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TABLE OF CONTENTS 

 

SECTION I OPERATORS MANUAL ............................................................................1 

SAFETY ...........................................................................................................................2 

INTRODUCTION ............................................................................................................5 

SPECIFICATIONS...........................................................................................................8 

CONTROLS ...................................................................................................................12 

INSTALLATION ...........................................................................................................15 

QUICK

 

START ..............................................................................................................18 

OPERATION..................................................................................................................22 

OPTIONS .......................................................................................................................32 

SECTION II SERVICE MANUAL................................................................................35 

CALIBRATION .............................................................................................................36 

PARTS

 

LIST...................................................................................................................38 

SCHEMATICS ...............................................................................................................39 

Summary of Contents for 3030D

Page 1: ...D SERVICE MANUAL HYAMP jr MODEL 3030D GROUND BOND TESTER SERIAL NUMBER Model 3030D Associated Research Inc 2002 13860 West Laurel Drive Lake Forest Illinois 60045 4546 U S A Item 37952 Ver 1 06 Printed Jan 25 2002 ...

Page 2: ...this instrument for warranty service Please contact our Customer Support Center at 1 800 858 TEST 8378 to obtain an RMA 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 no...

Page 3: ...ONTENTS SECTION I OPERATORS MANUAL 1 SAFETY 2 INTRODUCTION 5 SPECIFICATIONS 8 CONTROLS 12 INSTALLATION 15 QUICK START 18 OPERATION 22 OPTIONS 32 SECTION II SERVICE MANUAL 35 CALIBRATION 36 PARTS LIST 38 SCHEMATICS 39 ...

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Page 5: ...SECTION 1 OPERATORS MANUAL ...

Page 6: ...t line voltage 115 or 230 and the correct fuse is installed INSTRUCTION MANUAL SYMBOL PLEASE REFER TO THE INSTRUCTION MANUAL FOR SPECIFIC WARNING OR CAUTION INFORMATION TO AVOID PERSONAL INJURY OR DAMAGE TO THE PRODUCT INDICATES HAZARDOUS VOLTAGES MAY BE PRESENT CHASSIS GROUND SYMBOL CALLS ATTENTION TO A PROCEDURE PRACTICE OR CONDITION THAT COULD POSSIBLY CAUSE BODILY INJURY OR DEATH CALLS ATTENTI...

Page 7: ...es 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 annual safety check and maintained properly User Modifications Unauthorized user modifications will void your warranty Associated Research ...

Page 8: ...tches 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 what product is being tested and which products are waiting to be tested or have al...

Page 9: ...aterials Direct Current DC Current that flows in one direction only The source of direct current is said to be polarized and has one terminal that is 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 HYAMP Registered trademark of Associated Re...

Page 10: ...ct 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 Design performance Testing determining design adequacy to meet service conditions Production Line Testing detecting defects in material or workmanship during processing Acceptance Testing p...

Page 11: ... 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 and exposed metal of the item under test If a 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...

Page 12: ...lectable DWELL TIME SETTING 0 and 0 5 999 9 seconds 0 1 second step 0 for continuous running Accuracy 0 1 of Setting 0 05 seconds FAILURE SETTINGS High limit 0 120mΩ for 3 30 Amps 1mΩ step 0 510mΩ for 3 10 Amps 1mΩ step Accuracy 2 of setting 2mΩ MILLIOHM OFFSET Max Offset Capability 100mΩ 1mΩ step Accuracy 2 of setting 2mΩ METERING Ammeter 3 digits Range 0 30 Amps Resolution 0 1 Amp step Accuracy ...

Page 13: ...tachable 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 style with tilt up front feet Dimensions w x h x d 11 x 3 5 x 14 56 in 280 x 89 x 370mm Weight 20 lbs 9 kg ENVIRONMENTAL Operating Temperature 32 113 F 0 45 C Relative Humidity 0 to 95 CALIBRATION Traceable to National Institute of Standards an...

Page 14: ...d then advance to the Dielectric Withstand test and Insulation Resistance tests 6 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 7 User selectable output voltage frequencies of 50 or 60 hertz HYAMP jr was designed for the globa...

Page 15: ...front panel display indicates when the high voltage from the Hypot II is being applied to the item under test for greater operator safety 13 Software calibration control HYAMP jr is calibrated through the front panel keypad All calibration information is stored in non volatile memory This allows HYAMP jr to be completely calibrated without removing any covers and exposing the technician to hazardo...

Page 16: ...e test settings and test results 4 TEST LED INDICATOR This red LED lights to indicate to the operator that a test is in process 5 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 6 POWER SWITCH Rocker style switch with international ON l and OFF 0 markings 7 SET KEY Use this key to advance forw...

Page 17: ... may also be used to save settings into memory 11 CURRENT OUTPUT JACK For the connection of the detachable 5 foot 1 52 m red high current test lead This jack is always used when performing a Ground Bond test 12 RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black return test lead This jack is always used when performing a test ...

Page 18: ...ote START and RESET outputs 4 CALIBRATION ENABLE This recessed switch when depressed allows access to the calibration control program 5 REMOTE INPUT 9 pin D subminiature male connector for remote control of test and reset functions as well as withstand processing input 6 CHASSIS GROUND EARTH TERMINAL This safety terminal should be connected to a good earth ground before operation 7 FUSE RECEPTACLE...

Page 19: ...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 This instrument requires a power source 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 ...

Page 20: ...e red Current jack The black Return lead will connect to the black Return jack The test lead ratings are as follows Description Part Number Rating Return lead 37953 30 A 600V High Current lead 37954 30 A 600V 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 Ventilation When choosing a ben...

Page 21: ...e 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...

Page 22: ...his 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 b 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 ...

Page 23: ...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 If the instrument defaults are acceptable then be sure to connect the appropriate test leads to the device under test DUT or test fixture Be sure to connect this safety ground to a suitable known good ground before energizing this instru...

Page 24: ...ly then select the appropriate cable assembly for your needs using the descriptions in the table below Cable number Method Operation 3030D 22 Sequential HYAMP jr first then Hypot II 3030D 23 Simultaneous HYAMP jr and Hypot II at the same time Note The cables are identified on the cable label 2 Attach the male connector with two cables coming from it to the female output connector of the HYAMP jr A...

Page 25: ...ltage is active The display on the HYAMP jr will change to show a W On indicating that the Dielectric Withstand test is processing An example of this display is shown below The initialization of the AC or DC Dielectric Withstand test will now be controlled by the HYAMP jr through the interconnect cables Set M1 1 0s 25 00A W On 0mΩ ...

Page 26: ... will show the following message ARI HYAMP JR 3030D VER X X The instrument will recall the last memory program that was active and the display will show the parameters that were programmed into that memory The instrument is now ready for operation B SETUP PROCEDURE 1 Output Current Setting Please press the SET key the display will show CURRENT XX XA Please use the Up or Down arrow keys to adjust t...

Page 27: ...he Up or Down arrow keys to change the Frequency setting to 50Hz or 60Hz then press the EXIT key to store the frequency setting and return to the Run mode or press the SET key to advance to the next parameter 5 Offset Setting Please press the SET key until arriving at the Offset setting The display will show Offset XXX mΩ TEST to Auto Set Please use the Up or Down arrow keys to adjust the setting ...

Page 28: ... Memory Program Please press the SET key until the Memory Program is displayed then press the Up or Down arrow keys until the specific memory you wish to recall is displayed Pressing the EXIT key will activate this memory position To start a test press the TEST button 7 To Set Key Lock or Memory Lock The HYAMP jr is equipped with two different lockout selections The first selection is Key Lock Wit...

Page 29: ...o 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 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 Progra...

Page 30: ...t generates more that the maximum limit of 6VAC then red RESET switch will illuminate and the alarm will sound The display will show V OVLD MX XXX X s XX XA 6VAC To stop the alarm please press the RESET switch once The alarm will stop and the display will retain the failure information If the RESET switch is pressed again the data on the display screen will be cleared and the display will indicate...

Page 31: ... either plug or receptacle 747784 3 JACKSCREW SET 2 REMOTE INTERFACE REAR PANEL SIGNAL OUTPUTS 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...

Page 32: ...ct 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...

Page 33: ...rs 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 HYAMP jr Hypot II Sequential Connection B Simultaneous Testing HYAMP jr Hypot II Simultaneous Connections HYAMP jr OUT Hypot II I O HYAMP jr IN 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 Male Plug Female Plug Female Plug HYAMP jr OUT Hypot...

Page 34: ...1 The following sections describe the procedures for interconnecting your units Please refer to the test method you require for specific cable connection instructions 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 front panel of the Hypot II and the other end to the INTERCONNECT jack on the front pan...

Page 35: ...oduct If the high voltage lead is not used it should be secured out of the way If the HYAMP jr and the Hypot 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 Hypot II The return lead from the Hypot II should be connected to the HYAMP jr as described in the previous section Cable Connections This configuration would allo...

Page 36: ... s code would appear as follows fitted with option 02 OPT 02 fitted with option 02 and 03 OPT 0102 3030D Options List Code Description 01 Rear Outputs 02 Floating Return Description 01 Rear Outputs The Rear Outputs option gives the user the capability to access the High Current Return and Interconnect outputs from the rear panel for use in automated systems The configuration and descriptions are a...

Page 37: ...For the connection of the detachable 5 foot 1 52 m black return test lead This jack is always used when performing a test 02 Floating Return This option separates the Return from the Earth ground With this option the Return lead of instrument is not connected directly to earth ground The main purpose for this option is to allow customers the ability to test DUT s that are earth grounded ...

Page 38: ...OPTIONS 34 This page left intentionally blank ...

Page 39: ...SECTION 2 SERVICE MANUAL ...

Page 40: ...owing equipment will be needed to properly calibrate your instrument 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 Using a pen or small screw driver press and hold the rear panel recessed calibration key then turn on the Input Power Switch The display will show C a l i b ...

Page 41: ...y will show C u r r e n t __ A Please use the Up or Down arrow keys to enter the reading of the standard ac ammeter into the instrument then press the SET key to store the current setting To exit without changing the calibration press the EXIT key 3 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 ...

Page 42: ...37700 4 Foot Pad Rubber Adhesive 37554 1 LCD Display 16 x 2 Characters 33189 1 Line Cord Mains 37555 1 Power Switch 2P 10A 250V 35999 1 Return Connector Black Banana Jack 37673 1 Switch Reset Red 37497 1 Switch Test Green 38017 1 T1 Transformer Input Toroidal 37780 1 Fuse 6 3A 250V Slow Blow 20mm 37781 1 Fuse Holder 20mm 37953 1 Cable Assy High Current Return Lead 37954 1 Cable Assy High Current O...

Page 43: ...Reference Designator Pages S03030D Wiring Diagram 1 S37955 Main Control Board 3030 3 S37956 Power Amplifier Board AMP 260 1 S37593 Keypad Board CKB 02 1 S37515 Input Protection Board CSW 01 1 S37957 Rectifier Board REC 18 1 S38220 ROM Conversion Board 82147 1 ...

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