MODEL IRM-5000 USER’S MANUAL

MODEL IRM-5000 USER’S MANUAL

INSULATION-RESISTANCE METER

USER’S MANUAL

Vanguard Instruments Company, Inc.1824 East Elma Court

Ontario, California 91764

September 1999


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SAFETY SUMMARY

The following are general safety precautions that may not relate to a specific procedure andtherefore may not appear elsewhere in this document. These are recommended precautions thatpersonnel must understand and apply during many phases of IRM-5000 operation andmaintenance. The IRM-5000 operates at dangerous voltages, which may be lethal or causeinjury. Personnel should become completely familiar with all controls and indicators, test setups,procedural steps, and all safety precautions. The Model IRM-5000 should only be operated bypersonnel trained in its use.

KEEP AWAY FROM LIVE CIRCUITSOperating and maintenance personnel must observe all safety regulations at all times. Thedevice under test must be turned off (de-energized) and electrically isolated before anyconnection to the IRM-5000 is made. Never touch the IRM-5000 connections during testing(i.e., do not touch test connections while the power is turned on and the unit is ready for testingand capable of generating a lethal shock). Wait until the device being tested is completelydischarged after each test (one minute or more) before disconnecting any test lead.In some instances, the circuit or insulation being tested may break down and cause the test toterminate (and also cause a display failure) while the test circuit remains energized. When thishappens, it is necessary to allow the test circuit enough time to discharge and the IRM-5000 to beturned off before personnel touch any connection.

IRM-5000 CARE AND TEST PRECAUTIONSThe area around the IRM-5000 charging circuits and test terminals must be kept clean and dry toprevent high-voltage leakage paths, which can cause hazardous conditions or erroneousmeasurements. When performing operator maintenance (e.g., replacing fuses or batteries), it isextremely important that these components only be replaced with identically functioning parts.Failure to heed this precaution may result in unsafe operating conditions, cause erroneous testresults, and will void the Vanguard Instruments Company warranty.

DO NOT SERVICE OR ADJUST ALONEUnder no circumstances should any person touch the Model IRM-5000 for the purpose ofservicing or adjusting test setups except in the presence of someone who is capable of renderingaid.

RESUSCIATIONPersonnel working with or near high voltages should be familiar with modern methods ofresuscitation as specified by most electrical utility companies.


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TABLE OF CONTENTSSAFET SUMMARY1.0 FUNCTIONAL DESCRIPTION

1.1 Test Voltage1.2 High-Voltage Warning Display and Audible Alarm1.3 Capacitor Discharge1.4 Voltmeter1.5 Keypad1.6 LCD Display1.7 Built-in Thermal Printer1.8 Test Report Storage Capability1.9 Computer Interface1.10 Temperature Probe1.11 Power Source1.12 Test Terminals1.13 Test Probes1.14 Replacement Parts

2.0 TEST MODE SUMMARY2.2 Insulation Resistance (R) Test2.2 Polarization Index (PI) Test2.3 Step Voltage (SV) Test2.4 Dielectric Discharge

3.0 OPERATING PROCEDURES3.1 Insulation-Resistance Test Procedure Using Standard Voltages3.2 Insulation-Resistance Test3.3 Insulation-Resistance Test-in-Progress Display3.4 Typical Resistance Test Printout3.5 Typical Resistance Plot and Current Plot3.6 Polarization Index (PI) Test Using Standard Voltages3.7 PI Test-in-Progress Display3.8 Polarization Index Test Final Display3.9 Polarization Index (PI) Test Printout3.10 PI Resistance and Current Plot3.11 Step Voltage (SV) Test3.12 Step Voltage Test-in-Progress Display3.13 Step Voltage Test Result display (Screen #1)3.14 Step Voltage Test Printout3.15 Step Voltage Test Resistance and Current Plots3.16 Dielectric Discharge (DD) Test3.17 Dielectric Discharge Test Result3.18 Dielectric Discharge Test Printout3.19 Dielectric Discharge Voltage vs Time and Current vs Time3.20 Save Test Report in Memory3.21 Print Test Report Directory3.22 Recall Test Report From Memory3.23 Print Tabulated Test Report3.24 Print Graphic Test Report3.25 Delete a test Report from Memory3.26 Computer Interface

APPENDIX A Polarization Index RatioAPPENDIX B Dielectric Discharge RatioAPPENDIX C Guard Terminal Application


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LIST OF TABLES

Table 1-1. IRM-5000 SpecificationsTable 1-2. Serial Port Pin assignmentsTable 1-3. Power Source Jumper SelectionsTable 1-4. IRM-5000 Controls and DisplaysTable 3-1. Insulation Resistance Test ProcedureTable 3-2. Polarization Index (PI) Test ProcedureTable 3-3. Step Voltage (SV) Test ProcedureTable 3-4. Dielectric DischargeTable 3-5. Save Test Report in MemoryTable 3-6. Print Test-report Directory ProcedureTable 3-7. Recalling a Test reportTable 3-8. Printing a Test ReportTable 3-9. Printing a Graphic ReportTable 3-10. Delete a Test Report from MemoryTable 3-11. Putting the IRM-5000 under Computer Control


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1.0 FUNCTIONAL DESCRIPTIONVanguard Instruments Company’s Model IRM-5000 Meg-ohmmeter is a microprocessor-based,high-voltage, insulation-testing meter. The Model IRM-5000 is rugged and portable, making itideal for use in electrical utility substations and in many industrial applications.This sophisticated insulation tester uses a dual-microprocessor design. One processor isdedicated to the control of the power supply and measuring circuitry. The second microprocessoris dedicated to the display, printer control, and user interfaces. These microprocessors interfacewith each other via an optical link to ensure the operator’s safety and isolation from the highvoltage inside the unit.

1.1 Test VoltageThe IRM-5000 can run tests with preset voltages (500, 1000, 2500, and 5000 V dc), or can berun with user-selected voltages ranging from 50 V dc to 5000 V dc with a resolution of ±1 V dcresolution.

1.2 High-Voltage Warning Display and Audible AlarmA High-Voltage warning LED display indicates when high voltage is present at the testterminals. An Audible alarm indicates that a test is in progress.

1.3 Capacitor DischargeThe IRM-5000 automatically discharges any test-voltage charge left on the test material aftereach test. The High Voltage LED display warns the operator of the shock hazard that existsduring each discharge period.

1.4 VoltmeterThe IRM-5000 test-terminal voltage is always displayed on the LCD screen. Thus, the user canuse the IRM-5000 as a voltmeter. Measurable voltage input ranges from 50 to 1250 volts, ac ordc.

1.5 KeypadAn alpha-numeric keypad allows users to enter test ID numbers and control functions.

1.6 LCD DisplayA back-lighted 4-line by 20-character LCD screen displays test data and user messages. TheLCD back light turns itself off after 45 seconds to conserve energy. The LCD back light can berestored by pressing any key on the keypad.

NOTE1. The LCD contrast control can be programmed by the user from the keypad: Pressing the key

“↑” key for more than 3 seconds will darken the LCD screen. Pressing the “↓” for more than3 seconds will lighten the LCD screen.

2. Pressing then releasing the “↑” will advance the paper.


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Table 1-1. IRM-5000 Specifications

TYPE Insulation Resistance Meter, Y2K Compliant

SIZE 18 L by 15 W by 7 H (inches)

WEIGHT 18 pounds

RESISTANCE RANGE +5% 1 M to 1 T ohm @ 5 kV+5% 1 M to 100 G ohm @ 500 V+5% 1 M to 10 G 0hm @ 50V+20% 100 k to 1 M ohm @ 5 kV+20% 1 T to 5 T ohm @ 5 K V+20% 100 K to 1 M ohm @ 500 V+20% 100 G to 500 G ohm @ 500 V

TEST VOLTAGE (Vdc) 500 V, 1000 V, 2500 V, 5000 VOr selectable from 50 V to 5 kVdc in 1 V steps

OUTPUT VOLTAGE +2% +1V of selected voltageACCURACY with load resistance >100 M ohm(0 °C to 30 °C)

SHORT-CIRCUIT CURRENT 2 mA max

LEAKAGE-CURRENT 0.03 nA to 1.0 mARANGE Accuracy +5% ±0.2 nA (0 oC to 30 oC)

CAPACITANCE RANGE 0.01 uF to 10.0 uF (Test voltage >100 Vdc)Accuracy +15% + 0.03 uF (0 oC to +30 oC)

VOLTAGE READING 50-1250 V ac (rms) or DCRANGE Accuracy +5%, +1V (0 oC to +30 oC)

CAPACITOR DISCHARGE <2 Sec/uF, automatic discharge at the end of test

HUM REJECTION 1 mA rms per 1KV test voltage, not to exceed 2 mA rms maximum

BATTERIES Two 12 V, 2.2 Ah, sealed, lead-acid batteries. Battery life is typically6 hours of continuous testing. Unit can be operated during charging.

AC INPUT 110-120 Vac 50/60 Hz or 220-240 Vac 50/60 Hz, Selectable.


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1.7 Built-in Thermal PrinterA built-in thermal printer prints test results on 2½-inch-wide thermally sensitive paper. Testresult reports are printed in both tabular and graphic formats.

1.8 Test-Report Storage CapabilityThe Model IRM-5000 uses Flash Electrically Erasable PROMS (i.e., EEPROM) to store testreports in memory. Stored test results can be recalled later by the user to reanalyze test data, toprint test reports, or to transfer data to an IBM-compatible PC for record keeping. Up to 90 testreports can be stored in the EEPROMs.

1.9 Computer InterfaceAn RS-232C port can be used to interface with an IBM-compatible PC. A Windows-basedInsulation-Resistance Analysis program lets users retrieve test reports stored in the IRM-5000.Thus, the user can generate test reports with an office-based computer. A special feature of thesoftware allows the user to overlay several resistance curves on a color monitor. This featureallows the user to monitor the resistance deterioration of a test material over time.An RS-232C cable is also furnished with the unit. The IRM-5000 requires a 9-pin, D-type,male-to-female connector. The IRM-5000 RS-232C port connector pin outs are shown in Table1-2 below:

Table 1-2. Serial Port Pin Assignments

PIN SIGNAL2 Tx Data3 Rx Data

5 Gnd

1.10 Temperature ProbeA non-contacting infrared temperature probe allows users to record the test-material temperature.Recording the temperature of the device under test (DUT) lets the IRM-5000 convert therecorded resistance to the equivalent resistance reading at 40 °C. This feature lets the usercompare the resistance reading of DUT regardless of the temperature at which the reading wastaken.

NOTEA Fluke IR temperature probe, Model 80T-IR is furnished with each IRM-5000.

1.11 Power SourceThe Model IRM-5000 can operate from its internal, sealed, rechargeable, lead-acid batteries or itcan be operated from an external power source. The lead-acid batteries provide up to 6 hours ofcontinuous operation. An isolated transformer allows the IRM-5000 to be used during batterycharging. The user can select 110/220 V, 50/60 Hz or 220/440 V, 50/60 Hz power sources.


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Table 1-3. Power Source Jumper Selections

VOLTAGE SELECTION JUMPER 1(CPU PCB)

TRANSFORMER

120 V ac Pin 1&2, 3&4 Pin 1&2, 3&4240 V ac Pin 2&3 Pin 2&3

1.12 Test TerminalsThe IRM-5000 has three test terminals: POS, NEG, and GUARD. For measurements up to100GΩ, the user can make measurements using the POS and NEG terminals. For higherresistance-reading applications, the user may want to use the GUARD terminal to remove anysurface-leakage current affecting the measurement. For an additional explanation about theGUARD terminal, refer to Appendix C.

1.13 Test ProbesThree 5-foot long-voltage test probes are furnished with each IRM-5000.

WARNINGDo not touch test probes of the IRM-5000 during testing. Failure to heed this warning can causea lethal shock, resulting in death, or may cause a serious injury.


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Figure 1-1. IRM-5000 Controls and Indicators


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Table 1-4 IRM-5000 Controls and Displays

FigIndex no PANEL MARKING FUNCTIONAL DESCRIPTION

1 TEMPERATURE PROBE Connector, 4-pin

2 (Display, no panel marking)

3 CHARGER Battery charging indicator

4 120 Vac, 6A, 50/60HzFuse: 250Vac, 1A Fast-Blow

Power plug and fuse holder

5 (Printer, no panel marking) Thermal printer, prints on especially treated2.5-inch-wide paper.

6 POS Positive test lead terminal

7 NEG Negative test lead terminal

8 GUARD Guard test lead terminal

9 1-9, 0, ENTER, START, STOP, CLEAR, ↑↓ Keypad, 16-key; Keys are momentarycontact membrane switches: make menuselections, enter alpha-numeric data, andmove paper

10 HIGH VOLTAGE PRESENT Red LED indicator: Flashes when highvoltage is present at test terminals

11 RS-232C Connector, 9-pin: RS-232C computerinterface

12 POWER Power switch


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1.14 Replacement PartsWhen performing operator maintenance (e.g., replacing fuses or batteries), it is extremelyimportant that these components be replaced only with identically functioning parts. A list ofpart numbers and manufacturers of authorized replacement parts appears below. Failure to heedthis precaution by replacing defective parts with other than those listed can result in unsafeconfigurations and operating conditions, erroneous test results, and will void the VanguardInstruments Company warranty.

Front Panel AC voltage fuse: Replace this fuse with a 250 Vac, 1.0 A, Fast-Blow only.

High Voltage PCB fuse (F1): Replace this fuse with a 250 Vac , 1/10A, Fast-Blow only.

High Voltage PCB fuse (F2): Replace this fuse by a 250Vac, 2.0A, Fast-Blow only.

Rechargeable battery:, Panasonic P/N LC-R122RCPU (12V, 2.2 ah/20 HR) only.


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2.0 TEST MODE SUMMARY

2.1 Insulation Resistance ( R ) TestThis test measures insulation resistance at the selected test voltages to provide an instantaneousresistance reading.

2.2 Polarization Index (PI) TestThis test measures the ratio of insulation resistance after 1 minute and after 10 minutes. PolarityIndex is derived by the resistance ratio of the two periods (i.e., the resistance value at 10 minutesdivide by the resistance value at 1 minute). See Appendix A for more details.

2.3 Step Voltage (SV) TestThis test is based on an ideal insulator producing the same resistance measurement at allvoltages. As an example, an insulator that is over stressed will measure lower resistance valuesat the higher voltages. Accordingly, the resistances measured on an over-stressed insulator atincreasingly higher voltages (steps) will produce decreasingly lower resistance values.A typical Step Voltage test duration is 5 minutes. The IRM-5000 will sequentially takeresistance readings of the DUT at one-fifth increments of the final test voltage at 1-minuteduration each.Default test voltage is selectable at 2,500 V dc or 5,000 V dc. The user can also select a specificvoltage and time as desired.

2.4 Dielectric Discharge (DD) TestThis test measures the dielectric absorption of the tested material. The default test requires 30minutes of applying the full voltage followed by a 1-minute discharge of the DUT. The DDvalue is calculated from the formula:

Refer to Appendix B for more details.

eCapacitanc VoltageTest

(mA) minute after1Current RATIO DD

×=


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3.0 OPERATING PROCEDURES

3.1 Insulation-Resistance Test Procedure Using Standard Voltages

This test measures insulation resistance at selected voltages. Since the insulation resistance iscontinuously monitored during this test, users can plot resistance value vs time or current vstime. The following table provides the procedure for measuring Insulation Resistance.

Table 3-1. Insulation Resistance Test Procedure

STEP DESCRIPTION ACTION RESULTING DISPLAY1 Initiate Resistance Test Select key “1” 1. R 2. PI

3. DD 4.SVTERMINAL VGT: 0V

2 Select Resistance Test Select key “1” 1. 10 MIN 2. 20 MIN3. 30 MIN 4. CustomTERMINAL VTG: 0V

3 Select 10 Minute Test Select key “1” 1. 500V 2. 1000V3. 2500V 4 5000V5.CustomTERMINAL VTG: 0V

4 Select 500V Test Voltage Select key “1” READ D.U.T. TEMP?1. YES 2. NO3. ENTER MANUALLYTERMINAL VTG: 0V

5 Measure DUT Temp Select key #1Turn on IR Temp SensorAnd measure DUT temp.

“ENTER” To accept 80 FTERMINAL VTG: 0V

6 Register DUT Temp Select “ENTER” ACCEPT THIS: 80 F1. YES 2. NOTERMINAL VTG: 0V

7 Accept Temp Reading Select “1” PLEASE TURN OFF TEMP PROBE NOWTERMINAL VTG: 0V

8 Start Test! Select “ENTER” “ENTER” TO STARTR 500 Volts 10 MinTERMINAL VTG: 0V

9 Confirm Test Now Select “ENTER” Bat: --- Time: 09:39Resistance: 2.0160 TCurrent: 0.243 nATEST VOLTAGE: 503V

10 View Test Results None Res=2.082T 0.243nA504V 0.00uF

11 Print Test Report Select “ENTER” PRINT REPORT?1.YES 2.NOTERMINAL VTG: 0V

12 Confirm Print Select “1” PRINTING REPORTTERMINAL VGT: 0V

13 Get Test Report From Printer Tear Paper Off. 1. RUN TEST 08/09/992. UTILITIES 20:09:01Bat ----TERMINAL VTG: 0V

Table 3-1 notes:1. To select a custom test time, select “4” in step 2. Test duration is selected in minutes.2. To select a custom test voltage, select “5” in step 3. Select test voltage from 50 V dc to 5000

V dc.3. If no temperature measurement is required, Select “2” in step 4.4. User can enter temperature manually by selecting “3” in step 4.5. Test Terminal voltage is always shown at the bottom of the screen.


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3.2 Insulation-Resistance Test In Progress Display

A typical Insulation Resistance Test-in-Progress display is shown in Figure 3-1.

Bat:------- Time: 09:39Resistance: 516 MCurrent: 4.87 uATEST VOLTAGE: 2505V

Figure 3-1. Typical Insulation Resistance Display

Figure 3-1 example display readout data are interpreted as follows:

1. Battery Capacity is shown on Bat: -------. A discharged battery symbol is shown as a blankbattery

2. Remaining time of test is shown as Time: xx.xx (in minutes and seconds).3. Current resistance value is shown as Resistance:516 M4. Resistance value symbol: M is for Meg-ohm, T is for Tera-Ohm, K is for 1000 Ohms.5. Test Current is shown as Current: 4.87 uA6. Test voltage is shown on line 4 as TEST VOLATGE: 2505V.


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3.3 Insulation-Resistance Test Final Display

A typical Insulation Resistance result display is shown on Figure 3-2.

Res=515M 4.87 uA2505V 0.00uF 10.00

TERMINAL VTG: 0V

Figure 3-2. Typical Insulation Resistance Result Display


1. Final resistance value is shown as Res=515M2. Test current is 4.87uA3. Test voltage is shown on second line: 2505V4. Discharge capacitance is shown as 0.00uF (no capacitance in DUT)5. Test duration is 10.00 minute6. Terminal voltage is shown on line 4 as: TERMINAL VTG: 0V


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3.4 Typical Resistance Test Printout.

A typical Insulation Resistance printout is shown in Figure 3-3 (below).

Figure 3-3. Typical Resistance Printout

Figure 3-3 example display of readout data are interpreted as follows:

1. Time and Date of test are shown on top of test report.2 Test record ID is shown in the first box of test report.3 Final resistance value is shown as FINAL TEST RES: 515 M (515 Meg-Ohm)4 Final test voltage is shown on the second line as FINAL TEST VOLTAGE: 2505 V5 “Test capacitance“ displays capacitance value (in Micro-Farads) of the device under test

(measured during discharge). In this case no capacitance was detected (0.00 uF).6 “Test Duration” is identified under TEST DURATION: 10.00 MIN7 Device under test temperature (measured by IR sensor) is shown as: D.U.T

TEMPERATURE: 85 °F8 Equivalent resistance value @ 40 °C is also shown as: EQUIV RES @ 40 °C: 284M (284

Meg-Ohm)9 HUM Rejection is set for 60Hz


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3.5 Typical Resistance Plot and Current Plot.

A typical Resistance vs time and Current vs time plot for an Insulation Resistance test is shownin Figures 3-4 and 3-5.

Figure 3-4. Resistance vs Time Plot

Figure.3-5. Current vs Time Plot


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3.6 Polarization Index (PI) Test Using Standard Voltage

The Polarization Index test is derived from the ratio of insulation resistance value at 10 minutesdivided by the insulation value at 1 minute. Users can use standard voltages: 500 V, 1000 V,2500 V, 5000 V, or any selectable voltage from 50V to 5000V.The default test time is 10 minutes, however the user may select any test duration from 10 to 99minutes.

Table 3-2. Polarization Index (PI) Test Procedure

STEP DESCRIPTION ACTION RESULTING DISPLAY1 Initiate PI Test Select key “1” 1. R 2. PI


2 Select PI Test Select key “2” 1.10 MIN (Default) 2. CustomTERMINAL VTG: 0V

3 Select 10 Minute Test Select key “1” 1. 500V 2. 1000V3. 2500V 4 5000V5.CustomTERMINAL VTG: 0V






8 Start Test ! Select “ENTER” “ENTER” TO STARTPI 500 Volts 10 MinTERMINAL VTG: 0V


10 View Test Results None Res=2.082T PI=1.0504V 0.00uF



13 Get Test Report From Printer Tear Paper Off 1. RUN TEST 08/09/992. UTILITIES 20:09:01Bat ----TERMINAL VTG: 0V

Table 3-2 notes:

1. To select a custom test time, select “2” on step 2. Test duration is selected in minutes.2. To select a custom test voltage, select “5” on step 3. Test voltage is selectable from 50Vdc to

5000Vdc.3. If no temperature measurement is required, Select “2” in step 4.4. User can enter temperature manually by selecting “3” in step 4.5. Test Terminal voltage is always shown at the bottom of screen.


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3.7 PI Test In Progress Display

A typical PI Test-in-Progress LCD screen display is shown in Figure 3-4 (below).

Bat:------- Time: 09:39Resistance: 2.055 GCurrent: 0.488 nATEST VOLTAGE: 1005V

Figure 3-6. Typical PI Test-in-Progress Display


1. Battery Capacity is shown on Bat: -------. Discharged battery is shown as a blank batterysymbol.

2. Remaining time of test is shown as Time: xx.xx (in minutes and seconds).3. Current resistance value is shown as Resistance: 2.055 G4. Resistance value symbol: M is for Meg-ohm, T is for Tera-ohm, K for 1000 ohm G is for

Giga-ohm.5. Test Current is shown as Current: 0.488 nA.6. Test voltage is shown on line 4 as TEST VOLATGE: 1005V.


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3.8 Polarization Index Test Final Display

A typical Polarization Index Test result display is shown on Figure 3-7.

Res=3.012 G PI=1.471005V 0.00uF 10.00

TERMINAL VTG: 0V

Figure 3-7. Typical Polarization Index Result Display

Figure 3-7 example display of readout data are interpreted as follows:

1. Final resistance value is shown as Res=3.012G.2. PI value is PI=1.473. Test voltage is shown on second line: 1005V.4. Discharge capacitance is shown as 0.00uF.5. Test duration is 10.00 minutes.6. Terminal voltage is shown on line 4 as TERMINAL VTG: 0V


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3.9 Polarization Index (PI) Test Print Out

A typical Polarization Index Test printout is shown in Figure 3-8 (below).

Figure 3-8. Typical Polarization Index (PI) Test Printout


1. Time and Date of test are shown at top of test report.2. Test record ID is shown in the first box of test report.3. Polarization Index Ratio is shown as PI: 1.47.4. Resistance value at 1 minute is shown as RES @ 1:00=2.055 G (2.055 Giga Ohm)5. Resistance value at 10 minute is shown as RES @ 10:00= 3.012 G (3.012 Giga ohm).6. “Test capacitance“ displays capacitance value of the device under test (measured during

discharge). TEST CAPACITANCE: 0.00uF7. “Test Duration” is identified under TEST DURATION: 10:00 MIN.


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3.10 PI Resistance and Current Plot

Typical Resistance vs Time and Current vs Time plots for a PI test are shown in Figures.3-9 and3-10.

NOTEThe one-minute marker is highlighted on both the resistance and the current plots.

Figure 3-9. PI Resistance Plot

Figure 3-10. PI Current Plot


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3.11 Step Voltage (SV) Test

For the Step Voltage Test, the IRM-5000 measures the Insulation Resistance at 5 differentvoltages. The default test duration for each test voltage is 1 minute or a total test time of 5minutes. A non-standard test time can be selected by the user. Using the standard 2,500V testvoltage, the IRM-5000 will step through 500V, 1,000V, 1,500V, 2,000V, and 2,500V.Using the 5,000V test voltage, the IRM-5000 will step through 1,000V, 2,000V, 3,000V,4,000V, and 5,000V.

Table 3-3. Step Voltage (SV) Test Procedure

STEP DESCRIPTION ACTION RESULTING DISPLAY1 Initiate SV Test Select key “1” 1. R 2. PI


2 Select SV Test Select key “4” 1. 5 MIN (Default) 2. CustomTERMINAL VTG: 0V

3 Select 5 Minute Test Select key “1” 1. 2500V 2. 5000V3. CustomTERMINAL VTG: 0V






8 Start Test ! Select “ENTER” “ENTER” TO STARTSV 2500 Volts 5 MinTERMINAL VTG: 0V

9 Confirm Test Now Select “ENTER” Bat: --- Time: 09:39Resistance: 98.8 MCurrent: 0.243 nATEST VOLTAGE: 503V

10 View Test Results None 98.9M @ 01:00, 500V2509V 0.00F 05:00

11 View Test Results Select “ENTER” key 99.9M @ 02:00, 1007V2509V 0.00F..05:00

12 View Test Results Select “ENTER” key 100M @ 03:00, 1509V2509V 0.00F 05:00

13 View Test Results Select “ENTER” key 99.9M @ 04:00, 2009V2505V 0.00F 05:00

14 View Test Results Select “ENTER” key 99.9M @ 05:00, 2505V2509V 0.00F 05:00



17 Get Test Report From Printer Tear Paper Off 1. RUN TEST 08/09/992. UTILITIES 20:09:01Bat ----TERMINAL VTG: 0V


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3.12 Step Voltage Test-In-Progress Display

A typical SV Test-in-Progress LCD screen display is shown on Figure 3-11 (below).

Bat:------- Time: 09:39Resistance: 98.9 MCurrent: 0.243 nATEST VOLTAGE: 500V

Figure 3-11. Typical Step-Voltage Test-in-Progress Display


1. Battery Capacity is shown on Bat: -------. Discharged battery is shown as a blank batterysymbol.

2. Remaining time of test is shown as Time: 09.39 (in minutes and seconds).3. Current resistance value is shown as Resistance: 98.9 M (98.9 Meg-Ohm)4. Test Current is shown as Current: 0.243 nA.6. Test voltage is shown on line 4 as TEST VOLATGE: 500V.


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3.13 Step Voltage Test Result Display (Screen #1)

A typical Step Voltage Test result display is shown on Figure 3-12.

98.9M @ 01:00, 500V2509V 0.00F 5:00

Figure 3-12. Typical Step Voltage Test Result Display

Figure 3-12 example display readout data are interpreted as follows:1. Final resistance value at one minute is shown as Res=98.9M.2. Test voltage during the first minute is 500V.3. Final test voltage is shown on second line as: 2509V.4. Discharge capacitance is shown as 0.00uF.5. Test duration is 5.00 minutes.

NOTES1. To view the next resistance reading, press the ENTER key.2. Screen #1 displays the resistance reading of test at 500V , first minute duration.3. Screen #2 displays the resistance reading of test at 1007V , second minute duration4. Screen #3 displays the resistance reading of test at 1509V , third minute duration.5. Screen #4 displays the resistance reading of test at 2009V , fourth minute duration6. Screen #5 display she resistance reading of test at 2509V , fifth minute duration


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3.14 Step Voltage Test Print Out

A typical Step Voltage Test printout is shown in Figure 3-13 (below).

Figure 3-13. Typical Step-Voltage Test Printout


1. Time and Date of test are shown at top of test report.2. Test record ID is shown in the first box of test report.3. Resistance value tested at 500v in the first “one-minute” is shown as:

AT 01:00, 500V, R=98.9 M4. Resistance value tested at 1007V in the second “one-minute” is shown as:

AT 02:00, 1007V, R=99.9 M5. Resistance value tested at 1509V in the third “one-minute” is shown as:

AT 01:00, 1509V, R=100 M6. Resistance value tested at 2009V in the fourth “one-minute” is shown as:

AT 01:00, 2009V, R=99.9 M7. Resistance value tested at 2509V in the fifth “one-minute” is shown as:

AT 01:00, 2509V, R=99.8 M8. Test capacitance displays capacitance value of device under test (measured during discharge)

is shown as: TEST CAPACITANCE: 0.00uF9. “Test Duration” is identified under TEST DURATION: 05:00 MIN.10. Recorded DUT is 89 °F11. Equivalent resistance value at 40 °C of final reading is 56.0M.


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3.15 Step Voltage Test Resistance and Current Plots

Resistance and current plot for the SV test (previous page) is shown in Figures 3-14 and 3-15.

Fig 3-14 Resistance vs Time Plot of a SV test

NOTEResistance value does not vary significantly for a good insulation reading (i.e., straight line).

Fig 3-15 Current vs Time Plot of an SV test

NoteTest current increases as test voltage is increased.


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3.16 Dielectric Discharge (DD) Test

Dielectric Discharge Test measures the dielectric absorption of a tested material. A typical DDtest takes 30 minutes. The IRM-5000 performs this test automatically. Follow the steps below tostart a DD test.

Table 3-4. Dielectric Discharge Test Procedure

STEP DESCRIPTION ACTION RESULTING DISPLAY1 Initiate Resistance Test Select key “1” 1. R 2. PI


2 Select DD Test Select key “3” 1. 30 Min (Default)2 CustomTERMINAL VTG: 0V

3 Select Default Time Test Select key “1” 1. 500V2..CustomTERMINAL VTG: 0V






8 Start Test! Select “ENTER” “ENTER” TO STARTDD 500 Volts 30 MinTERMINAL VTG: 0V


10 View Test Results None Res=2.082T DD=504V 0.00uF 30:00



13 Get Test Report From Printer Tear Paper Off. 1. RUN TEST 08/09/992. UTILITIES 20:09:01Bat ----TERMINAL VTG: 0V

Table 3-4 notes:1. To select a custom test time, select “2” in step 3. Test duration is selected in minutes.2. To select a custom test voltage, select “2” in step 4. Select test voltage from 50 V dc to 500 V

dc.3. If no temperature measurement is required, Select “2” in step 4.4. User can enter temperature manually by selecting “3” in step 4.5. Test Terminal voltage is always shown at the bottom of the screen


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3.17 Dielectric Discharge Test Result Display

A typical Dielectric Discharge Test result display is shown on Figure 3-12.

Res=1.99M DD=4.7100V 3.08uF 10:00

Figure 3-16. Typical Dielectric Discharge Test Result Display

Figure 3-16 example display readout data are interpreted as follows:1. Final resistance value at one minute is shown as Res=1.99M.2. Test voltage is 100V.3. DD value is shown as DD=4.74. Discharge capacitance is shown as 3.08uFF.5. Test duration is 10.00 minutes.


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3.18 Dielectric Discharge Test Printout

A typical Dielectric Discharge Test printout is shown in Figure 3-17 (below).

Figure 3-17. Typical Dielectric Discharge Test Printout


1. Time and Date of test are shown at top of test report.2. Test record ID is shown in the first box of test report.3. DD Ratio is shown DD RATIO: 4.74. Discharge current after 1 minute is shown as I @ TEST+1:00= 1.45uA5. Final Test voltage is shown as FINAL TEST VOLTAGE: 100V6. Test capacitance displays capacitance value of device under test (measured during discharge)

is shown as: TEST CAPACITANCE: 3.08uF7. Test Duration is identified under TEST DURATION: 10:00 MIN.8. Recorded DUT is 85 °F


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3.19 Dielectric Discharge Voltage vs Time and Current vs Time Plots

Resistance and current plot for the DD test (previous page) is shown in Figures 3-18 and 3-19.

Fig 3-18 Resistance vs Time Plot of a DD test

Fig 3-19 Current vs Time Plot of an DD test


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3.20 Save Test Report In Memory

The IRM-5000 is capable of saving up to 90 test reports in Flash EEPROM. This feature allowsthe user to recall test reports generated in the field, which reports can be printed in an office ordown-loaded to an IBM PC. To store a test report in memory, follow the steps described in Table3-5 below:

Table 3-5. Save Test Report In Memory

STEP DESCRIPTION ACTION RESULTING DISPLAY1 Select Utilities menu Select key “2” 1. PRINT 2. SAVE/RES

3. SET UPTERMINAL VGT: 0V

2 Select “SAVE/RES” Test Select key “2” 1. SAVE 2. RESTORE2. ERASE 4. DIRECTORYTERMINAL VTG: 0V

3 Confirm ”SAVE” Test Select key “1” SAVING SHOT

TERMINAL VTG: 0V4 IRM-5000 confirm save None TEST NUMBER 4

HAS BEEN SAVED!

TERMINAL VTG: 0V


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3.21 Print Test Report Directory

To print the Test Report Directory of the IRM-5000, follow the steps listed in Table 3-6 below:

Table 3-6. Print Test-report Directory Procedure


3. SET UP

TERMINAL VGT: 0V2 Select “SAVE/RES” Test Select key “2” 1. SAVE 2. RESTORE

3. ERASE 4. DIRECTORY

TERMINAL VTG: 0V3 Confirm ”DIRECTORY” Test Select key “4” TEST DIRECTORY

1. FULL 2.BRIEF

TERMINAL VTG: 0V4 Select “FULL” directory Select “1” PRINT DIECTORY

TERMINAL VTG: 0V

Figure. 3-20 Typical Test Report Directory Print Out.


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3.22 Recall Test Report From Memory

To recall a specific test report from memory, follow the steps below:Test report can then be printed.

Table 3-7. Recalling a Test Report


3. SET UP



TERMINAL VTG: 0V3 Select “RESTORE” Test Select key “2” RECALL TEST

NUMBER:

TERMINAL VTG: 0V4 Enter test number Enter two digit test

numberRECALL TESTNUMBER: XX

TERMINAL VOLTAGE5 Confirm test number Select “ENTER” key RESTORING TEST: XX6 Return to main menu Select “ENTER” key 1. RUN TEST 09/06/99

2. UTILITIES 21:10:01

TERMINAL VTG: 0V


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3.23 Print Tabulated Test Report

To print a test report, follow the steps in Table 3-8.

Table 3-8 Printing a Test Report


3. SET UP

TERMINAL VGT: 0V2 Select Print Summary Test Select key “1” 1. PLOT R 2. PLOT I

3. PLOT R,I 4. SUMARY

TERMINAL VTG: 0V3 Print Summary Select key “4” PRINT REPORT

TERMINAL VTG: 0V


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3.24 Print Graphic Test Report

Follow the steps in table 3-9 below to print a graphic report

Table 3-9. Printing a Graphic Report


3. SET UP

TERMINAL VGT: 0V2 Select “PRINT” test report Select key “1” 1. PLOT R 2. PLOT I

3. PLOT R,I 4. SUMARY

TERMINAL VTG: 0V3 Plot Resistance vs time curve Select key “1” PRINT REPORT

TERMINAL VTG: 0V


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3.25 Delete a Test Report From Memory

To delete a specific test report, follow the steps in Table 3-10 below:

Table 3-10. Delete a Test Report from Memory


3. SET UP



TERMINAL VTG: 0V3 Select “ERASE” Test Select key “3” ERASE TEST

NUMBER:

TERMINAL VTG: 0V4 Enter test number Enter two digit test

numberERASE TESTNUMBER: XX

TERMINAL VOLTAGE5 Confirm erase command Select “ENTER” key ERASING TEST

PLEASE WAIT6 Return to main menu Select “ENTER” key 1. RUN TEST 09/06/99

2. UTILITIES 21:10:01

TERMINAL VTG: 0V


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3.26 Computer Interface

A built-in RS-232C port allows the IRM-5000 to be connected to an IBM PC. The RS-232C portis controlled by the main CPU board and is optically isolated from the high -voltage generatorboard.A Windows-based software package (provided with the IRM-5000) allows the user to retrievetest reports from the IRM-5000. From this same software package, the user can print test reportsusing his office printers.To interface the IRM-5000 with an IBM PC, first connect the IRM-5000 to the IBM PC serialport, using the RS-232 cable provided. Follow the steps in Table 3-11 below to put the IRM-5000 in a computer-interface mode:

Table 3-11. Putting the IRM-5000 under Computer Control

STEP DESCRIPTION ACTION RESULTING DISPLAY1 Select Utilities Menu Select key #2 1.PRINT 2.SAVE/RES

3.SETUP2 Select Set Up menu Select key #3 1.TEST ID 2.CLOCK

3.COMP INT 4.50/60Hz3 Select Computer ITF Select key #3 COMPUTER INTERFACE

MODE

NOTETo return the IRM-5000 to the stand-alone mode, press the STOP key on the front panel.


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Appendix A

Polarization Index RatioThe Polarization Index (PI) number is derived from the ratio of the resistance value at 10 minutesto the resistance value reading at 1 minute. Since the resistance readings are taken very closelyin time, the temperature is virtually the same at both resistance measurement times.Accordingly, the PI value is virtually free of any temperature variation. For a typical insulation,the resistance value increases as time increases during a test.

INSULATION CONDITION PI RATIO

Unsatisfactory Less than 1.0

Questionable 1.0 to 2.0 (Note 1)

Good 2.0 to 4.0

Very Good Above 4.0 (Note 2)

Notes1. A resistance load (i.e., a load with low capacitance, such as short runs) PI reading will be

satisfactory with this reading.2. A dry, brittle insulation may show a good PI reading, but may fail under shock condition. 3. This table gives a rough guide to the condition of insulation under test. The user needs to

consider the equipment’s history and the user’s own experience with the equipment.


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Appendix B

Dielectric Discharge Ratio

When a dielectric is subjected to a voltage gradient, some charge will slowly permeate into thedielectric. This effect is referred to as Dielectric Absorption. Since the dielectric is by intent aninsulator, one can imagine that the movement of these small charges has a very long timeconstant. While virtually all dielectrics exhibit this effect to some extent, poorer dielectrics ordielectrics that have undergone degradation will absorb more charge.

The Dielectric Discharge test incorporated in the IRM-5000 has a standard test voltage of 500 Vand a standard test time of 30 minutes. During this time some charge migrates into the dielectricmaterial under test, as described above. At the completion of the 30 minute test, the insulationsystem is discharged (zero potential). At this point, the absorbed charge will start to migrate outof the insulator’s dielectric. After discharging the dielectric for 1 minute, the DielectricDischarge current flow is measured. As can be seen in the equation below, the DielectricDischarge Ratio is proportional to the current measured:

In general, higher ratios indicate a poorer insulation system.

As one would expect, a higher test voltage will produce a higher electric field across theinsulator’s dielectric material, and more charge can be expected to be absorbed by the dielectric.Thus, doubling the test voltage can be expected to double both the absorbed charge as well as thedischarge current measured at the end of the test. To make the Dielectric Discharge Ratioindependent of this natural phenomenon, the formula for the Dielectric Discharge Ratio dividesby the test voltage.

An insulation system that has longer lengths of insulated conductors can naturally be expected toabsorb more charge (due to the physically longer length of the conductors and dielectric). Ofcourse, such systems will also have a higher capacitance, as the capacitance of a pair ofconductors in a cable is proportional to the length of the cable. Thus, a system with twice asmuch cable will absorb, in general, twice as much charge, but will also have twice as muchcapacitance. Dividing the discharge current by the measured capacitance in the DD Ratioformula above will normalize this effect.

eCapacitanc VoltageTest

(mA) minute after1Current RATIO DD

×=


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Appendix C

Guard Terminal Application

When testing an insulation system, there may be times where the measured leakage current is notnecessarily a function of a poor insulation system, but rather of contamination at the connectionpoint, which allows leakage currents to flow along the surface of the connection point. Thesereadings can cause the test operator to incorrectly assume that the insulation system under testhas failed and must be replaced.

To exclude these surface effects and get an accurate measurement of the insulation system itself,it is often advisable to perform the Insulation Test with a guard terminal attached as shown in thefigure below.

Surface leakage currents, which may flow along the surface of the exposed wires, will flow fromthe Positive HV Test lead to the Guard lead. These currents are not measured by the IRM-5000.The cable itself will also have some inherent leakage current that will flow from the Positive HVlead, through the cable, and out the Negative HV lead. This is the current that will be used forthe Insulation Resistance measurements.

The guard terminal is at very nearly the same voltage potential as the Negative Test lead. Forthis reason, the guard connection should be positioned to avoid arcing from the Positive Testlead. As shown in the illustration, this can usually be accomplished by placing the guard nearthe Negative Test lead.


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Vanguard Instruments Company, Inc.1824 East Elma Court

Ontario, California 91764Tel: 909-937-6850Fax: 909-937-6851

MODEL IRM-5000 USER’S MANUAL

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