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Associated Research Hypot II 4500D, Operation And Service Manual

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Associated Research Hypot II 4500D Operation And Service Manual Download Page 46

PARTS LIST

42

 Replacement Parts List HYPOT II

Model  4500D

ECO 5172  REV D

Part 

Number  Qty.

Reference

Designator

Description

38111

1

CHV-4500 

High Voltage Control Board

37593

1

CKB-02

Key Board Assembly

38135

1

CSW-05

Input Protection Board

38110

1

4500

Main Control Board

38112

1

AMP-510 

Power 

Amplifier 

Board

38113

1

REC-19

Rectifier Board

37571

1

-

Earth Connector

35999

4

-

Black Banana Jacks

37478

2

-

High Voltage Connector

38101

1

-

Feet Kit w/o Rubber Inserts

38102

4

-

Rubber Insert for Feet

38788

2

-

3U Rack Mount Bracket

38787

2

-

3U Rack Mount Handle

37999

1

-

Fuse 15A, 250V, Fast Blow, 20 mm

37554

1

-

LCD Display 16 x 2 Characters

38109

1

-

Power Switch  2P 10A/250V

37673

1

-

Test Switch,  Green

37497

1

-

Reset Switch,  Red

38075

1

-

Interlock Connector Std. M/F

38108

1

T-4500-T2 

Output High Voltage Transformer

38107

1

T-4500-T1  Input 

Transformer

38071

1

-

Input Power Cable  15A/6Ft.

04040A-08

1

-

High Voltage Output cable

02100A-13

2

-

Return cable

37697

1

U9

Microcontroller 8 Bit P89C52

38009

1

U10

IC W27E257 EEPROM

37605

2  FAIL,READY 

Bulbs

Summary of Contents for Hypot II 4500D

Page 1: ...t II MODEL 4500D 500 VA Enhanced AC Only Hipot With Ground Continuity Check SERIAL NUMBER Model 4500D Associated Research Inc 2010 13860 West Laurel Drive Lake Forest Illinois 60045 4546 U S A Item 38088 Ver 1 13 Printed February 16 2010 ...

Page 2: ...1984 EN 60 555 2 1987 IEC 801 4 1998 Supplementary Information The product herewith complies with the requirements of the Low Voltage Directive 73 23 EEC as amended by 93 68 EEC and the EMC Directive 89 336 EEC as amended by 92 31 EEC The CE marking has been affixed on the device according to article 10 of the EMC Directive 8 336 EEC The technical file and other documentation are on file with Asso...

Page 3: ...ts 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 the instrument for warranty service must be prepaid by the customer AR will assume the return freight costs when returning th...

Page 4: ...NTENTS SECTION I OPERATORS MANUAL 1 SAFETY 2 INTRODUCTION 7 SPECIFICATIONS 13 CONTROLS 17 INSTALLATION 20 QUICKSTART 23 OPERATION 26 OPTIONS 36 SECTION II SERVICE MANUAL 39 CALIBRATION 40 PARTS LIST 42 SCHEMATICS 43 ...

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

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

Page 7: ...er ASSOCIATED RESEARCH INC 13860 WEST LAUREL DRIVE LAKE FOREST IL 60045 4546 U S A PHONE 1 847 367 4077 1 800 858 TEST 8378 FAX 1 847 367 4080 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 re...

Page 8: ...device to be tested Construct the guards of a non conducting material such as clear acrylic so that the item being tested is within the guards or enclosure during the test If possible the guards or enclosure should also contain safety switches that will not allow the tester to operate unless the guards are in place or the enclosure closed Keep the area clean and uncluttered All test equipment and ...

Page 9: ...lator never touch the clip directly Be certain that the operator has control over any remote test switches connected to the Hipot Double check the return and high voltage connections to be certain that they are proper and secure NEVER TOUCH THE ITEM UNDER TEST OR ANYTHING CONNECTED TO IT WHILE HIGH VOLTAGE IS PRESENT DURING THE HIPOT TEST When testing with DC always discharge the capacitance of th...

Page 10: ...zed personnel away from the test area Arrange the test station in a safe and orderly manner Never touch the product or connections during a test In case of any problem turn off the high voltage first Properly discharge any item tested with DC before touching connections ...

Page 11: ...ials 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 Insulation Gas liquid or solid material which...

Page 12: ...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 13: ... testing to be done However in other cases the Compliance Agency only allows for an AC test If you are unsure which specification you must comply with please contact our CUSTOMER SUPPORT GROUP at 1 800 858 TEST 8378 Many safety agency specifications allow either AC or DC voltages to be used during the hipot test When this is the case the manufacturer must make the decision on which type of voltage...

Page 14: ...h DC testing This can present increased safety risks as operators are exposed to higher currents DC testing characteristics During DC hipot testing the item under test is charged The same test item capacitance that causes reactive current in AC testing results in initial charging current which exponentially drops to zero in DC testing DC testing advantages 1 Once the item under test is fully charg...

Page 15: ...rements calling out this test A low current test merely indicates that there is a safety ground connection It does not completely test the integrity of the connection that would be accomplished by using much higher currents in the range from 10 to 30amps The high current test is known as a Ground Bond test The Ground Continuity test verifies that the ground circuit between the Continuity and Retur...

Page 16: ... of insulation condition it does not replace the need to perform a Dielectric Withstand test TYPES OF FAILURES DETECTABLE ONLY WITH A HIPOT TEST Weak Insulating Materials Pinholes in Insulation Inadequate Spacing of Components Pinched Insulation IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION OF YOUR INSTRUMENT CALL 1 800 858 TEST 8378 IN THE U S A ...

Page 17: ...ion via UP and DOWN arrow keys OUTPUT FREQUENCY 50 60 Hz selectable WAVE FORM Sinewave 1 3 Crest Factor 1 5 DWELL TIME SETTING 0 and 0 2 999 9 seconds 0 1 second step 0 for continuous running RAMP TIME SETTING 0 and 0 2 999 9 seconds 0 1 second step 0 ramp setting 0 1 seconds fixed ramp FAILURE SETTINGS AC mode High limit 0 00 99 99 mA 0 01 mA step Low limit 0 00 99 99 mA 0 01 mA step 0 OFF Accura...

Page 18: ... a three prong grounding plug Terminations 5ft 1 52m high voltage and return leads 2 with clips and a standard U S style NEMA 5 15 remote receptacle box for testing items terminated with a line cord International receptacles also available Mechanical Tilt up front feet Dimensions W x H x D 17 x 5 8 x 12 in 432 x 147 x 305mm Weight 56 70 Lbs 25 92 kgs Environmental Operating Temperatures 32 104 F 0...

Page 19: ... remain consistent and within safety agency requirements 6 The LCD display allows monitoring of current down to 100 microamps AC This allows the 4500D to be used even when test requirements only allow a very low level of acceptable leakage current 7 Electronic dwell settings The electronic dwell control helps keep test results consistent by ensuring that the test duration is the same for each prod...

Page 20: ...indicator A flashing LED located directly over the high voltage terminal clearly indicates when high voltage is active to provide maximum operator safety 16 Comes complete with a test box for products terminated in a line cord The standard US style receptacle box allows easy testing of hipot and continuity on line cord terminated products As an additional benefit termination boxes are available fo...

Page 21: ...nabled 3 LCD DISPLAY The Liquid Crystal Display is the main readout for the operator and programmer of the test settings and test results 4 CONTINUITY CHECK OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black return test lead or three prong receptacle adapter box This jack is always used when performing a continuity test Please refer to page 35 for details on connecting the adapte...

Page 22: ...E OUTPUT JACK For the connection of the detachable 5 foot 1 52 m red high voltage test lead The silicone rubber insulation is flexible for easy handling and is rated at 30KVDC The jack is recessed for safety when this lead is not being used 11 HIGH VOLTAGE ARROW LED INDICATOR This indicator flashes to warn the operator that high voltage is present at the high voltage output terminal 12 RETURN OUTP...

Page 23: ...onnection of the detachable 5 foot 1 52 m black return test lead or three prong receptacle adapter box This jack is always used when performing a continuity test Please refer to page 35 for details on connecting the adapter box between Hypot II and the device under test 6 RETURN OUTPUT JACK For the connection of the detachable 5 foot 1 52 m black return test lead This lead is always used when perf...

Page 24: ... will assist you in the repair or replacement of your instrument Please do not return your product without first notifying us and receiving an RMA return materials authorization number Preparation for Use Power Requirements and Line Voltage Selection This instrument requires a power source of 115 volts AC 10 50 60 Hz 5 single phase or 230 volts AC 10 50 60 Hz 5 single phase Please check the rear p...

Page 25: ...MENT Environment This instrument may be stored or shipped in environments with the following limits Temperature 40 to 75 C Altitude 7 620 meters 25 000 feet The instrument should also be protected against temperature extremes that may cause condensation within the instrument Packaging Original Packaging Please retain all original packaging materials if you do not have an alternate method of repack...

Page 26: ...tation 350 lb test material is adequate 6 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 7 Seal the container securely 8 Mark the container FRAGILE to insure proper handling 9 Please ship model 4500D via Federal Express or UPS air 10 Please refer in all correspondence to your AR service number Field...

Page 27: ... unless you choose to override them with your own test program The default settings will appear in memories 1 5 The instrument default settings are as follows DEFAULTS Input Voltage 115 or 230 volts AC country specific rear panel switch selectable Lock OFF Voltage Output 1 240 volts AC High Current Trip HI LMT 10 mA Low Current Trip LO LMT 0 mA Ramp Timer 0 second Dwell Timer 1 second AC Output Fr...

Page 28: ...d 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 addition you will see the Associated Research name and Model Number briefly appear on t...

Page 29: ...he 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 and cut off the HIGH VOLTAGE When HI...

Page 30: ...k for the condition of the ram chips PCB s and other critical components In addition the display will show the following message with the model and version number The instrument will recall the last setup that was active and the display will show the parameters that were programmed into the unit The instrument is now ready for operation 2 SETUP PROCEDURE 2 1 To Select the Memory location Please pr...

Page 31: ...illiamperes as the minimum setting 2 4 To set the Low Leakage Current Limit Please press the SET key until the display shows LO LMT X XX mA Use the Up Down Arrow keys to enter the leakage current low limit setting then press the EXIT key to exit to the test mode or toggle to another setting using the SET key The unit of measure is in AC milliamperes with 0 00 milliamperes as the minimum setting 2 ...

Page 32: ...ll show the set status immediately Press the EXIT key to exit to the test mode or toggle to another setting using the SET key If the Continuity Function is set to ON the Ground Continuity cable has to be connected between the Cont Check connector on the instrument panel and the chassis of the DUT The instrument will test the ground connection of the DUT automatically If continuity is present a gre...

Page 33: ...ST and RESET You can toggle this selection only from a power OFF state Please turn the power switch to the off position then press and hold the SET key then turn the power ON Momentarily you will see one of the following screens to indicate if the keys are locked or unlocked Key Lockout or Key Unlock To change the key lock function power down the instrument and repeat the process ...

Page 34: ...d the High Limit Setting and memory location Set MX XXX Xs X XXKVAC XX XxmA 3 1 Ground Continuity Check If you are performing a Ground Continuity Check the Ground Continuity must be set to the ON Enabled position The ground check cable has to be connected properly to the chassis of the DUT and the green indicator on the TEST switch should be illuminated before activating the Test switch Otherwise ...

Page 35: ...ing the test which results in an OFL condition due to the current exceeding the maximum metering range Breakdown will be indicated as follows The red indicator light will illuminate on the RESET switch and an alarm will sound The display will show HI LMT MX XXX Xs X XXKVAC OFL mA 3 5 Leakage Current Exceeding the Metering Range If the leakage current exceeds the metering range and neither a short ...

Page 36: ...e cleared and the display will indicate the setting data from the last test The instrument is now ready for the next test 3 9 Pass If the DUT passed the test the instrument will output a short audible beep tone to indicate the DUT has passed the test The display will show Pass MX XXX Xs X XXKVAC XX XxmA The instrument is now ready to perform another test 3 10 Aborting a Test If the operator elects...

Page 37: ... CONTACT for plug 745253 7 CRIMP SNAP IN SOCKET CONTACT for receptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 747784 3 JACKSCREW SET 2 Remote Interface Rear Panel 4 1 Signal Outputs on Remote I O The rear panel connector provides three output signals to remotely monitor PASS FAIL and PROCESSING conditions The monitoring signals are provided by three normally open internal rela...

Page 38: ...vated through the test switch A normally open momentary switch can then be wired across pins 3 and 5 to allow remote operation of the TEST function A normally open momentary switch can also be wired across pins 2 and 5 which allows remote operation of the RESET function For safety the front panel RESET switch remains active even when a remote reset switch is connected so that high voltage can be s...

Page 39: ...is or dead metal of the product With the HYPOT II you can perform both the hipot and continuity tests at the same time by activating the continuity function on the instrument When the HYPOT II tests the ground conductor of the line cord if the resistance of the ground conductor exceeds 1Ω the hipot will signal a continuity failure If continuity is present high voltage is applied to both conductors...

Page 40: ...ppear as follows fitted with option 05 OPT 05 fitted with option 04 and 05 OPT 0405 4500D Options Option List Code Description 04 Arc Detection 05 Floating Return 06 Remote Memory Select Description 04 Arc Detection This option provides the user with the capability of detecting low level arcing The arc detection circuit has nine preset sensitivity levels Arc Detection Specifications FAILURE SETTIN...

Page 41: ...und The metering circuit monitors only leakage current flowing from the DUT through the Return test lead to the Return connector Therefore it is crucial that the DUT does not make direct contact with earth ground or the metering circuit and leakage fail detectors will be Bypassed 06 Remote Memory Select This option enables remote operation of three pre programmed test setups Memories 1 3 through t...

Page 42: ...PTIONS 38 MEMORY THREE Momentarily connecting pin 7 to pins 8 and 9 immediately begins the test program that is stored in memory three 6 9 SIGNAL INPUT 1 5 INTERLOCK TEST RESET MEMORY 2 MEMORY 1 MEMORY 3 ...

Page 43: ...SECTION 2 SERVICE MANUAL ...

Page 44: ...ainty ratio of the calibration standards being used Calibration Equipment Required The following equipment will be needed to properly calibrate your instrument 1 Digital Multimeter with the minimum ranges AC Voltage 5 000 volts AC Current 100mA range 2 10KΩ 100Watt resistor 100KΩ 10Watt resistor 1 CALIBRATION PROCEDURE Model 4500D To enter the calibration mode the instrument must be in the OFF pos...

Page 45: ...r 10K Ohms 100 watts Please connect a 10KΩ resistor in series with the standard ac milliammeter and connect these across the output leads of the instrument Press the Down Arrow key The instrument will provide around 1000VAC on the output and the display will show Current X XX mA Please use the Up Down Arrow keys to enter the reading of the standard AC milliammeter into the instrument Then press th...

Page 46: ...e Connector 38101 1 Feet Kit w o Rubber Inserts 38102 4 Rubber Insert for Feet 38788 2 3U Rack Mount Bracket 38787 2 3U Rack Mount Handle 37999 1 Fuse 15A 250V Fast Blow 20 mm 37554 1 LCD Display 16 x 2 Characters 38109 1 Power Switch 2P 10A 250V 37673 1 Test Switch Green 37497 1 Reset Switch Red 38075 1 Interlock Connector Std M F 38108 1 T 4500 T2 Output High Voltage Transformer 38107 1 T 4500 T...

Page 47: ...X Drawing Number Description Pages S04500D Wiring Diagram 1 4500 Main Control Board 5 AMP 510 Power Amplifier Board 1 REC 19 Rectifier Board 1 CHV 4500 HV Control Board AC DC 1 CKB 02 Keypad Board 1 CSW 05 Input Protection Board 1 ...

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