay contact closes the connection between pin 8 and pin 9 after detecting
that the device under test failed the test. The connection is opened when the next test is
initiated or the reset function is activated.
34
REMOTE I/O
REMOTE INTERFACE FOR MODEL 2525
Two 9 pin “D” type connectors are mounted on the rear panel which provide REMOTEINPUT-OUTPUT control and information. These connectors mate with standard 9 pin
D-subminiature connector provided by the user. The output mates to a male (plug)
connector while the input mates to a female (receptacle) connector. For best performance,
a shielded cable should be used. To avoid ground loops the shield should not be
grounded at both ends of the cable. Suggested AMP part numbers for interconnecting to
the Remote I/O are shown below.
205204-4
205203-3
745254-7
745253-7
745171-1
747784-3
PLUG SHELL WITH GROUND INDENTS
RECEPTACLE SHELL
CRIMP SNAP-IN PIN CONTACT (for plug)
CRIMP SNAP-IN SOCKET CONTACT (for receptacle)
SHIELDED CABLE CLAMP (for either plug or receptacle)
JACKSCREW SET (2)
Remote Interface Rear Panel:

35
Signal Outputs on Remote I/O
The rear panel connector provides three output signals to remotely monitor PASS,
FAIL, and PROCESSING conditions. The monitoring signals are provided by three
normally open internal relays, that switch on to indicate the current condition of the
tester. These are normally open free contacts and will not provide any voltage or
current. The ratings of the contacts are 1A / 250 VAC ( 0.5 ADC ). The signal outputs
are provided on the 9 pin female type D connector. Below is a listing that indicates
what conditions activate each pin. When a terminal becomes active the relay closes
thereby allowing the external voltage to operate an external device.
REMOTE I/O
Pins 1 and 2 provide the PASS signal.
Pins 3 and 4 provide the FAIL signal.
Pins 5 and 6 provide the PROCESSING signal.
The following describes how the relays operate for each test condition.
PROCESSING – The relay contact closes the connection between pin (5) and pin (6)
while the instrument is performing a test. The connection is opened at the end of the
test.
PASS – The relay contact closes the connection between pin (1) and pin (2) after
detecting that the item under test passed all tests. The connection is opened when the
next test is initiated or the reset function is activated.
FAIL – The relay contact closes the connection between pin (3) and pin (4) after
detecting that the item under test failed any test. The connection is opened when the
next test is initiated, or the reset function activated.

Signal Inputs on Remote I/O
The model 2525 remote connector enables remote operation of the TEST, RESET and
REMOTE INTERLOCK function. When the PLC remote function is (ON) the test
switch on the front panel will be disabled to prevent a test from being activated
through the test switch. A normally open momentary switch can then be wired across
pins 3 and 5 to allow remote operation of the TEST function. A normally open
momentary switch can also be wired across pins 2 and 5 which allows remote
operation of the RESET function. For safety, the front panel RESET switch remains
active even when a remote reset switch is connected so that high voltage can be shut
down from either location.
Remote Interlock is a feature that inverts the present reset logic on the instrument
from normally opened (must close contacts to activate the reset) to normally closed
(must open contacts to activate the reset). Hardware and software have been
configured to provide the interlock connections on pins 4 and 5 of the Remote
Interface, Signal Input port. This reset scheme is designed for use with an external
safety interlock device that utilizes a “Fail-When-Open” configuration on its output
interface. The instrument can still be used without the external reset device as long as
the Interlock Connector (provided with unit) is plugged into the Remote Interface,
Signal Input port. If there is nothing connected to the Remote Interface, Signal Input
port to provide a connection to the interlock (reset), then the instrument will not
function.
36
OPTIONS
MODELS 2503/2510/2550 OPTIONS
Introduction
This section contains a list and descriptions of available factory installed options at the
time of this printing. The list of options contains an option code number which can be
referenced on the model option label on the rear panel of the unit when options are
present.
Model Option Label
On the rear panel of the instrument, you will find a label that contains the option code.
For example, your options code would appear as follows:
fitted with option 01
OPT: 01
2503/2510/2550 Options
Option List
Code
01
37
Description
Ground Continuity
CALIBRATION
CALIBRATION PROCEDURE MODELS 2503/2510/2550
This instrument has been fully calibrated at the factory in accordance to our published
specifications. It has been calibrated with standards traceable to NIST. You will find in
this manual a copy of the "Certificate of Calibration". It is recommended that you have
this instrument recalibrated and a safety check done at least once per year. Slaughter
recommends you use "Calibration Standards" that are NIST traceable, or traceable to
agencies recognized by NIST to keep this instrument within published specifications.
End user metrology standards or practices may vary. These metrology standards
determine the measurement uncertainty ratio of the calibration standards being used.
Calibration adjustments can only be made in the Calibration mode and calibration checks
or verification can only be made while operation in Test mode.
Calibration Equipment Required:
The following standard equipment will be needed to properly calibrate your instrument.




A Standard AC Voltmeter with 5,000 Volts range (models 2510, 2550 only)
A Standard DC Voltmeter with 5,000 Volts range (model 2503 only)
A Standard AC Milliammeter with 10 mA range (models 2510, 2550 only)
A Standard DC Milliammeter with 3 mA range (model 2503 only)
1. Calibration Initialization
To enter the calibration mode the instrument must be in the OFF position. Using a pen or
small screwdriver, press and hold the recessed calibration key on the rear panel, then turn
on the input POWER switch. The display will show: CAL.
2. To calibrate AC Voltage (models 2510, 2550 only)
Please connect a standard 5000V AC Voltmeter to the HV and RETURN connectors.
Then press the SET key on the front panel. The instrument will provide around 5000VAC
on the output connectors. The display will show a voltage around 5000 V.
Press the Up () or Down () arrow keys to enter the reading of the standard AC
Voltmeter into the instrument. Then press SET key to store the voltage setting or press
the RESET button or EXIT key to return to the calibration menu without changing the
calibration setting. Press the EXIT key again to exit from the calibration mode and to
return to the test mode.
3. To calibrate DC Voltage (models 2503 only)
Please connect a standard 5000V DC Voltmeter to the HV and RETURN connectors.
Then press the SET key on the front panel. The instrument will provide around 5000VDC
on the output connectors. The display will show a voltage around 5000 V.
Press the Up () or Down () arrow keys to enter the reading of the standard DC
Voltmeter into the instrument. Then press SET key to store the voltage setting or press
38
CALIBRATION
the RESET button or EXIT key to return to the calibration menu without changing the
calibration setting. Press the EXIT key again to exit from the calibration mode and to
return to the test mode.
4. To calibrate AC Current (models 2510, 2550 only)
Please connect a load resistor (200 k for 2510 and 2550) in series with the standard
10mA AC Milliammeter and connect these across the HV and RETURN connectors of
the instrument.
Press the Down () arrow key to initiate the calibration process. The instrument will
provide around 1000V on the output connectors. The display will show some current.
Press the Up () or Down () arrow keys to enter the reading of the standard AC
Milliammeter into the instrument. Then press SET key to store the current setting or press
the RESET button or EXIT key to return to the calibration menu without changing the
calibration setting. Press the EXIT key again to exit from the calibration mode and to
return to the test mode.
5. To calibrate DC Current (models 2503 only)
Please connect the 400 k load resistor in series with the standard 3 mA DC
Milliammeter and connect these across the HV and RETURN connectors of the
instrument.
Press the Down () arrow key to initiate the calibration process. The instrument will
provide around 1000V on the output connectors. The display will show some current
around 2.5 mA.
Press the Up () or Down () arrow keys to enter the reading of the standard DC
Milliammeter into the instrument. Then press SET key to store the current setting or press
the RESET button or EXIT key to return to the calibration menu without changing the
calibration setting. Press the EXIT key again to exit from the calibration mode and to
return to the test mode.
39
CALIBRATION
CALIBRATION PROCEDURE MODEL 2525
This instrument has been fully calibrated at the factory in accordance to our published
specifications. It has been calibrated with standards traceable to NIST. You will find in
this manual a copy of the "Certificate of Calibration". It is recommended that you have
this instrument recalibrated and a safety check done at least once per year. Slaughter
recommends you use "Calibration Standards" that are NIST traceable, or traceable to
agencies recognized by NIST to keep this instrument within published specifications. End
user metrology standards or practices may vary. These metrology standards determine the
measurement uncertainty ratio of the calibration standards being used.
Calibration Equipment Required:
The following equipment will be needed to properly calibrate your instrument.

Digital Multimeter with the minimum ranges;
AC Voltage: 5,000 volts
AC Current: 100mA range.

10K/100Watt resistor
100K/10Watt resistor
To enter the calibration mode the instrument must be in the OFF position. Using a pen or
small screwdriver, press and hold the recessed calibration key on the rear panel, then turn
on the Input Power Switch.
For model 2525 the display will show:
CAL Mode
SET:V :A
Press the SET key for kilovolts calibration, Down Arrow key () for milliamps.
Equipment needed: STANDARD AC VOLTMETER capable of measuring 5000VAC.
Please connect a standard ac voltmeter with 5000V minimum full-scale range to the high
voltage and return connectors.
Then press the SET key on the front panel. The instrument will provide around
5000VAC on the output connectors and the display will show:
Voltage=
XXXX V
40
CALIBRATION
Please use the Up/Down Arrow keys to enter the reading off the AC Voltmeter, into the
instrument. Then press the SET key to store the voltage setting. Press the EXIT or
RESET key to return to the calibration menu without changing the calibration setting.
The instrument will output two short “beeps” when attempting to save a missing or bad
parameter and will not allow return to the calibration menu.
1. Calibration of Dielectric Withstand Current
Equipment needed: STANDARD AC MILLIAMMETER with a range of 100mA and a
fixed Resistor 10K Ohms, 100 watts.
Please connect a 10K resistor in series with the standard ac milliammeter and connect
these across the output leads of the instrument. Press the Down Arrow key. The
instrument will provide around 1000VAC on the output and the display will show:
Current= X.XX mA
Please use the Up/Down Arrow keys to enter the reading of the standard AC
milliammeter, into the instrument. Then press the SET key to store the current setting.
Press the EXIT or RESET key to return to the calibration menu without changing the
calibration setting.
The instrument will output two short “beeps” when attempting to save a missing or bad
parameter and will not allow return to the calibration menu.
2. Save Calibration
After the calibration, the instrument has to be turned off to save the calibration
parameters. The power must be turned off and on again to switch from the calibration
mode to the run mode.
41
PARTS LIST
REPLACEMENT PARTS LIST
Rev: C, 12/18/2013 ECO 5671
Part Number
Qty
Reference
Designator
Models 2503, 2510, 2550
102-050-913
1
102-069-904
1
125-013-001
1
175-974-003
4
99-10312-01
1
330-113-001
1
330-113-002
1
575-704-001
1
DSP-11
575-705-001
1
99-10016-01
1
99-10017-01
1
99-10018-01
1
99-10681-01
1
Models 2503, 2510, 2550
575-701-001
1
AMP-2510
575-703-001
1
CSW-06
99-10097-01
1
150-135-003
1
Models 2503, 2510, 2550
102-055-913
1
99-10040-01
1
Models 2503, 2510, 2550
99-10124-02
1
2510
575-691-004
1
CGC-04
Model 2510, 2550
240-061-003
1
T1
200-057-003
1
T2
Model 2503
575-702-001
1
HV-2503
240-061-002
1
T1
200-057-002
1
T2
Model 2550
99-10098-01
1
HV-2550
Model 2525 only
99-10625-01
1
CHV-4500
99-10324-01
1
CKB-06
Description
High Voltage Probe (6ft.)
Return Lead (6ft.)
Input Power Cable (6ft.)
Leg
Power Switch
Test Switch
Reset Switch
Display Board
Red LED
Earth Connector
Return Connector
High Voltage Connector
Microcontroller, 8-bit (89516AC25J)
Power Amplifier Board
Input Protection Board
Fuse, 2A, 250V, 5x20mm, Fast Blow
Fuse Holder (20mm)
High Voltage Clip (6ft.)
Interlock Connector
Main Control Board
Ground Continuity Check Board
Input Transformer
High Voltage Transformer, 5.5kV, 10mA
High Voltage Control Board
Input Transformer
High Voltage Transformer, 4kV, 8mA
High Voltage Control Board
High Voltage Control Board
Keyboard Assembly
42
PARTS LIST
Part Number
Qty
575-728-001
99-10624-01
99-10179-01
99-10148-01
99-10016-01
99-10017-01
99-10631-01
175-946-013
175-974-002
99-10168-01
99-10057-01
330-118-001
330-113-001
330-113-002
99-10040-01
200-060-001
99-10632-01
99-10164-01
102-055-913
99-10017-01
99-10031-01
99-10671-01
99-10672-01
1
1
1
1
1
4
2
1
4
1
1
1
1
1
1
1
1
1
1
2
1
1
1
43
Reference
Designator
CSW-05
4500
AMP-510
REC-19
T-4500-T2
T-4500-T1
U9
Test/Pass
Reset/Fail
Description
Input Protection Board
Main Control Board
Power Amplifier Board
Rectifier Board
Earth Connector
Black Banana Jacks
High Voltage Connector
Feet Kit w/o Rubber Inserts
Rubber Insert for Feet
Fuse 15A, 250V, Fast Blow, 20 mm
LCD Display 16 x 2 Characters
Power Switch 2P 10A/250V
Test Switch, Green
Reset Switch, Red
Interlock Connector Std. M/F
Output High Voltage Transformer
Input Transformer
Input Power Cable 15A/6Ft.
High Voltage Output cable
Return/Continuity cable
Microcontroller 8 Bit P89C52
Replacement Bulb
Replacement Bulb
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