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Associated Research HYAMP II 5030DT Operation And Service Manual

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OPERATION AND SERVICE MANUAL
HYAMP
II
MODEL 5030DT GROUND BOND TESTER
SERIAL NUMBER
© Associated Research, Inc., 2002
Model 5030DT
13860 West Laurel Drive
Lake Forest, Illinois, 60045-4546
U.S.A.
Item 37637
Ver 1.12
Printed Aug 15, 2002
i

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Summary of Contents for Associated Research HYAMP II 5030DT

  • Page 1 OPERATION AND SERVICE MANUAL  HYAMP MODEL 5030DT GROUND BOND TESTER SERIAL NUMBER © Associated Research, Inc., 2002 Model 5030DT 13860 West Laurel Drive Lake Forest, Illinois, 60045-4546 U.S.A. Item 37637 Ver 1.12 Printed Aug 15, 2002...
  • Page 2 This warranty does not cover batteries or accessories not of Associated Research manufacture. Parts used must be parts that are recommended by AR as an acceptable specified part. Use of non-authorized parts in the...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 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......................

  • Page 5: Section I Operators Manual

    SECTION 1 OPERATORS MANUAL...

  • Page 6: Safety

    SAFETY SAFETY PRECAUTIONS 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 Power Ground Bond 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. Power to the test station should be arranged so that it can be shut off by one prominently marked switch located at the entrance to the test area.

  • Page 9: 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 10 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 11 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 12: Specifications

    SPECIFICATIONS Model 5030DT Functional Specifications GROUND BOND TEST MODE Unless otherwise stated, accuracies are relative to a laboratory standard measurement. Descriptions Specifications INPUT VOLTAGE 115 / 230V selectable, ± 15 % variation 47 - 63 Hz FUSE 115 VAC, 230VAC -- 5A fast acting 250VAC OUTPUT Current: AC 3 - 31 Amps, 0.01 Amp / step...
  • Page 13 SPECIFICATIONS REMOTE CONTROL The following input and output signals are provide through two 9 pin “D” type connectors; SECURITY Password lockout capability to avoid unauthorized access to test set-up program. LINE CORD Detachable 7 ft. (2.13m) power cable terminated in a three prong grounding plug.
  • Page 14 SPECIFICATIONS KEY FEATURES & BENEFITS OF HYAMP II 1. All parameters for the setups can be adjusted through a simple menu driven program by using quick access front panel keys. The easy to follow setup screens ensure that the operator correctly sets up all test parameters.
  • Page 15 SPECIFICATIONS 9. Low Limit Trip Range. This capability makes it possible to ensure that a test item was properly connected since the HYAMP II can be set to monitor minimum and maximum levels of resistance during a ground bond test. 10.

  • Page 16: What's New

    WHAT’S NEW WHAT’S NEW IN HYAMP II STORAGE OF UP TO 10 DIFFERENT TEST SETUPS Allows users who test many different products to access various test setups through the keypad or through PLC remote. MICROPROCESSOR CONTROLLED The easy to follow menu screens ensure that the user will set all parameters through the keypad correctly.
  • Page 17 WHAT’S NEW FRONT PANEL CALIBRATION By going into the restricted access calibration mode the user can calibrate the unit through the keypad with no need to remove any panels or covers which could expose the technician to hazardous voltages. STANDARD ACCESSORIES A set of rack mount 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.

  • Page 18: Controls

    CONTROLS FRONT PANEL CONTROLS RESET SWITCH: This is a momentary contact switch. If out-of-range resistance 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). This switch may also be used to abort a Test in Progress.
  • Page 19 CONTROLS FRONT PANEL CONTROLS WITHSTAND PROCESSING LED: The Withstand Processing LED illuminates when Remote I/O signal input contacts 6 and 7 have been activated. Used to indicate HV on when interconnected to a hipot tester. 10. KEY LOCKOUT LED: When the Key Lockout light is ON the "password" software lockout has been enabled.
  • Page 20 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. 18. UP ARROW : (FUNCTION KEY) Use this key to advance backwards through the setup menus, remote, volume, and contrast.
  • Page 21 CONTROLS FRONT PANEL CONTROLS 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.
  • Page 22 CONTROLS REAR PANEL CONTROLS 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. RETURN OUTPUT JACK: For the connection of the detachable 5 foot (1.52 m) black kelvin return test lead.

  • Page 23: 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 24 INSTALLATION Power Cable BEFORE CONNECTING POWER TO THIS INSTRUMENT, THE WARNING 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 25 INSTALLATION 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 26: Quick Start

    QUICK START QUICK START This quick start guide assumes the operator has some familiarity with automated ground bond 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 27 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 28 QUICK START If you wish to not 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.
  • Page 29 QUICK START QUICK GUIDE TO INTERCONNECTING HYAMP II TO HypotPLUS II USING THE SUPPLIED CABLE KIT 1. Enable the HypotPLUS II remote interface. Operation menu REMOTE = "ON". 2. Connect the Double ended banana plug cable from the HypotPLUS II rear RETURN jack to the HYAMP II INTERCONNECT jack.
  • Page 30 QUICK START This page intentionally left blank...

  • Page 31: Operation

    OPERATION OPERATION INSTRUCTIONS FOR HYAMP II Model 5030DT 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. Connect the male end of the plug to the outlet receptacle.
  • Page 32 OPERATION 2. To set the output test voltage Please press the “VOLTAGE” key, the display will show: V o l t a g e = X.XX V Use the “Numerical” keys to enter the voltage setting, then press the “Enter” key to store the setting.
  • Page 33 OPERATION depressed and released. It will stop when the DUT (Device Under Test) goes into failure or the manual reset button is pressed. 6. To set the output frequency Please press the “50/60HZ” key, the display will show: F r e q = XX HZ Use the “Enter”...
  • Page 34 OPERATION 6. If a password for Lock Function is required, please use the numerical keys to enter a four digit “Numerical Code” and press the “Enter” key. The program will go to the Memory Lock Function. Once the password is set, the password has to be entered to activate or deactivate the “Lock”...
  • Page 35 OPERATION Please use the “Numerical” keys to enter the four numeral password and then press the “Enter” key to exit and return to the test mode. If the current position of the lock function is “OFF”, the status will be changed to “ON” and the “Lock” indicator on the front panel will be illuminated.
  • Page 36 OPERATION Use the “Numerical” keys to enter the range of alarm volume from “0” to “9”. A total of 10 levels. Then press the “Enter” key to store the selected alarm volume setting. The instrument will emit a tone signal as a sample of the alarm volume selected and the LCD screen will show the set point immediately.
  • Page 37 OPERATION C. OPERATING PROCEDURES: 1. Please follow the Setup Procedures to set the general status of Remote Control, LCD Contrast and the Alarm Volume. 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 38 OPERATION 5. If the resistance exceeds the high limit trip setting and exceeds the metering range, the red “FAIL” symbol will illuminate and the alarm will sound. The display will show: HI - LMT MX XXX . X s XX . XX A OFL m Ω...
  • Page 39 OPERATION D. CONNECTION OF REMOTE I/O: Two 9 pin “D” type connectors are mounted on the rear panel that 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 40 OPERATION not provide any voltage or current. The ratings of the contacts are 1A / 250 VAC ( 0.5 ADC ). The signal outputs are provided on the 9 pin female type D connector. Below is a listing that indicates what conditions activate each pin. When a terminal becomes active the relay closes thereby allowing the external voltage to operate an external device.
  • Page 41 OPERATION The HYAMP II also allows access to three MEMORY PROGRAMS through the remote control connector. This gives the user the capability to quickly change parameters and initiate a test remotely. The HYAMP 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 42 OPERATION the front panel test button on the HYAMP II. The hipot test will begin automatically relative to the test method selected. 1. INSTRUCTIONS FOR USER-FABRICATED INTERCONNECT CABLES. The following diagrams show how to connect the Remote I/O of both units. The associated pin numbers are given for the connectors on both units and the pins to be wired together.
  • Page 43 OPERATION B. Simultaneous Testing HYAMP II SIGNAL INPUT \ HypotPLUS II SIGNAL OUTPUT CONNECTION HYAMP II HypotPLUS II 1 • • 1 2 • • 2 3 • • 3 4 • • 4 5 • • 5 6 • •...
  • Page 44 OPERATION Part Number Description Qty. HS-8-11 Cable Assembly Return 5030DT-21 Cable Assembly R/P Interface COM 5030DT-22 Cable Assembly R/P Interface SEQ 5030DT-23 Cable Assembly R/P Interface SIM 36541 Adapter Box HV, HC Domestic The following sections describe the procedures for interconnecting your units. Please refer to the test method you require for specific cable connection instructions.
  • Page 45 The adapter box is an optional accessory and is not provided as standard equpment with the HYAMP II. If you would like to aquire a 36541 adapter box for use with your HYAMP II please contact Associated Research using the contact information provided in the Safety section of this manual.

  • Page 46: Options

    OPTIONS MODEL 5030DT 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 47 OPTIONS fail condition will remain until the resistance drops below the Hi-Limit setting, or until the Reset button is pressed to deenergize the output. This operation emulates the basic audible continuity testers found on many multimeters, and is useful in doing multipoint ground bond tests on the DUT by disconnecting and reconnecting the test leads without disabling the output.
  • Page 48 OPTIONS This page left intentionally blank.

  • Page 49: Section Ii Service Manual

    SECTION 2 SERVICE MANUAL...

  • Page 50: 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 51 CALIBRATION Please use the numerical keys to enter the reading from 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 52: Parts List

    PARTS LIST Replacement Parts List HYAMP II Model 5030DT Rev. E 6/03/2002 ECO 4890 Part Number Reference Description Designator 37515 CSW-01 PCB Assy Input Protection Board 37550 CKB-01 PCB Assy Keyboard Assembly 37629 CG7310 PCB Assy Main Control Board 37636 AMP-250 PCB Assy Main Power Amplifier Board 37591...

  • Page 53: Schematics

    SCHEMATICS SCHEMATIC INDEX Drawing Number Description Pages S05030DT Wiring Diagram S37622 Main Control Board S37624 Main Power Amplifier Board S37550 Keypad Board S37515 Input Protection Board S37591 Rectifier Board S38220 ROM Conversion Board...

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