1. Manuals
  2. Brands
  3. Associated Research Manuals
  4. Test Equipment
  5. Hypot II 4500D
  6. Operation and service manual

Associated Research Hypot II 4500D Operation And Service Manual

500 va enhanced ac only hipot with ground continuity check
Hide thumbs
Table of Contents

Advertisement

Quick Links

OPERATION AND SERVICE MANUAL
®
Hypot
II
MODEL 4500D
500 VA Enhanced
AC Only Hipot With Ground Continuity Check
SERIAL NUMBER
Model
© Associated Research, Inc. 2010
13860 West Laurel Drive
4500D
Lake Forest, Illinois 60045-4546
U.S.A.
Item 38088
Ver 1.13
Printed February 16, 2010
i

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Hypot II 4500D and is the answer not in the manual?

Questions and answers

Related Manuals for Associated Research Hypot II 4500D

Summary of Contents for Associated Research Hypot II 4500D

  • Page 1 ® Hypot MODEL 4500D 500 VA Enhanced AC Only Hipot With Ground Continuity Check SERIAL NUMBER Model © Associated Research, Inc. 2010 13860 West Laurel Drive 4500D Lake Forest, Illinois 60045-4546 U.S.A. Item 38088 Ver 1.13 Printed February 16, 2010...
  • Page 2 DECLARATION OF CONFORMITY Manufacturer: Associated Research, Inc. Address: 13860 W. Laurel Dr. Lake Forest, IL 60045 Product Name: Hypot® II 500VA Dielectric Withstand Voltage Tester Model Number: 4500D Conforms to the following Standards: Safety: EN 61010-1: 1993 + A2, EN 61010-2-031: 1994...
  • Page 3 Warranty Policies 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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 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 I Operators Manual

    SECTION 1 OPERATORS MANUAL...

  • Page 6: Safety

    SAFETY SAFETY PRECAUTIONS REQUIRED FOR HIGH VOLTAGE TESTING! 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.
  • Page 7 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 annual safety check and maintained properly.
  • Page 8 SAFETY 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 – HIGH VOLTAGE TEST IN PROGRESS – UNAUTHORIZED PERSONNEL KEEP AWAY.” Power Dielectric Voltage-Withstand 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.
  • Page 9 SAFETY 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.
  • Page 10 SAFETY KEY SAFETY POINTS TO REMEMBER: • Keep unqualified and unauthorized 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. •...

  • Page 11: Introduction

    Hipot Tester: Common term for dielectric-withstand test equipment. Hypot®: Registered trademark of Associated Research, Inc., for its dielectric-withstand test equipment. Gas, liquid or solid material which has a volume resistivity of at least 10 12 ohm-cm and is Insulation: used for the purpose of resisting current flow between conductors.
  • Page 12 INTRODUCTION 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.
  • Page 13 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”...
  • Page 14 INTRODUCTION current reading. This means that unless the product is sensitive to a sudden application of voltage the operator can immediately apply full voltage and read current without any wait time. 3. Another advantage of AC testing is that since AC voltage cannot charge a load there is no need to discharge the item under test after the test.
  • Page 15 INTRODUCTION 2. Since a DC hipot does charge the item under test it becomes necessary to discharge the item after the test. 3. DC testing unlike AC testing only charges the insulation in one polarity. This becomes a concern when testing products that will actually be used at AC voltages. This is a key reason that some safety agencies do not accept DC testing as an alternative to AC.
  • Page 16 INTRODUCTION between the two points and any component resistance which might also be connected between the two points. Although the IR test can be a predictor of insulation condition it does not replace the need to perform a Dielectric Withstand test. TYPES OF FAILURES DETECTABLE ONLY WITH A HIPOT TEST •...

  • Page 17: Specifications

    SPECIFICATIONS Model 4500D Functional Specifications Unless otherwise stated, accuracy’ s are relative to a laboratory standard measurement. DIELECTRIC WITHSTAND TEST MODE Descriptions Specifications 115 / 230V selectable, ± 10 % variation INPUT VOLTAGE 50/60 Hz ± 5% FUSE 115 VAC, 230VAC – 15A fast acting 250VAC OUTPUT Rating AC 0 –...
  • Page 18 SPECIFICATIONS Current : DC 0.1 A ± 0.01A, fixed GROUND Max. ground resistance : 1 Ω ± 0.1Ω, fixed CONTINUITY CHECK GENERAL SPECIFICATIONS Remote Control and The following input and output signals are provided through two Signal Output 9 pin D type connectors; 1.
  • Page 19 SPECIFICATIONS KEY FEATURES & BENEFITS OF MODEL 4500D 1. No load setup of trip current and output voltage. This provides the operator with an easy and safe way to set trip currents and output voltages since parameters are set without the high voltage activated. 2.
  • Page 20 SPECIFICATIONS 11. Software calibration control. The 4500D is calibrated through the front panel keypad. All calibration information is stored in non-volatile memory. This allows the 4500D to be completely calibrated without removing any covers and exposing the technician to hazardous voltages. 12.

  • Page 21: Controls

    INSTALLATION FRONT PANEL CONTROLS 1. RESET SWITCH: This is a momentary contact switch. If an out-of-range reading is detected during a hipot test or an IR test or if continuity failure occurs, the red failure lamp within the switch will light. To reset the system for the next test, press and release this switch.
  • Page 22 INSTALLATION FRONT PANEL CONTROLS ∧) 8. UP ARROW ( : Use this key to increment numeric values in the setup mode. This key also used to toggle ON/OFF functions. Also may be used to increase output voltage during a test in 10 volt increments. 9.
  • Page 23 INSTALLATION REAR PANEL CONTROLS 1. REMOTE INTERFACE SIGNAL OUTPUT: 9 pin D subminiature female connector which provides; Pass, Fail and Test in process signals 2. REMOTE INTERFACE SIGNAL INPUT: 9 pin D subminiature male connector which provides remote control access over Test, Reset and Interlock. 3.

  • Page 24: Installation

    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.
  • Page 25 INSTALLATION Power Cable BEFORE CONNECTING POWER TO THIS INSTRUMENT, WARNING 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.
  • Page 26 INSTALLATION 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. 5. Use a strong double-wall container that is made for shipping instrumentation. 350 lb. test material is adequate.

  • Page 27: Quickstart

    QUICK START QUICKSTART This quick start guide assumes the operator has some familiarity with automated hipot 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.
  • Page 28 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 the LCD readout and then clear itself.
  • Page 29 QUICK START 5. 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 instrument, connect the return lead first (black) to the test fixture or item followed by the high voltage output lead (red).

  • Page 30: Operation

    OPERATION OPERATION INSTRUCTIONS FOR Hypot II Model 4500D 1. POWER UP: Check that the correct input line voltage has been selected on the rear panel, either 115 volts AC or 230 CAUTION volts AC. Plug the line cord into its socket on the rear panel of the instrument.
  • Page 31 OPERATION 2.2. To set the Output Test Voltage Please press the SET key until the display shows: Voltage= X.XX KV Please use the Up/Down Arrow keys to enter the desired test voltage, then press the EXIT key to exit to the test mode or toggle to another setting using the SET key.
  • Page 32 OPERATION 2.6. To set the Dwell Time Please press the SET key until the display shows: Timer X.X s Use the Up/Down Arrow keys to enter the dwell time setting, then press the EXIT key to exit to the test mode or toggle to another setting using the SET key. If the dwell time is set to “...
  • Page 33 OPERATION 2.9. To lock or unlock the front panel keyboard The Hypot II is equipped with a lockout mode. Within this mode, you can lockout all front panel control functions except TEST 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.
  • Page 34 OPERATION 3. OPERATING PROCEDURES: 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.
  • Page 35 OPERATION 3.2. Initiating a Test To initiate a test, press the TEST switch on the front panel. The red High Voltage Arrow indicator will flash and the display will immediately show: Ramp MX XXX.Xs Dwell MX XXX.Xs X.XXKVAC XX.XxmA X.XXKVAC XX.XxmA The instrument will continue to output the desired voltage for the duration of the selected dwell time.
  • Page 36 OPERATION 3.7. Low Limit If the leakage current does not exceed the low limit setting, the red indicator light will illuminate on the RESET switch and an alarm will sound. The display will show: LO-LMT MX XXX.Xs X.XXKVAC XX.XxmA 3.8. Resetting the Alarm To stop the alarm, please press the RESET switch once.
  • Page 37 OPERATION 4. CONNECTION OF REMOTE I/O Two 9 pin “ D” type connectors are mounted on the rear panel which 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.
  • Page 38 OPERATION Pins 1 and 2 provide the PASS signal. Pins 3 and 4 provide the FAIL signal. Pins 5 and 6 provide the PROCESSING signal. The following describes how the relays operate for each test condition. PROCESSING – The relay contact closes the connection between pin (5) and pin (6) while the instrument is performing a test.
  • Page 39 OPERATION 5. ADAPTER BOX CONNECTION: The following diagram shows how to connect the adapter box to the HYPOT II and to the device under test. 4500D 36544 CONT CHASSIS Test Connections The adapter box allows you an easy way to connect an item that is terminated in a two or three-prong line cord.

  • Page 40: Options

    OPTIONS MODEL 4500D OPTIONS Introduction This section contains a list and descriptions of available 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.
  • Page 41 OPTIONS Arc-Sen= Use the Up/Down Arrow keys to select the arc sensitivity level. The arc sensitivity level may be set between the values of 1 and 9, 1 being the least sensitive, 9 being the most sensitive. To deactivate the Arc Detection set the arc sensitivity to 0. Press the EXIT key to exit to the test mode or toggle to another setting using the SET key.
  • Page 42 OPTIONS MEMORY THREE – Momentarily connecting pin 7 to pins 8 and 9 immediately begins the test program that is stored in memory three. SIGNAL INPUT RESET TEST INTERLOCK MEMORY 1 MEMORY 2 MEMORY 3...

  • Page 43: Section Ii Service Manual

    SECTION 2 SERVICE MANUAL...

  • Page 44: Calibration

    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 this 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.
  • Page 45 CALIBRATION Then press the SET key on the front panel. The instrument will provide around 5000VAC on the output connectors and the display will show: Voltage= XXXX V Please use the Up/Down Arrow keys to enter the reading off the AC Voltmeter, into the instrument.

  • Page 46: Parts List

    PARTS LIST Replacement Parts List HYPOT II Model 4500D ECO 5172 REV D Part Number Qty. Reference Description Designator 38111 CHV-4500 High Voltage Control Board 37593 CKB-02 Key Board Assembly 38135 CSW-05 Input Protection Board 38110 4500 Main Control Board 38112 AMP-510 Power Amplifier Board...

  • Page 47: Schematics

    SCHEMATICS SCHEMATIC INDEX Drawing Number Description Pages S04500D Wiring Diagram 4500 Main Control Board AMP-510 Power Amplifier Board REC-19 Rectifier Board CHV-4500 HV Control Board AC/DC CKB-02 Keypad Board CSW-05 Input Protection Board...

Table of Contents