Model 5030DT - Advanced Test Equipment Rentals
Contents
1. HYAMP II HypotPLUS II le e 2 2 3 3 4 e 4 5 5 6 e 6 7 e 7 8 e 8 9 o e 9 Male Plug Female Plug RETURN CABLE CONNECTION For the return cable connection it is suggested that two insulated banana plugs be used with 18AWG stranded wire For proper connection one end of the return cable should be connected the RETURN jack on the rear panel of the HypotPLUS II and the other end connected to the INTERCONNECT jack on the rear panel of the HYAMP II The suggested E F Johnson part number for the banana plug is as follows 108 0303 001 Banana Plug Insulated 2 2 INTERCONNECTING WITH THE HAA 01 ACCESSORY CABLE KIT Accessory kit HAA 01 includes the rear interface cables needed for interfacing the HY AMP II with the HypotPLUS I The following table lists the kits contents in detail 39 40 D ASSOCIATED RESEARCH INC OPERATION HS 8 11 Cable Assembly Return 5030DT 21 Cable Assembly R P Interface COM 5030DT 22 Cable Assembly R P Interface SEQ 5030DT 23 Cable Assembly R P Interface SIM 36541 Adapter Box HV HC Domestic The following sections describe the procedures for interconnecting your units Please refer to the test method you require for specific cable connection instructions A Common Cable Connections First locate the HS 8 11 return cable identified by its double banana plug connectors Connect one end to the RETURN jack on the rear panel of the HypotPLUS II and the other end to the INTERCONNEC2. PCB Assy Keyboard Assembly 37629 1 CG7310 PCR Aas Main Control Board L i Ri Bracket Mounting 19 A Cabinet Chassis po Cabinet Caer 38101 a Feet Kit Plastic w o Rubber Inserts 38102 4 Rubber Insert 37561 1 CableRS 232 20cm F F 37562 Cable RS 232 20cm M F 37632 2 Capacitor Electrolytic 47000uF 20V 37633 oao Capacitor Tantalum 10uF 35V 37631 2 Diode Rectify Bridge 50V 50A 37563 fo 2 Handle Rack Mount 37554 oaao ee LCD Display 16 x 2 Characters 33189 o Line Cord Maing 37637 a Manual Operating amp Service 5030DT 37555 PowerSwitch2P 10A 250V 35999 oao ee Return Connector Black Banana Jack 37557 op Switch Reset Red 37556 pot Switch Test Green 37879 T Transformer Input Toroidal 37878 1 Fuse 5A 250V Very Slow Blow 20mm 37781 poto Fuse Bolder 20mm 5002D 37 Cable Assy High Current Return Lead 5002D 24 a Cable Assy High Current Output Lead 37239 E o High Current Return Jack 37239 A High Current Output Jack 37236 p Grommet Red High Current Output Jack 37237 PF Grommet Black High Current Return Jack NTN m m l e l ra l n l e l e l e l re l re ILA IEA l a mele E l Q1 Q14 16 1C34 Microcontroller 8 Bit 89C52 1C24 8 Bit D A Converter DAC0800 82147 1C27 ROM Conversion Board 48 D ASSOCIATED RESEARCH INC SCHEMATICS SCHEMATIC INDEX Drawing Number Description Pages S05030DT Wiring Diagram S37622 Main
3. 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 RESET OUT The relay contact closes the connection between pin 7 and pin 8 while the reset function is activated This is only a continuous closure dependent on the length of time the reset button is held in an active state START OUT The relay contact closes the connection between pin 7 and pin 9 momentarily after the completion and pass of the ground bond test This is only a momentary closure and therefore the contact does not stay closed 2 SIGNAL INPUTS OF REMOTE I O AND MEMORY PROGRAMS The HYAMP II remote connector enables remote operation of the TEST and RESET functions or allows the operator to select one of three pre programmed tests A signal input is also provided to indicate that a withstand test is processing When the remote function is ON the test switch on the front panel will be disabled to preve
4. 10 DIFFERENT TEST SETUPS Allows users who test many different products to access various test setups through the keypad or through PLC remote MICROPROCESSOR CONTROLLED The easy to follow menu screens ensure that the user will set all parameters through the keypad correctly PLC REMOTES Two 9 pin interfaces provide the user with all the necessary remotes required to configure HYAMP II through simple PLC control Outputs include Pass Fail Test in Process and Reset out Inputs include Test Reset and Withstand Processing Remote recall of memory programs 1 3 DWELL TIMER COUNTDOWN The countdown timer allows the user to clearly see how much time is left on the test TAMPER PROOF CONTROLS With the user programmable password access to setup screens can be limited to authorized personnel only METER MEMORY This standard feature holds results of failed tests on the LCD allowing the user to further review test results HIGHER OUTPUT CURRENT Increased output current of 31 Amps allows the HY AMP II to meet safety agency requirements FRONT PANEL LCD WITH ADJUSTABLE DIMMER HYAMP II utilizes an enhanced LCD to display setups and test results For easier reading of the screen the user can set the contrast to 10 different levels using the keypad ALARM VOLUME CONTROL The user can change the volume of the failure alarm to fit a variety of environments FREQUENCY SELECTION This feature allows the user to toggle between 50hz and 60hz so p
5. 50 60 Hz select mode Active only when AC mode is selected The enter key 16 toggles from 50 to 60 Hz HI LIMIT KEY Dedicated key used to select Upper Resistance limit entry The numeric keypad 22 is used to enter the value The Enter key 16 is used to save the new value CURRENT KEY Dedicated key used to select Output Current entry The numeric keypad 22 is used to enter the value The Enter key 16 is used to save the new value DWELL KEY Dedicated key used to select Test Voltage time duration entry The numeric keypad 22 is used to enter the value The Enter key 16 is used to save the new value LO LIMIT KEY Dedicated key used to select Lower Resistance limit entry The numeric keypad 22 is used to enter the value The Enter key 16 is used to save the new value VOLTAGE KEY Dedicated key used to select Output Voltage maximum limit entry The numeric keypad 22 is used to enter the value The Enter key 16 is used to save the new value 10 11 12 13 14 15 16 S ASSOCIATED RESEARCH INC CONTROLS FRONT PANEL CONTROLS 8 91011 12 13 14 15 16 17 18 19 20 21 22 23 2425 WITHSTAND PROCESSING LED The Withstand Processing LED illuminates when Remote I O signal input contacts 6 and 7 have been activated Used to indicate HV on when interconnected to a hipot tester KEY LOCKOUT LED When the Key Lockout light is ON the password software lockou
6. UP 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 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 led indicators pcb s and other critical components All of the front panel led s will light temporarily then go out In addition the display will show the following message ARI HYAMP II 5030DT VER X X The instrument will recall the last memory program which was active and the display will show the parameters which were programmed into that memory The instrument is now ready for operation B SETUP PROCEDURE 1 To set the output test current Please press the CURRENT key the display will show CURRENT XX XXA Please use the Numerical keys to enter the desired test current then press the Enter key to store the current setting If an incorrect value is entered press the Exit key then the correct value may be re enter
7. 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 This is a momentary button and does not need to be held in the pressed position during the test The instrument will then cycle ON and begin the automated test sequence using the defaults Ifa 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 may also be used as a safety button to quickly ABORT a test and cut off the HIGH CURRENT When HIGH CURRENT is present a green TEST indicator located to the TE S T left ofthe CURRENT receptacle will flash until the HIGH CURRENT is OFF If the device under test PASSED then a single beep will sound and the GREEN PASS indicator will light In the case ofa FAIL condition the RED FAIL indicator will light and the audible alarm will sound The instrument will provide a memory of the test condition results on the LCD display that will remain until the next test is initiated Depressing the reset button will reset the instrument alarm while keeping the last test results on the display Depressing the reset button a second time will clear the display 24 D ASSOCIATED RESEARCH INC QUICK START QUICK GUIDE TO INTERCONNECTING HYAMP I
8. mains cord FUSE RECEPTACLE To change the fuse unplug the power mains cord and turn the fuse cap counter clockwise to remove the fuse D ASSOCIATED RESEARCH INC INSTALLATION INSTALLATION Introduction This section contains information for the unpacking inspection preparation for use and storage of your Associated Research 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 Associated Research customer support department immediately Please save the shipping carton and packing material for the carriers 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 RGA return goods authorization number Preparation for Use Power Requirements and Line Voltage Selection CAUTION This instrument requires a power source of either 115 volts AC 15 47 63 Hz single phase or 230 volts AC 15 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 In addition please be
9. optional accessory and is not provided as standard equpment with the HY AMP II If you would like to aquire a 36541 adapter box for use with your HY AMP II please contact Associated Research using the contact information provided in the Safety section of this manual The following diagram shows how to connect the optional adapter box to the HY AMP II and the Device Under Test This adapter box allows the user an easy way to connect an item which is terminated in a three prong line cord The high current is wired to the ground pin of the receptacle box and from there the test is performed on the ground conductor of the DUT to the chassis or dead metal of the product The high voltage lead is not used and should be secured out of the way If the HY AMP II and the HypotPLUS II are being used as a test system the high voltage lead should be plugged into the high voltage jack on the front panel of the HypotPLUS IL The return lead from the HypotPLUS II should be connected to the HY AMP II as described in the previous section Common Cable Connections This configuration would allow you to do both the ground bond and hipot tests by pushing a single test button on the HYAMP II once all connections are made and the test parameters are set up 5030DT 36541 Optional Test Connections 41 D ASSOCIATED RESEARCH INC OPTIONS MODEL 5030DT OPTIONS Introduction This section contains a list and descriptions of availa
10. 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 This may cause internal damage and represents a safety risk to the operator NOTE For operation at 115 Volts AC and 230 Volts AC use a 5A 250VAC fast acting fuse 19 D ASSOCIATED RESEARCH INC INSTALLATION Power Cable WARNING 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 Test Leads The test leads provided are designed specifically for use with this instrument The red High Current lead will mate with the red Current jack The black Return lead will install into the black Return jack The test lead ratings are as follows High Current lead 05002D 24 31 A 750V
11. the insulating material will protect the user against electrical shock The equipment used for this test a dielectric withstand tester is often called a hipot for high potential tester The rule of thumb for testing is to subject the product to twice its normal operating voltage plus 1 000 volts D ASSOCIATED gt INTRODUCTION However specific products may be tested at much higher voltages than 2X operating voltages 1 000 volts For example a product designed to operate in the range between 100 to 240 volts can be tested between 1 000 to 4 000 volts or higher Most double insulated products are tested at voltages much higher than the rule of thumb Testing during development and prototype stages is more stringent than production run tests because the basic design of the product is being evaluated Design tests usually are performed on only a few samples of the product Production tests are performed on each and every item as it comes off the production line The hipot tester must also maintain an output voltage between 100 and 120 of specification The output voltage of the hipot must have a sinusoidal waveform with a frequency between 40 to 70 Hz and has a peak waveform value that is not less than 1 3 and not more than 1 5 times the root mean square value Why Perform a Ground Bond Test Ground bond testing is done to insure that a low resistance path exists between the safety ground pin of a three wire line cord
12. time is set to 0 the instrument will operate in a continuous ON mode when the test button is 28 D ASSOCIATED RESEARCH INC OPERATION depressed and released It will stop when the DUT Device Under Test goes into failure or the manual reset button is pressed 6 To set the output frequency Please press the 50 60HZ key the display will show Freq XX HZ Use the Enter key to toggle between either 50 or 60 HZ then press the Exit key to store the selection 7 To lock or unlock the keyboard of the front panel The HY AMP II is equipped with two lockout modes one requires a password to activate or deactivate the lockout feature the other does not require a password Within each mode you can selectively lockout all front panel control functions except TEST and RESET or you may allow the operator to select from the pre programmed memories A Setup of Password and Lock Functions To setup a PASSWORD or change the MEMORY LOCK functions you must power up the instrument in the calibration mode To do this you must do the following 1 Place the power switch in the off position 2 Press and hold in the 0 key then turn on the power switch The display will indicate the following Calibration Mode 0 V 1 A 7 Lock 3 Press the 7 key the display will show P W XXXX P W 0 4 If the password is not to be changed please press the Exit key The program will go to the Memory Loc
13. 0 1 second step SETTING 0 for continuous running Accuracy 0 1 of Setting 0 05 seconds FAILURE SETTINGS High limit 0 600me for 3 12 Amps 1mo step 0 150ma for 3 31 Amps Ime step Accuracy 2 of setting 2ma Low limit 0 600ma for 3 12 Amps Imo step 0 150ma for 3 31 Amps Ime step Accuracy 2 of setting 2ma Max Offset Capability 100ma 1ma step OFFSET Accuracy 2 of setting 2ma METERING Ammeter 4 digits Range 0 31 Amps Resolution 0 01 Amp step Accuracy 3 of Reading 0 03A Ohmmeter 3 digits Range 0 600mo Resolution 1 ma step Accuracy 2 of Reading 2ma Timer 4 digits Range 0 999 9 seconds Resolution 0 1 seconds step Accuracy 0 1 of Reading 0 05 seconds D ASSOCIATED Ir SRECIFICATIONS REMOTE CONTROL The following input and output signals are provide through two 9 pin D type connectors set up program Detachable 7 ft 2 13m power cable terminated in a three prong grounding plug TERMINATIONS 5ft 1 52m high current and return leads with clips MECHANICAL Bench or rack mount 2U height with tilt up front feet Dimensions wx hx d 17 x 3 5 x 16 5in 432 x 88 x 419mm Weight 27 6 lbs 12 5kgs Relative Humidity 0 to 95 CALIBRATION Traceable to National Institute of Standards and Technology NIST Calibration controlled by software Adjustments are made through front panel keypad in a restric
14. 05002D 37 31 A 750V Operating Environment This instrument may be operated in temperatures from 32 113 F 0 45 C Relative humidity of 0 to 95 Altitude up to 15 000 feet 4 600 meters Ventillation When choosing a bench location or in rack mount applications insure that there is at least 6 inches 15 cm of space from the rear panel to any wall or obstruction behind the unit STORAGE AND SHIPMENT Environment This instument may be stored or shipped in environments with the following limits TP adas 40 to 75 C Altitude 7 620 meters 25 000 feet 20 D ASSOCIATED RESEARCH INC INSTALLATION The instrument should also be protected against temperature extremes which may cause condensation within the instrument Packaging Original Packaging Please retain all original packaging materials if you do not have an alternate method of repackaging If you are returning your instrument to us for servicing please repackage the instrument in its original container or use an alternate packaging solution Please do not reuse the original packing material if there appears to be damage or missing packing material Contact our customer support department 1 800 858 8378 for an RGA return goods authorization number Please enclose the instrument with all options accessories and test leads Indicate the nature of the problem or type of service needed Also please mark the container FRAGILE to insure proper handling Upo
15. ATTENTION TO A PROCEDURE PRACTICE OR CONDITION THAT COULD POSSIBLY CAUSE DAMAGE TO EQUIPMENT OR PERMANENT LOSS OF DATA Pk Oe D ASSOCIATED RESEARCH INC SAFETY 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 ventillation 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 aquired directly from Associated Research Inc Refer servicing to an Associated Research Inc authorized service center PHONE 1 847 367 4077 ASSOCIATED RESEARCH INC 1 800 858 TEST 8378 13860 WEST LAUREL DRIVE FAX 1 847 367 4080 LAKE FOREST IL 60045 4546 U S A E MAIL info asresearch com www asresearch com Service Interval The instrument and its power cord test leads and accessories must be returned at least once a year to an Associated Research authorized service center for calibration and inspection of safety related components Associated Research will not be held liable for injuries suffered if the instrument is not returned for its
16. Advanced Test Equipment Rentals A ished 1981 www atecorp com 800 404 ATEC 2832 OPERATION AND SERVICE MANUAL HYAMP II MODEL 5030DT GROUND BOND TESTER SERIAL NUMBER 4 Associated Research Inc 2002 Model 503 ODT 13860 West Laurel Drive Lake Forest Illinois 60045 4546 U S A Item 37637 Ver 1 12 Printed Aug 15 2002 5 YEAR WARRANTY POLICY Associated Research Inc 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 AR recommends that your instrument be calibrated on a twelve month cycle Instruments purchased and used in the U S may have their warranty extended in one year increments to a maximum of 5 years provided they are returned to AR at least annually for calibration and inspection The annual calibration and inspection must be performed annually each and every year following receipt of instrument Any instrument not calibrated and inspected annually will not be eligible for extended warranty status This extended warranty is non transferable and is offered only to the o
17. Control Board S37624 Main Power Amplifier Board 49
18. I TO HypotPLUS II USING THE SUPPLIED CABLE KIT 1 2 Enable the HypotPLUS II remote interface Operation menu REMOTE ON Connect the Double ended banana plug cable from the HypotPLUS II rear RETURN jack to the HYAMP II INTERCONNECT jack Based on the test method select one of the two 9 pin dsub control cables shown in the table below Connect this cable along with the Common control cable 9 pin dsub 5030DT 21 between the HYAMP and the HypotPLUS II remote I 0 with the BLUE ends on the HYAMP Il Note The cables are identified on the blue tubing 030DT 22 YAMP first then Hypot 030DT 23 YAMP and Hypot at the same time Connect the high current plug red from the receptacle adapter box P N 36541 to the HYAMP II jack marked CURRENT red and the high voltage plug white to the HypotPLUS II jack marked HV white Connect the RETURN lead with the alligator clip black to the HYAMP II jack marked RETURN black The alligator clip should be connected to the DUT chassis Check the test parameters and initiate the tests by pressing the Hyamp test button The Reset buttons on both instruments are active to disable the tests or for failure reset e Fora more detailed description on interconnecting your system see page 37 25 Af 26 OCIATED EARCH INC This page intentionally left blank QUICK START D ASSOCIATED RESEARCH INC OPERATION OPERATION INSTRUCTIONS FOR HYAMP Il Model 5030DT A POWER
19. PANEL CONTROLS INTERCONNECT RETURN CURRENT 6 __sionai_oureul Sionat eur FAIL PASS L rest 5 1 ki 5 ow v caution A 10 INTERCONNECT JACK For the connection of the return lead from the hipot tester used when performing both hipot and Ground Bond tests on the same test item RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black kelvin return test lead This lead is always used when performing a test CURRENT OUTPUT JACK For the connection of the detachable 5 foot 1 52 m red kelvin test lead This lead is always used when performing a ground bond test THERMAL FAN Cycles on to cool the instrument automatically REMOTE OUTPUT 9 pin D subminiature female connector for monitoring PASS FAIL and PROCESSING output relay signals as well as remote START and RESET outputs REMOTE INPUT 9 pin D subminiature male connector for remote control of test and reset funtions as well as program memory selection 1 2 or 3 and withstand processing input CHASSIS GROUND EARTH TERMINAL This safety terminal should be connected to a good earth ground before operation 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 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power
20. S ON REMOTE I O The rear panel connector provides three output signals to remotely monitor PASS FAIL and PROCESSING conditions and it also provides a RESET OUT pulse signal and a START OUT pulse signal The monitoring signals are provided by three normally open internal relays that switch on to indicate the current condition of the tester The RESET OUT signal and the START OUT pulse signal are also provided by a normally open internal relay The RESET OUT gives a signal whenever the reset function is activated This can be used to abort a withstand test while the units are interfaced as a test system The START OUT gives a momentary output pulse at the end of the ground bond test which can be used to start the hipot test These are normally open free contacts and will 35 D ASSOCIATED RESEARCH INC OPERATION 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 Pins 1 and 2 provide the PASS signal Pins 3 and 4 provide the FAIL signal Pins 5 and 6 provide the PROCESSING signal Pins 7 and 8 provide the RESET OUT signal Pins 7 and 9 provide the START OUT pulse signal The following describes how the relays operate for each test condition
21. T jack on the rear panel ofthe HY AMP II Then locate the cable marked 5030DT 21 COMMON Connect the female plug the end with the blue tubing to the signal input receptacle on the rear panel of the HYAMP Il Then connect the male plug the end with the black tubing to the signal output receptacle on the rear panel of the HypotPLUS II B Test Method Specific Connection 1 For sequential testing methods use the following cable connection Locate the cable marked 5030DT 22 SEQUENTIAL Connect the male plug the end with the blue tubing to the signal output receptacle on the rear panel of the HY AMP II Then connect the female plug the end with the black tubing to the signal input receptacle on the rear panel of the HypotPLUS II 2 For simultaneous testing methods use the following cable connection Locate the cable marked 5030DT 23 SIMULTANEOUS Connect the male plug the end with the blue tubing to the signal output receptacle on the rear panel of the HYAMP II Then connect the female plug the end with the black tubing to the signal input receptacle on the rear panel of the HypotPLUS IL REAR PANEL HYAMP II PRONT PANEL INTERCONNECT O 0 OUTPUT INPUT RETURN O O OUTPUT INPUT i REAR PANEL FRONT PANEL HV CHASSIS HypotPLUS II Device Under Test Basic Test Setup D ASSOCIATED RESEARCH INC OPERATION F ADAPTER BOX CONNECTION The adapter box is an
22. VAC on the output connectors and the display will show Voltage _ V 46 D ASSOCIATED RESEARCH INC CALIBRATION Please use the numerical keys to enter the reading from the ac voltmeter into the instrument Then press the Enter key to store the voltage setting Ifan incorrect value is entered press the EXIT key Then the correct value may be re entered 2 Calibration of Current Equipment needed STANDARD AC AMMETER with a range of 304 Please connect the standard ac ammeter across the output leads of the instrument Press the 1 key The instrument will provide around 30A on the output and the display will show Please use the numerical keys to enter the reading of the standard ac ammeter into the instrument Then press the Enter key to store the current setting Ifan incorrect value is entered press the EXIT key The correct value may be re entered 3 Setup of the Password and Lock Function Please refer to the setup procedures section of this manual 4 Exit Calibration Mode After the calibration is complete turn the input power switch to OFF 0 to exit the Calibration Mode Turn the power switch to ON to return to standard operating test mode for calibration verification 47 D ASSOCIATED RESEARCH INC PARTS LIST Replacement Parts List HYAMP Il Model 5030DT Rev E 6 03 2002 ECO 4890 Designator 37515 1 CSW 01 PCB Assy Input Protection Board 37550 1 CKB 01
23. always at a higher potential than the other Hipot Tester Common term for dielectric withstand test equipment Hypot Registered trademark of Associated Research Inc for its 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 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 resistance required to cause an indication of unacceptable performance during a ground bond test Voltage Electrical pressure the force which causes current through an electrical conductor Symbol V ASSOCIATED INTRODUCTION The importance of testing User safety In an era of soaring liability costs original manufacturers of electrical and electronic products must make sure every item is as safe as possible All products must be designed and built to prevent electric shock even when users abuse the equipment or by pass built in safety features To meet recognized safety standards one common test is the dielectric voltage withstand test Safety agencies which require compliance safety testing at both the initial product design stage and for routine production line testing include Underwriters Laboratories Inc UL the Canadian Standards Associa
24. and exposed metal of the item under test Ifa live wire inside the item under test came loose and contacted the chassis the fault current would flow through the low resistance safety ground and protect the user The need for high current bonding i e 10A or 30A as apposed to low current go no go type testers results from the nature of line voltage breakers high current characteristics Safety Grounding circuits must withstand the line voltage breaker current rating in order to maintain a safe voltage potentials on the chassis of the faulty device Verifying the integrity of the grounding circuit at high currents insures that the line breaker will open before the grounding circuit wires fail This insures that the power will be deenergized at the device while maintaining safe voltage levels on the chassis IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION OF YOUR INSTRUMENT CALL 1 800 858 TEST 8378 IN THE U S A D ASSOCIATED Dr SPECIFICATIONS Model 5030DT Functional Specifications GROUND BOND TEST MODE Unless otherwise stated accuracies are relative to a laboratory standard measurement Specifications INPUT VOLTAGE 115 230V selectable 15 variation 47 63 Hz 115 VAC 230VAC 5A fast acting 250VAC OUTPUT Current AC 3 31 Amps 0 01 Amp step Regulation 2 of Setting 0 02 A Voltage AC 3 8 Volts 0 1 Volt step OUTPUT 50 60 Hz selectable FREQUENCY DWELL TIME 0 and 0 5 999 9 seconds
25. annual safety check and maintained properly User Modifications Unauthorized user modifications will void your warranty Associated Research will not be responsible for any injuries sustained due to unauthorized equipment modifications or use of parts not specified by Associated Research Instruments returned to Associated Research 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 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 TEST IN PROGRESS UNAUTHORIZED PERSONNEL KEEP AWAY D ASSOCIATED RESEARCH INC SAFETY Power Ground Bond 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 offe
26. ble factory installed options at the time of this printing Option Label If your instrument has been modified with options there will be an option label on the rear panel of the unit The option label contains an option s code that may be cross referenced to the Options List For example your options code would appear as follows fitted with option 01 OPT 01 5030DT Options Option List Continuous Output with PASS buzzer Description 01 Continuous Output with PASS buzzer The Continuous Output with PASS buzzer option allows the user to perform multiple ground bond tests without the need to repeatedly energize and deenergize the output All of the standard specifications for output ratings remain the same as the standard instrument The operation of the failure judgment and indication are the fundamental differences in the operation of the instrument To make the best use of the continuous running feature the Dwell timer should be set to 0 0 seconds to enable the continuous running mode However if the Dwell timer is set to any value other than 0 0 s when the timer has completed the test results will be captured until the test is restarted To start the ground bond test the TEST button on the front panel can be pressed with the test leads connected or disconnected from the DUT Once the test leads are connected to the DUT and the measured resistance is less than the Hi Limit setting the instrument will indicate a PASS condition wit
27. current for the length of time set on the dwell timer The display will show Dwell MX XXX Xs XX XXA XXX mo NOTE If the alarm volume is set to 0 OFF no audible alarm will be heard during a failure condition 4 Ifthe resistance exceeds the high limit trip setting but does not exceed the metering range the red FAIL symbol will illuminate and the alarm will be activated The display will show HI LMT MX XXX Xs XX XXA XXX ma 33 D ASSOCIATED RESEARCH INC OPERATION 5 Ifthe resistance exceeds the high limit trip setting and exceeds the metering range the red FAIL symbol will illuminate and the alarm will sound The display will show HI LMT MX XXX Xs XX XXA OFL mo 6 If the resistance does not exceed the low limit setting the red FAIL symbol will illuminate and the alarm will sound The display will show LO LMTMX XXX Xs XX XXA XXX mo 7 To stop the alarm please press the RESET switch once The alarm will stop and the display will retain the failure information Ifthe 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 8 Ifthe DUT passed all of the tests the green PASS symbol on the front panel will illuminate and the instrument will output a short audible beep tone to indicate the DUT has passed the tests The instrument is now rea
28. dy to perform another test The display will show Pass MX XXX Xs XX XXA XXX mo 9 Ifthe 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 The display will show Abort MX XXX Xs XX XXA XXX mo Please press the Test switch to initiate another test 34 AT ASSOCIATED RESEARCH INC D CONNECTION OF REMOTE I O OPERATION Two 9 pin D type connectors are mounted on the rear panel that provide REMOTE INPUT 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 1 O are shown below 205204 4 PLUG SHELL WITH GROUND INDENTS 205203 3 RECEPTACLE SHELL 745254 7 CRIMP SNAP IN PIN CONTACT for plug 745253 7 CRIMP SNAP IN SOCKET CONTACT for receptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 747184 3 JACKSCREW SET 2 REMOTE INTERFACE REAR PANEL REMOTE 1 0 SIGNAL OUTPUT SIGNAL INPUT caida MEMORY 1 START RESET PROCESSING MEMORY 2 OUT OUT MEMORY 3 WITHSTAND PROCESSING 1 SIGNAL OUTPUT
29. ed The maximum current which may be entered is 31 00 Amps Any value above these will produce an ERROR message 27 D ASSOCIATED RESEARCH INC OPERATION 2 To set the output test voltage Please press the VOLTAGE key the display will show Voltage X XX V Use the Numerical keys to enter the voltage setting then press the Enter key to store the setting The unit of measure is in volts with 3 00 8 00 being the range 3 To set the high limit resistance trip setting Please press the HI LIMIT key the display will show HI LMT XXX mo Please use the Numerical keys to enter the high limit resistance trip setting then press the Enter key to store the setting The unit of measure is in milliohms with a range from 0 600 mos 4 To set the low limit resistance trip setting Please press the LO LIMIT key the display will show LO LMT XXX mo Please use the Numerical keys to enter the low limit resistance trip setting then press the Enter key to store the setting The unit of measure is in milliohms with a range from 0 600 mo s if set for 0 the low limit resistance trip setting will be disabled 5 To set the dwell time Please press the DWELL key the display will show Dwell T XXX Xs Use the Numerical keys to enter the dwell time setting then press the Enter key to store the dwell time setting The range is 0 to 999 9 seconds if the dwell
30. em should be treated as a serious offense and should result in severe penalties such as removal from the Ground Bond 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 4 D ASSOCIATED gt INTRODUCTION GLOSSARY OF TERMS as used in this manual 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 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
31. h audible alarm and the PASS light illuminated on the front panel When the continuity is broken or the instrument measures a resistance value greater than the Hi Limit setting the FAIL indicator will illuminate but the alarm will not sound The 42 D ASSOCIATED RESEARCH INC OPTIONS fail condition will remain until the resistance drops below the Hi Limit setting or until the Reset button is pressed to deenergize the output This operation emulates the basic audible continuity testers found on many multimeters and is useful in doing multipoint ground bond tests on the DUT by disconnecting and reconnecting the test leads without disabling the output This method is perfectly safe to the operator with regards to the voltage potential that is available on the test leads This open circuit voltage is controlled by the voltage setting parameter The user can access the voltage setting parameter by pressing the VOLTAGE button on the left hand side of the display on the front panel The maximum voltage setting available is 8 volts AC and presents absolutely no risk to the operator 43 Af 44 OCIATED EARCH INC This page left intentionally blank OPTIONS SECTION 2 SERVICE MANUAL D ASSOCIATED RESEARCH INC CALIBRATION CALIBRATION PROCEDURES 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 th
32. h on the front panel is locked out but the Reset switch will still be functional Ifthe Remote Control is set to OFF the operation will be controlled by the Test and Reset switches on the front panel B LCD Contrast setting Press the UP or DOWN arrow keys to toggle the programs to the display shown Contrast X Please use the Numerical keys to enter the range of Contrast from 0 to 9 Then press the Enter key to store the Contrast range A total of 10 ranges are available The LCD will change the Contrast immediately and the display will show the set value on the screen The Contrast number 0 is the weakest and 9 is the strongest Toggle the arrow keys to another setting or press the Exit key to exit from the setting mode and enter the testing mode C Alarm volume setting Press the UP or DOWN key to toggle the programs until the display shows 31 D ASSOCIATED RESEARCH INC OPERATION Use the Numerical keys to enter the range of alarm volume from 0 to 9 A total of 10 levels Then press the Enter key to store the selected alarm volume setting The instrument will emit a tone signal as a sample of the alarm volume selected and the LCD screen will show the set point immediately Level 0 will turn off the alarm Level 1 produces the lowest volume and level 9 is the loudest Press the EXIT key to exit
33. is 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 AR 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 calibration checks can only be made in the Test mode of operation Calibration Equipment Required The following equipment will be needed to properly calibrate your instrument 1 Digital Multimeter with the minimum ranges ac voltage 10 VAC ac current 30 AAC CALIBRATION PROCEDURE To enter the calibration mode the instrument must be in the OFF position Press and hold the 0 key then turn on the Input Power Switch The display will show Calibration Mode 0 V 1 A 7 Lock Press 0 for volts calibration 1 for amps and 7 for the password and lock mode settings 1 Calibration of Voltage Equipment needed STANDARD AC VOLTMETER capable of measuring 1OVAC Please connect a standard ac voltmeter with 10V minimum full scale range to the current and return connectors Then press the 0 key on the front panel The instrument will provide approximately 7 5
34. k Function setting Please refer to item 7 listed below 5 Ifa password for the Lock Function is not required please use the numerical key to enter 0 and press the Enter key The program will go to the Memory Lock Function setting 29 D ASSOCIATED RESEARCH INC OPERATION 6 Ifa password for Lock Function is required please use the numerical keys to enter a four digit Numerical Code and press the Enter key The program will go to the Memory Lock Function Once the password is set the password has to be entered to activate or deactivate the Lock function 7 After setting the password press the Exit key the display will show MR Lock ON MR Lock OFF or Press the Enter key to select Memory Lock ON or OFF Ifthe MR Lock is in the ON position all the memory programs will be locked along with keyboard functions The operator will be locked out of recalling memory programs while in the lock mode If the MR Lock is in the OFF position the instrument will not lock the memory programs even if the keyboard is locked The memory programs may be recalled while in the lock mode but the test parameters within each setup cannot be changed B Turning the LOCK function ON or OFF with no password activated Press the Lock key the display will show Lock ON Lock OFF Press the Enter key to select the Lock ON or Unlock OFF mode
35. kwards through the setup menus remote volume and contrast Also may be used to increase output current during a test in 10 mA increments PASS LED INDICATOR This green indicator lights at the end of a ground bond test ifno failure has occurred during the test FAIL LED INDICATOR When a failure occurs Hi or Low during a ground bond test this red indicator will light POWER SWITCH Rocker style switch with international ON and OFF 0 markings DATA ENTRY NUMERIC KEYPAD For numeric entry or change of testing parameters during the Setup mode Keypad entry is unavailable if the Lock indicator on the front panel is on Press and hold one of these keys until the second tone is heard to store parameters in memory Also used to recall test parameters stored in memory TEST LED INDICATOR This green LED flashes to indicate to the operator that voltage is present at the output terminal and a test is in process RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black kelvin return test lead This lead is always used when performing a test D ASSOCIATED RESEARCH INC CONTROLS FRONT PANEL CONTROLS 12 13 14 15 16 17 18 19 20 21 22 232425 25 CURRENT OUTPUT JACK For the connection of the detachable 5 foot 1 52 m red kelvin test lead This lead is always used when performing a ground bond test 17 D ASSOCIATED RESEARCH INC CONTROLS REAR
36. memory 1 MEMORY 2 Momentarily connecting terminal 7 to 9 signals the instrument to immediately begin the test program that is stored in memory 2 MEMORY 3 Momentarily connecting terminal 7 to terminals 8 and 9 signals the instrument to immediately begin the test program that is stored in memory 3 With the HY AMP II and the HypotPLUS II being used as a test system the processing signal from the hipot tester will be sent across pin 6 and pin 7 of the HYAMP II remote input This signal will illuminate the front panel Withstand Processing indicator which notifies the operator that high voltage is enabled E HYAMP II AND HypotPLUS II INTERCONNECTION The two units have been designed to interface and work as one test system Testing may be performed in either a sequential method or simultaneously The traditionally sequential method performs the ground bond test first to verify the ground integrity and then performs the hipot test when a good ground is indicated The simultaneous method is used for high speed testing and performs the ground bond test and hipot test at the same time Due to this there are two methods to interconnect your units You may either use the cables we provide or you can make your own cables Instructions regarding both cabling options are provided in the next two sections Also refer to the end of section E for a complete diagram of a basic test setup When preparing your interconnected system be sure to se
37. n receipt your instrument will be issued an AR service number Please refer to this number in all correspondence Other Packaging If you do not have the original packaging materials please follow these guidelines 1 Wrap the instrument in a bubble pack or similar foam Enclose the same information as above 2 Use a strong double wall container that is made for shipping instrumentation 350 lb test material is adequate 3 Use a layer of shock absorbing material 70 to 100 mm 3 to 4 inch thick around all sides of the instrument Protect the control panel with cardboard 4 Seal the container securely 5 Mark the container FRAGILE to insure proper handling 6 Please ship models 5030DT via Federal Express or UPS air 7 Please refer in all correspondence to your AR service number Field Installation Of Options There are no field installable options on the model 5030DT 21 D ASSOCIATED RESEARCH INC QUICK START QUICK START This quick start guide assumes the operator has some familiarity with automated ground bond 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 e Input Voltage e Communications e Mode e Current Output e Voltage Output e Resistance Trip High e Resistance Trip Low e Dwell Time
38. n of the ram chips led indicators pcb s and other critical components All of the front panel led s will light temporarily then go out In addition you will see the Associated Research name and Model Number briefly appear on the LCD readout and then clear itself ARI HY AMP II 5030 DT VER P Current software version displayed here You should then see the default parameters on the LCD meter as follows Set M1 1 0s 25 00A 100mQ These abbreviated parameters stand for the following SET This is the parameter settings review screen M1 The instrument is using the default set ups contained in memory 1 1 0s The dwell timer is set to a test duration of 1 second 25 004 The test current is set to 25 00 Amps 100m2 The high resistance trip point is set to 100 milliohms 23 D ASSOCIATED RESEARCH INC QUICK START If you wish to not use any one of these parameters you must overwrite the memory 1 position or change your parameters and save them in a different memory such as memory position 2 e Ifthe 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 current output lead red WARNING f Please check your connections to be sure they are making good
39. nt a test from being activated through the test switch refer to page 31 for details 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 36 D ASSOCIATED RESEARCH INC OPERATION The HYAMP II also allows access to three MEMORY PROGRAMS through the remote control connector This gives the user the capability to quickly change parameters and initiate a test remotely The HY AMP II basically operates in a PLC mode by responding to simple switch or relay contact closures The built in memory programs of the instrument are used to accomplish this Three internal memory programs can be accessed By connecting terminals 7 8 and 9 in different combinations the user can select the correct memory program WARNING ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE REMOTE CONNECTOR SELECTS THE PROGRAM AND STARTS THE TEST WHICH IS PREPROGRAMMED INTO THAT MEMORY CAUTION DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY MEMORY 1 Momentarily connecting terminal 7 to 8 signals the instrument to immediately begin the test program that is stored in
40. r e AC Output Frequency eo Buzzer e Contrast Oo Remote e Lock 22 115 volts AC rear panel switch selectable local front panel key selectable set up 25 00 Amps 8 00 volts AC 100 mo 0 ma 1 second 60Hz Volume Level 5 LCD contrast level 1 OFF OFF D ASSOCIATED RESEARCH INC a Unpack this instrument from its special shipping container Be sure to save all packaging materials in case you need to return it to the factory for service QUICK START WARNING 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 CAUTION c 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 connecting to a grounded power source d 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 conditio
41. r assistance Work Area Perform the tests on a nonconducting 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 Do not perform Ground Bond Tests in a combustible atmosphere or in any area where combustible materials are present TEST OPERATOR Qualifications 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 syst
42. riginal purchaser A return goods authorization RGA must be obtained from AR before returning this instrument for warranty service Please contact our Customer Support Center at 1 800 858 TEST 8378 to obtain an RGA number It is important that the instrument is packed in its original container for safe transport If the original container in not available please contact our customer support center for proper instructions on packaging Damages sustained as a result of improper packaging will not be honored Transportation costs for the return of instrument for warranty service must be prepaid by the customer AR will assume the return freight costs when returning the instrument to the customer during the first year of ownership All freight charges after the first year are the customers responsibility The return method will be at the discretion of Associated Research Except as provided herein Associated Research 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 by passing any safety systems will void this warranty This warranty does not cover batteries or accessories not of Associated Research manufacture Parts used mu
43. roducts can be tested at the same frequency they will be used at D ASSOCIATED RESEARCH INC WHAT S NEW FRONT PANEL CALIBRATION By going into the restricted access calibration mode the user can calibrate the unit through the keypad with no need to remove any panels or covers which could expose the technician to hazardous voltages STANDARD ACCESSORIES A set of rack mount handles and a receptacle box for testing products terminated with a line cord are standard to allow HYAMP II to fit a variety of testing applications MILLIOHM OFFSET CAPABILITY This feature minimizes the effect of lead resistance The milliohm offset allows for the use of longer test leads and test fixtures without compromising test results ADJUSTABLE OUTPUT VOLTAGE User adjustable voltage from 3 8 Volts AC in 0 1 volt steps allows HYAMP II to meet safety agency requirements 13 D ASSOCIATED RESEARCH INC CONTROLS FRONT PANEL CONTROLS 12 13 14 15 16 17 18 19 20 21 22 232425 RESET SWITCH This is a momentary contact switch Ifout of range resistance failure occurs the red Failure lamp 20 will light To reset the system for the next test press and release the red Reset switch 1 This switch may also be used to abort a Test in Progress TEST SWITCH This is a momentary contact switch Press the green switch to turn on the high current output when in test mode 50 60 KEY Dedicated key used to enter
44. st be parts that are recommended by AR as an acceptable specified part Use of non authorized parts in the repair of this instrument will void the warranty TABLE OF CONTENTS SECTION I OPERATORS MANUAL 1 o ae ee eee ne EN Oe ee REO OE OE ve 2 A Ta eere 5 SA II tennssen beds eo dderenacs 8 II ene eee E 12 CONO a a eo aes 14 INSTALLA ON oo a tensietareaee etd 19 UM STR e ld EE E 22 OPERATION ra dl e a andea aaa a a A i EEEE 37 OPTIONS tada delicados desd sega cad egos ee ed caos sacd co ade 42 SECTION H SERVICE MANUAL ss 45 CALIBRA TION cad dicas di desd ctotite a cos sad ao ed 46 T 48 SA MATIC A Meh ah ca ect A 49 111 SECTION 1 OPERATORS MANUAL D ASSOCIATED RESEARCH INC SAFETY SAFETY PRECAUTIONS 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 WARNING CONDITION THAT COULD POSSIBLY CAUSE BODILY INJURY OR DEATH CAUTION CALLS
45. t beep tone and the display will indicate the test parameters stored in that program To start a test press the TEST key 32 assocures RESEARCH INC OPERATION C OPERATING PROCEDURES 1 Please follow the Setup Procedures to set the general status of Remote Control LCD Contrast and the Alarm Volume 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 Then connect the return lead first to the test fixture or the DUT followed by the high current 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 a HAS BEEN STARTED 2 Please follow the setup procedures to set or recall setups from memory programs The display will show the number of the Memory Program time of Dwell value of Test Current and the value of the High Limit Resistance Trip as follows Set M__ XXX Xs Set MX XXX Xs XX XXA XXX mo or XX XXA XXX mo If the set data is to be stored in the memory program please follow the procedure outlined in the setup procedures on Storage of Memory Program 3 To initiate a test press the Test switch on the front panel The instrument will output the set
46. t has been enabled This means that the operator will be unable to access the program mode of the instrument to change any settings REMOTE LED This LED illuminates when the unit is in remote control mode LCD DISPLAY The Liquid Crystal Display is the main readout for the operator and programmer of the test settings and test result EXIT KEY Use this key when you desire to enter the Run Mode to initiate a test or use this key when you enter numeric data during a Setup routine and you wish to clear the information mQ OFFSET KEY The milliohm offset key is used to offset any unwanted resitance that should not be included in the actual resistance value to be used for criteria comparison DOWN ARROW V FUNCTION KEY Use this key to advance forward through the setup menus remote volume and contrast Also may be used to decrease output current during a test in 10 mA increments ENTER KEY Use the enter key after entering new data through the keypad to save it This key also used to toggle ON OFF functions 15 17 18 19 20 21 22 23 24 D ASSOCIATED RESEARCH INC CONTROLS FRONT PANEL CONTROLS 12 13 14 15 16 17 18 19 20 21 22 23 2425 LOCK KEY Used to enter the security Lock Menu This menu may or may not ask for a password depending on how the Lock function was configured in the calibration mode UP ARROW d FUNCTION KEY Use this key to advance bac
47. t the HypotPLUS II s Remote Control menu setting to ON as described in the Operation section of the HypotPLUS II manual After configuring the required test parameters for both instruments and connecting the cables initiate the test cycle by activating either the remote test signal or 37 D ASSOCIATED RESEARCH INC OPERATION the front panel test button on the HY AMP Il The hipot test will begin automatically relative to the test method selected 1 INSTRUCTIONS FOR USER FABRICATED INTERCONNECT CABLES The following diagrams show how to connect the Remote I O of both units The associated pin numbers are given for the connectors on both units and the pins to be wired together Refer to section D of this manual for the required parts to make these cables A Sequential Testing HY AMP II SIGNAL INPUT HypotPLUS II SIGNAL OUTPUT CONNECTION HYAMP IT HypotPLUS II le e 2e e 2 3 e e 3 4e s 4 a nn a nnn 7 e7 8 o 6 8 Qe e 9 Female Plug Male Plug HY AMP II SIGNAL OUTPUT HypotPLUS II SIGNAL INPUT CONNECTION HYAMP II HypotPLUS II e 1 D 00 Du Un a Male Plug Female Plug 38 ASSOCIATED RESEARCH INC B Simultaneous Testing OPERATION HY AMP II SIGNAL INPUT HypotPLUS II SIGNAL OUTPUT CONNECTION HYAMP II HypotPLUS I le e 2 o s 2 3 e e 3 4e ed 5 o e 5 ne UNAS 7 e7 R e e 8 9 o s 9 Female Plug Male Plug HYAMP II SIGNAL OUTPUT HypotPLUS II SIGNAL INPUT CONNECTION
48. ted access calibration mode Calibration information stored in non volatile memory PROGRAM 10 sets MEMORY D ASSOCIATED A SPECIFICATIONS KEY FEATURES amp BENEFITS OF HYAMP II l All parameters for the setups can be adjusted through a simple menu driven program by using quick access front panel keys The easy to follow setup screens ensure that the operator correctly sets up all test parameters Tamper proof front panel controls This makes it possible to limit user access to the setup screens so that only authorized personnel with a security password can change test parameters Passwords are programmable this ensures that the required test parameters can not be tampered with Four wire measurement Kelvin method and milliohm offset capability These features minimize the effect of test lead resistance The four wire measurement technique eliminates test lead resistance when using the standard test leads The milliohm offset function allows the use of longer test leads and test fixtures without compromising the test results Storage ofup to 10 different test programs A real benefit for manufacturers that test different products This makes it possible to store all the various test parameters required and quickly recall them for each of the different products that needs to be tested The first three program memories can also be accessed through the remote control PLC port so that a manufacturer can quickly toggle thro
49. test Front panel LCD displays test parameters and results A front panel LCD allows the operator to monitor the test The display holds the results after a test item failure so that the operator can easily review the test results Indications of low fail amp high fail are clearly displayed PLC remote inputs and outputs The standard 9 pin interfaces provide outputs for Pass Fail and Test in Process Inputs include Test Reset and Program Select This gives the user all the basic remotes required to configure the HYAMP II through simple PLC relay control Flashing Test indicator A flashing LED located directly over the high current terminal clearly indicates when high current is active to provide maximum operator safety Withstand processing indicator A front panel LED indicates when the high voltage from the HypotPLUS II is being applied to the item under test for greater operator safety Easily configurable into an automated test system HYAMP II comes standard with rear output connectors and rack mount handles to make it simple to build into an automated system Software calibration control HYAMP II is calibrated through the front panel keypad All calibration information is stored in non volatile memory This allows HYAMP II to be completely calibrated without removing any covers and exposing the technician to hazardous voltages 11 D ASSOCIATED RESEARCH INC WHAT S NEW WHAT S NEW IN HYAMP II STORAGE OF UP TO
50. then press the Exit key to exit and return to the test mode If the Lock mode is selected the Lock indicator on the front panel will light and the keyboard will be locked Ifthe Lock indicator is not lit the keyboard will be operational C Turning the LOCK function ON or OFF with a Password Press the Lock key the display will show 30 D ASSOCIATED RESEARCH INC OPERATION Please use the Numerical keys to enter the four numeral password and then press the Enter key to exit and return to the test mode If the current position of the lock function is OFF the status will be changed to ON and the Lock indicator on the front panel will be illuminated In the reverse case the status will be changed to OFF and the Lock indicator will be off 8 To setup the Remote Control LCD Contrast and Alarm Volume A Status of Remote Control setting Press the UP or DOWN arrow key to toggle the programs until the display shows or Press the Enter key to select the ON or OFF function of the Remote Control mode the display will show the status immediately Press the Exit key to exit to the test mode or toggle to another setting using the arrow keys Ifthe Remote Control is set to ON the Test function will be controlled by the Remote Control via the remote connectors located on the rear panel The Test switc
51. tion CSA the International Electrotechnical Commission IEC the British Standards Institution BSI the Association of German Electrical Engineers VDE the Japanese Standards Association JSI These same agencies may also require that an insulation resistance test and high current ground bond test be performed The Dielectric Withstand Hipot Test The principle behind a dielectric voltage withstand test is simple Ifa product will function when exposed to extremely adverse conditions it can be assumed that the product will function in normal operating circumstances The most common applications of the dielectric withstand test are e Design performance Testing determining design adequacy to meet service conditions e Production Line Testing detecting defects in material or workmanship during processing e Acceptance Testing proving minimum insulation requirements of purchased parts e Repair Service Testing determine reliability and safety of equipment repairs The specific technique varies with each product but basically during a dielectric voltage withstand test an electrical devise is exposed to a voltage significantly higher than it normally encounters The high voltage is continued for a given period of time If during the time the component is tested stray current flow remains within specified limits the device is assumed to be safe under normal conditions The basic product design and use of
52. to the test mode or toggle to another program using the arrow keys 9 To store and recall the memory programs HY AMP II is equipped with a total of 10 memory programs numbered 0 to 9 This makes it possible to store all the various test parameters required and quickly recall them for each of the different products that need to be tested Program memories can also be accessed through the remote control PLC port so that a manufacturer can quickly toggle through the various programs without going into the setup menu A Storage of Memory Program Once you have entered all the test parameters such as Current Voltage Hi Limit Trip Resistance Dwell Time etc as outlined in the above procedures you may store your setup into one of the 10 memories The display will show Set M XXX Xs XX XXA XXX mo Select one of the memory positions 0 to 9 to store the data which was just entered This is done by pressing and holding a Numerical key in for approx 2 seconds HY AMP II will respond with two beep tones one short tone when you select the key and one longer tone when the data is stored into that memory position Please select the correct memory position as you may inadvertently overwrite a previously stored program The display will show Set MX XXX Xs XX XXA XXX mo B Recall ofa Memory Program Please press the Numerical key of the Memory Program that you wish to recall The instrument will respond with a shor
53. ugh the various programs without going into the set up menu Versatile PLC control for either sequential or simultaneous testing Interconnection of the HYAMP II and the HypotPLUS II makes these two instruments a true semi automated test system The test system can be configured to test Ground Bond first and then advance to the Dielectric test The system can also be set up to test Ground Bond and Dielectric simultaneously for greater time savings and increased throughput Line and load regulation This system maintains the output voltage to within 1 from no load to full load and over the line voltage range to ensure that test results remain consistent and within safety agency requirements User selectable output voltage frequencies of 50 or 60 hertz HYAMP II was designed for the global market This feature makes it simple for the user to select the output frequency in the Ground Bond mode so that products can be tested at the same frequency they will be used at Adjustable output current output voltage and milliohm trip ranges This capability makes the HYAMP II versatile enough to meet all safety agency specifications for ground bond test requirements 10 11 12 13 14 15 u ASSOCIATED Dr SPECIFICATIONS Low Limit Trip Range This capability makes it possible to ensure that a test item was properly connected since the HYAMP II can be set to monitor minimum and maximum levels of resistance during a ground bond
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