Associated Research HypotPLUS II Operation And Service Manual
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Associated Research HypotPLUS II Operation And Service Manual

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  • Page 1 (217) 352-9330 | Click HERE Find the Associated Research 5500DT at our website:...
  • Page 2 HypotPLUS MODEL 5500DT (AC ONLY HIPOT WITH GROUND CONTINUITY CHECK) MODEL 5560DT (AC/DC HIPOT WITH GROUND CONTINUITY CHECK) SERIAL NUMBER Models © Associated Research, Inc., 2003 13860 West Laurel Drive 5500DT/5560DT Lake Forest, Illinois, 60045-4546 U.S.A. Printed Oct 16, 2003 Item 37545 Ver 1.45...
  • Page 3 DECLARATION OF CONFORMITY Manufacturer: Associated Research, Inc. Address: 13860 W. Laurel Dr. Lake Forest, IL 60045 Product Name: HypotPLUS® II Dielectric Withstand Voltage Tester Model Number: 5500DT, 5560DT Conforms to the following Standards: Safety: EN 61010-1: 1993 + A2 EN 61010-031: 1994...
  • Page 4 WarrantyPolicies 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 5: Table Of Contents

    TABLE OF CONTENTS SECTION I OPERATORS MANUAL................. 1 SAFETY ........................2 INTRODUCTION ....................... 6 SPECIFICATIONS ....................11 WHAT S NEW ......................16 CONTROLS ......................18 INSTALLATION....................... 23 QUICKSTART ......................26 OPERATION......................29 OPTIONS ........................43 SECTION II SERVICE MANUAL ................51 CALIBRATION......................

  • Page 6: Section I Operators Manual

    SECTION 1 OPERATORS MANUAL...

  • Page 7: 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 8 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 9 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 10 SAFETY 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. TEST PROCEDURES !NEVER PERFORM A HIPOT TEST ON ENERGIZED CIRCUITRY OR EQUIPMENT! If the instrument has an external safety ground connection be sure that this is connected.

  • 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 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.
  • Page 14 INTRODUCTION voltage and read current without any wait time. 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. AC testing disadvantages A key disadvantage of AC testing surfaces when testing capacitive products. Again, since AC cannot charge the item under test, reactive current is constantly flowing.
  • Page 15 INTRODUCTION the item after the test. 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: Specifications

    SPECIFICATIONS Model 5500DT and 5560DT Functional Specifications DIELECTRIC WITHSTAND TEST MODE Unless otherwise stated, accuracies are relative to a laboratory standard measurement. Descriptions Specifications 115 / 230V selectable, ± 15 % variation INPUT VOLTAGE 47 - 63 Hz FUSE 115 VAC, 230VAC -- 5A slow-blo 250VAC OUTPUT Rating AC 0 - 5000V, 2V / step, 20mA DC 0 - 6000V, 2V / step, 6mA (5560DT only)
  • Page 17 SPECIFICATIONS METERING Voltmeter (4 digits) Range : AC 0.00 - 5.00 KV : DC 0.00 - 6.00 KV Resolution : 0.01 KV : ± (2 % of reading + 10 V) Accuracy Ammeter (4 digits) Range : AC 0.05 - 20.00 mA : DC 0.02 - 6.00 mA Resolution : 0.01 mA : ±...
  • Page 18 6. Posi-TestÔ current sensing system. This capability makes it possible to ensure that a test item was properly connected since the HypotPLUS II can be set to monitor minimum and maximum levels of current during a hipot test. 7. The LCD display allows monitoring of current down to 50 microamps AC and 20 microamps DC.
  • Page 19 10 volt increments by simply pressing the up and down arrow keys. This makes it very easy to adjust the output voltage even while HypotPLUS II is in the dwell mode so you can analyze test results at different voltages.
  • Page 20 18. Easily configurable into an automated test system. HypotPLUS II comes standard with rear output connectors and rack mount handles to make it simple to build into an automated system. 19. Comes complete with a test box for products terminated in a line cord.

  • Page 21: What S New

    This standard feature holds results of failed tests on the LCD, allowing the user to further review test results. DIGITALLY CONTROLLED ARC DETECTION This provides the user with the ability to select whether low level arcs should be detected. With a range of 2-20mA peak, the HypotPLUS II can...
  • Page 22 HypotPLUS II with enough output to meet most applications. FRONT PANEL LCD WITH ADJUSTABLE DIMMER HypotPLUS 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.

  • Page 23: Controls

    CONTROLS FRONT PANEL CONTROLS 1. RESET SWITCH: This is a momentary contact switch. If out-of-range leakage current, or an arc breakdown is detected during the hipot test or continuity 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).
  • Page 24 CONTROLS FRONT PANEL CONTROLS 9. KEY LOCKOUT LED: When the Key Lockout light is ON the "password" software lockout has been enabled. This means that the operator will be unable to access the "program" mode of the instrument to change any settings. 10.
  • Page 25 CONTROLS FRONT PANEL CONTROLS 17. 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. é 18. UP ARROW : (FUNCTION KEY) Use this key to advance backwards through the setup menus (continuity, remote, volume, contrast).
  • Page 26 CONTROLS FRONT PANEL CONTROLS 24. HIGH VOLTAGE 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.
  • Page 27 CONTROLS REAR PANEL CONTROLS 1. HIGH VOLTAGE 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.

  • Page 28: 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 29 INSTALLATION Power Cable BEFORE CONNECTING POWER TO THIS INSTRUMENT, THE PROTECTIVE GROUND (EARTH) TERMINALS OF THIS INSTRUMENT MUST BE WARNING 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 30 INSTALLATION Altitude......7,620 meters (25,000 feet) 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.

  • Page 31: Quickstart

    QUICK START QUICK START 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 32 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 33 QUICK START SET: This is the parameter settings review screen. M 1: The instrument is using the default set ups contained in memory 1. 1.0 S: The dwell timer is set to a test duration of 1 second. 1.24KVAC: The test voltage is set to 1,240 volts AC. 10.00 mA: The high leakage current trip point is set to 10 milliamps.

  • Page 34: Operation

    OPERATION OPERATION INSTRUCTIONS FOR HypotPLUS II Model 5500DT and 5560DT A. POWER UP: Check to be sure the correct input line voltage has been selected on the CAUTION 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.
  • Page 35 OPERATION 2. To set the high leakage current limit Please press the HIGH LIMIT key, the display will show: H I - L M T = XX.XX mA Use the Numerical keys to enter the leakage current high limit setting, then press the Enter key to store the setting.
  • Page 36 7. To lock or unlock the keyboard of the front panel The HypotPLUS II is equipped with two lockout modes; one requires a password to 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.
  • Page 37 OPERATION 1. Place the power switch in the off position. 2. Press and hold in the key, then turn on the power switch. The display will indicate the following: C a l i b r a t i o n M o d e 2 : K V 3 : m A...
  • Page 38 OPERATION ( B.) Turning the LOCK function ON or OFF with no password activated: Press the Lock key, the display will show: L o c k L o c k O F F Press the Enter key to select the Lock (ON) or Unlock (OFF) mode, then press the Exit key to exit and return to the test mode.
  • Page 39 If continuity is present the Ready indicator will be illuminated and the operator may proceed with the hipot test. The HypotPLUS II will continue to test the ground connection of the DUT during other tests. If no continuity is present while the operator tries to initiate a test, the instrument will signal a continuity failure.
  • Page 40 10. To store and recall the memory programs HypotPLUS 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.
  • Page 41 This is done by pressing and holding a Numerical key in for approx., 2 seconds. HypotPLUS II will respond with two beep tones, one short tone when select the key and one longer tone when the data is stored into that memory position.
  • Page 42 OPERATION switch. Otherwise, the instrument will signal a continuity failure when the test switch is activated. The display will show: C O N T . M X XXX . X s - - - - KVAC - - - - mA If you are not performing a Ground Continuity Check the Ground Continuity must be set to the OFF (Disabled) position.
  • Page 43 OPERATION during a failure condition. 6. If there is a short circuit in the DUT during the test, the red FAIL symbol will illuminate and an alarm will sound. The display will show: S h o r t M X XXX . X s X .
  • Page 44 OPERATION 11. If there is an arcing condition over the Arc sensitivity limit, the red FAIL symbol will illuminate and the alarm will sound. The display will show: M X XXX . X s X . XX K V A C XX . XX mA 12.
  • Page 45 OPERATION D. CONNECTION OF REMOTE I/O: Two 9 pin type connectors are mounted on the rear panel which provide REMOTE- INPUT-OUTPUT control and information. These connectors mate with standard 9 pin subminiature connector provided by the user. The output mates to a male (plug) connector while the input mates to a female (receptacle) connector.
  • Page 46 This gives the user the capability to quickly change parameters and initiate a test remotely. The HypotPLUS 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.
  • Page 47 II, you can perform both the hipot and continuity tests at the same time by activating the continuity function on the instrument. When the HypotPLUS II tests the ground conductor of the line cord, if the resistance of the ground conductor exceeds 1W, the hipot will signal a continuity failure. If continuity is present, high voltage is applied to both conductors of the line cord to insure that all current carrying conductors in the primary circuit are tested.

  • Page 48: Options

    OPTIONS MODEL 5500DT / 5560DT 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 49 OPTIONS Description 01 10 Volt Analog Interface (For a description of standard remote I/O see page 40). The 10 Volt Analog Interface option allows the user to remotely set the Voltage applied to the item under test and measure the actual test voltage and leakage current during the test.
  • Page 50 OPTIONS Analog Interface Specifications: Descriptions Specifications (Ratios are relative to the display) V-Set Input Range: 0 - 10VDC Ratio: 10V = 5 KVAC or 6 KVDC Accuracy: ±2% of Reading KV Meter Output Range: 0 - 10VDC Ratio: 10V = 6KV Accuracy: ±2% of Reading mA Meter Output Range:...
  • Page 51 The Associated Research Real Current option allows the operator to view either real or total current. The real current and total current cannot be measured or monitored simultaneously.
  • Page 52 OPTIONS The specifications for the Real Current option are as follows: Descriptions Specifications Voltmeter Range : 0.00 - 3.00 KVAC Resolution : .01 KV Accuracy : ± (2 % of reading + 10 V) Current Meter Total mode Range : 0.05 - 35.00mA Resolution : .01 mA Accuracy : ±(2% of reading + .02mA) Real mode...
  • Page 53 OPTIONS 04 8KVAC @ 10mA (AC Only) The 8KVAC option increases the output voltage of the unit to 8KVAC but reduces the output current to 10mA with both hardware and software control. The trip points are adjusted to a maximum of 10mA and the hardware has been modified so the high speed maximum current shutdown is fixed at 10mA.
  • Page 54 OPTIONS 08 7 Remote Memories Select The 7 Remote Memories Select option increases the number of memory programs that may be accessed through the remote control connector from 3, to 7. This gives the user the capability to quickly change parameters and initiate a test remotely. The HypotPLUS II basically operates in a PLC mode by responding to simple switch or relay contacts closures, the built in memory programs of the instrument are used to accomplish this.
  • Page 55 OPTIONS This page is intentionally left blank.

  • Page 56: Section Ii Service Manual

    SECTION 2 SERVICE MANUAL...

  • Page 57: 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 58 CALIBRATION Please use the numerical keys to enter the reading off the ac voltmeter into the instrument. Then press the Enter key to store the voltage setting. If an incorrect value is entered, press the EXIT key. Then the correct value may be re-entered. 2.

  • Page 59: Parts List

    CALIBRATION Replacement Parts List HYPOTPLUS II Model 5500DT 5560DT Rev. F 12/07/99 ECO 4742 Part Number Qty. Reference Description Designator 37547 AMP-100 Main Power Amplifier Board 37548 CGC-01 Ground Continuity Check Board 37570 CHV-03-AC High Voltage Control Board (5500DT only)

  • Page 60: Schematics

    Keypad Board S37515 Input Protection Board S38220 ROM Conversion Board Alternate or Additional Schematics (note: These schematics apply only to HypotPLUS II with installed options. Some optional hardware changes are refered to on standard schematics) Options Drawing Description Pages 0102...

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