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Associated Research HYAMP II 5030DT, Operation And Service Manual

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SECTION 1 

OPERATORS MANUAL 

 
 

Summary of Contents for HYAMP II 5030DT

Page 1: ...D SERVICE MANUAL HYAMP II MODEL 5030DT GROUND BOND TESTER SERIAL NUMBER Model 5030DT Associated Research Inc 2002 13860 West Laurel Drive Lake Forest Illinois 60045 4546 U S A Item 37637 Ver 1 12 Printed Aug 15 2002 ...

Page 2: ...pport 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 ...

Page 3: ... SECTION I OPERATORS MANUAL 1 SAFETY 2 INTRODUCTION 5 SPECIFICATIONS 8 WHAT S NEW 12 CONTROLS 14 INSTALLATION 19 QUICK START 22 OPERATION 27 OPTIONS 42 SECTION II SERVICE MANUAL 45 CALIBRATION 46 PARTS LIST 48 SCHEMATICS 49 ...

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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: ...hes 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...

Page 9: ...ge may appear across the two conductive materials Direct Current DC Current which flows in one direction only The source of direct current is said to be polarized and has one terminal which is always at a higher potential than the other Hipot Tester Common term for dielectric withstand test equipment Hypot Registered trademark of Associated Research Inc for its dielectric withstand test equipment ...

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: ...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 600mΩ for 3 12 Amps 1mΩ step 0 150mΩ for 3 31 Amps 1mΩ step Accuracy 2 of setting 2mΩ Low limit 0 600mΩ for 3 12 Amps 1mΩ step 0 150mΩ for 3 31 Amps 1mΩ step Accuracy 2 of setting 2mΩ MILLIOHM OFFSET Max Offset Capability 100mΩ 1mΩ step Accuracy 2 of setting 2mΩ METERING Amme...

Page 13: ...nt and return leads with clips MECHANICAL Bench or rack mount 2U height with tilt up front feet Dimensions w x h x d 17 x 3 5 x 16 5in 432 x 88 x 419mm Weight 27 6 lbs 12 5kgs ENVIRONMENTAL Operating Temperature 32 113 F 0 45 C Relative Humidity 0 to 95 CALIBRATION Traceable to National Institute of Standards and Technology NIST Calibration controlled by software Adjustments are made through front...

Page 14: ...t 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 through the various programs without going into the set up menu 5 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 automa...

Page 15: ...er all the basic remotes required to configure the HYAMP II through simple PLC relay control 12 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 13 Withstand processing indicator A front panel LED indicates when the high voltage from the HypotPLUS II is being applied to the item u...

Page 16: ...learly 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 HYAMP II to meet safety agency requ...

Page 17: ...nt 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 ...

Page 18: ... limit entry The numeric keypad 22 is used to enter the value The Enter key 16 is used to save the new value 5 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 6 DWELL KEY Dedicated key used to select Test Voltage time duration entry The numeric keypad 22 is used to enter the value The Ente...

Page 19: ...operator and programmer of the test settings and test result 13 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 14 mΩ 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 ...

Page 20: ...ound bond test this red indicator will light 21 POWER SWITCH Rocker style switch with international ON and OFF 0 markings 22 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 use...

Page 21: ...CONTROLS 17 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 FRONT PANEL CONTROLS ...

Page 22: ...L and PROCESSING output relay signals as well as remote START and RESET outputs 6 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 7 CHASSIS GROUND EARTH TERMINAL This safety terminal should be connected to a good earth ground before operation 8 INPUT POWER SWITCH Line voltage ...

Page 23: ...ill 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 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 pane...

Page 24: ... 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 Description Part Number Rating High Current lead 05002D 24 31 A 750V Return lead 05002D 37 31 A 750V Operating Environment This instr...

Page 25: ...of service needed Also please mark the container FRAGILE to insure proper handling Upon 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 st...

Page 26: ...hoose to override them with your own test program The instrument default settings are as follows DEFAULTS Input Voltage 115 volts AC rear panel switch selectable Communications local front panel key selectable Mode set up Current Output 25 00 Amps Voltage Output 8 00 volts AC Resistance Trip High 100 mΩ Resistance Trip Low 0 mΩ Dwell Timer 1 second AC Output Frequency 60Hz Buzzer Volume Level 5 Co...

Page 27: ...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 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...

Page 28: ...he pressed position during the test The instrument will then cycle ON and begin the automated test sequence using the defaults If a failure occurs you will HEAR an audible alarm go off To stop the alarm you must depress the RED button marked RESET This will silence the alarm and reset the instrument to begin another test This RESET button may also be used as a safety button to quickly ABORT a test...

Page 29: ...s are identified on the blue tubing Cable number Method Operation 5030DT 22 Sequential HYAMP first then Hypot 5030DT 23 Simultaneous HYAMP and Hypot at the same time 4 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 5 Connect the RETURN lead with the alligato...

Page 30: ...QUICK START 26 This page intentionally left blank ...

Page 31: ...formed 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 th...

Page 32: ...illiohms with a range from 0 600 mΩ s 4 To set the low limit resistance trip setting Please press the LO LIMIT key the display will show LO LMT XXX mΩ 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 mΩ s if set for 0 the low limit resistance trip setting will be di...

Page 33: ...r 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 foll...

Page 34: ...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 L o c k ON or L o ...

Page 35: ...mote 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 switch on the front panel is locked out but the Reset switch will still be functional If the 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...

Page 36: ... 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 S e t M __ XXX X s XX XX A XXX mΩ Select one of the memory positions 0 to 9 to store th...

Page 37: ...ures 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 S e t M __ XXX Xs XX XX A XXX mΩ or S e t MX XXX X s XX XX A XXX mΩ If the set data is to be stored in the memory program please follow the procedure outlined in the setup procedures on Storage of Mem...

Page 38: ...essed 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 If the 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 ready to perfor...

Page 39: ...eceptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 747784 3 JACKSCREW SET 2 REMOTE INTERFACE REAR PANEL 1 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 i...

Page 40: ... 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 pa...

Page 41: ... 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 ...

Page 42: ...ated 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 HYAMP II SIGNAL INPUT HypotPLUS II SIGNAL OUTPUT CONNECTION HYAMP II SIGNAL OUTPUT HypotPLUS II SIGNAL INPUT CONNECTION HYAMP II HypotPLUS II 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 Female Plug Male Plug HYAMP I...

Page 43: ... 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 HYAMP II with the HypotPLUS II The following t...

Page 44: ...e 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 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 II 2 For simultaneous testing methods use the following cable connection Locate the cable marked 5030DT 23 SIMULTANEOUS Co...

Page 45: ...n 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 HYAMP 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 II The return lea...

Page 46: ...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 r...

Page 47: ...y 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...

Page 48: ...OPTIONS 44 This page left intentionally blank ...

Page 49: ...SECTION 2 SERVICE MANUAL ...

Page 50: ... 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 the...

Page 51: ...t will provide around 30A on the output and the display will show C u r r e n t __ A 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 If an 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 procedu...

Page 52: ... Diode Rectify Bridge 50V 50A 37563 2 Handle Rack Mount 37554 1 LCD Display 16 x 2 Characters 33189 1 Line Cord Mains 37637 1 Manual Operating Service 5030DT 37555 1 Power Switch 2P 10A 250V 35999 1 Return Connector Black Banana Jack 37557 1 Switch Reset Red 37556 1 Switch Test Green 37879 1 T1 Transformer Input Toroidal 37878 1 Fuse 5A 250V Very Slow Blow 20mm 37781 1 Fuse Holder 20mm 5002D 37 1 ...

Page 53: ...Drawing Number Description Pages S05030DT Wiring Diagram 1 S37622 Main Control Board 4 S37624 Main Power Amplifier Board 1 S37550 Keypad Board 1 S37515 Input Protection Board 1 S37591 Rectifier Board 1 S38220 ROM Conversion Board 1 ...

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