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Summary of Contents for Associated Research 3030D
- Page 1 OPERATION AND SERVICE MANUAL HYAMP MODEL 3030D GROUND BOND TESTER SERIAL NUMBER Model 3030D © Associated Research, Inc., 2002 13860 West Laurel Drive Lake Forest, Illinois, 60045-4546 U.S.A. Item 37952 Ver 1.06 Printed Jan 25, 2002...
- Page 2 5 YEAR WARRANTY POLICY 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION I OPERATORS MANUAL ................1 SAFETY ...........................2 INTRODUCTION ......................5 SPECIFICATIONS......................8 CONTROLS ........................12 INSTALLATION ......................15 QUICK START ......................18 OPERATION........................22 OPTIONS ........................32 SECTION II SERVICE MANUAL................35 CALIBRATION ......................36 PARTS LIST........................38 SCHEMATICS.......................39... -
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.
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Page 9: Introduction
Registered trademark of Associated Research, Inc., for its dielectric-withstand test equipment. HYAMP®: Registered trademark of Associated Research for its Ground Bond 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"...
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Page 12: Specifications
SPECIFICATIONS Model 3030D Functional Specifications GROUND BOND 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 6.3A slow blow 250VAC... - Page 13 SPECIFICATIONS REMOTE CONTROL The following input and output signals are provide through two AND SIGNAL 9 pin D type connectors; OUTPUT 1. Remote control: Test, Reset and Withstand Processing 2. Outputs: Pass, Fail, Test in Process, Start Out, and Reset Out SECURITY Key Lock capability to avoid unauthorized access to all test parameters.
- Page 14 SPECIFICATIONS KEY FEATURES & BENEFITS OF HYAMP jr. 1. All parameters for the setups can be adjusted through a simple menu driven program by using front panel keys. The easy to follow setup screens ensure that the operator correctly sets up all test parameters.
- Page 15 SPECIFICATIONS 11. Test indicator. An LED located directly over the high current terminal clearly indicates when high current is active to provide maximum operator safety. 12. Withstand processing indicator. The front panel display indicates when the high voltage from the Hypot II is being applied to the item under test for greater operator safety.
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Page 16: Controls
CONTROLS FRONT PANEL CONTROLS RESET SWITCH: This is a momentary contact switch. 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. TEST SWITCH: This is a momentary contact switch. - Page 17 CONTROLS FRONT PANEL CONTROLS 10. EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test. This key may also be used to save settings into memory. 11. CURRENT OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) red high current test lead.
- Page 18 CONTROLS REAR PANEL CONTROLS 1. THERMAL FAN: Runs continuously to cool the instrument. 2. INPUT POWER SWITCH: Line voltage selection is set by the position of the switch. In the left position it is set for 115-volt operation, in the right position it is set for 230-volt operation.
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Page 19: 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 20 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 21 4). Seal the container securely. 5). Mark the container "FRAGILE" to insure proper handling. 6). Please ship model 3030D via Federal Express or UPS air. 7). Please reference in all your correspondence your AR service number. Field Installation of Options...
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Page 22: 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. The instrument default settings are as follows: DEFAULTS •... - Page 23 This test will check for the condition of the ram chips, led indicators, PCB’s and other critical components. In addition, you will see the Associated Research name and Model Number briefly appear on the LCD readout and then clear itself.
- Page 24 Ground Bond and Hipot test simultaneously or sequentially then select the appropriate cable assembly for your needs, using the descriptions in the table below. Cable number Method Operation 3030D-22 Sequential HYAMP jr. first then Hypot II. 3030D-23 Simultaneous HYAMP jr. and Hypot II at the same time.
- Page 25 QUICK START NOTE: When interconnecting HYAMP jr. to a model in the Hypot II family, HYAMP jr. will automatically sense when high voltage is active. The display on the HYAMP jr. will change to show a “W-On” indicating that the Dielectric Withstand test is processing. An example of this display is shown below.
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Page 26: Operation
OPERATION OPERATION INSTRUCTIONS FOR HYAMP jr. Model 3030D A. POWER UP: Check to be sure that the correct input line voltage has been selected on the 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 27 OPERATION Ω milliohms with a range from 0-510m 3. Dwell Time Setting Please press the SET key until arriving at the Timer setting. The display will show: T i m e r = XXX . X s Use the Up (∧) or Down (∨) arrow keys to adjust the Timer setting, then press the EXIT key to store the Timer setting and return to the Run mode, or press the SET key to advance to the next parameter.
- Page 28 OPERATION 6. Memory Storage and Recall HYAMP jr. is equipped with a total of 5 memory programs numbered 1 through 5. 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. (A).
- Page 29 OPERATION The memory lock screens appear as follows: Memory Lock = ON Memory Lock = OFF To toggle the Memory Lock function on and off use the up or down arrow keys, then press exit to select, or press the set key again to reach the Key Lock screens. Use the following chart to set the Key Lock and Memory Lock for your application.
- Page 30 OPERATION 4. If the resistance exceeds the high limit trip setting but does not exceed the metering range, the red RESET switch will illuminate and the alarm will be activated. The display will show: HI - LMT MX XXX . X s XX .
- Page 31 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 32 OPERATION (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. Pins 1 and 2 provide the PASS signal.
- Page 33 OPERATION jr.. The Hipot test will be controlled by the Hyamp jr. automatically, through the interconnecting control cables. 1. INSTRUCTIONS FOR USER-FABRICATED INTERCONNECT CABLES. The following diagrams show how to connect to 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 34 HYAMP jr. with the Hypot II . The following table lists the kit contents. Part Number Description Qty. HS-8-11 Cable Assembly Return Interconnect 3030D-22 Cable Assembly R/P Interface Sequential 3030D-23 Cable Assembly R/P Interface Simultaneous 37893 Adapter Box High Voltage High Current The following sections describe the procedures for interconnecting your units.
- Page 35 DUT to the chassis or dead metal of the product. If the high voltage lead is not used, it should be secured out of the way. 3030D 37893 CURRENT...
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Page 36: Options
If your instrument has been modified with options, there will be an option label on the rear panel of the unit. The option label contains an option(s) code that may be cross- referenced to the 3030D Options List. The option(s) code would appear as follows: fitted with option 02 .............. - Page 37 OPTIONS 2. 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. 3. RETURN OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) black return test lead.
- Page 38 OPTIONS This page left intentionally blank.
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Page 39: Section Ii Service Manual
SECTION 2 SERVICE MANUAL... -
Page 40: 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 41 CALIBRATION 2. Calibration of Current Equipment needed: STANDARD AC AMMETER with a range of 30A. Please connect the standard ac ammeter across the output leads of the instrument. Press the Down ( ∨ ) arrow key. The instrument will provide around 30A on the output and the display will show: C u r r e n t = __ Please use the Up ( ∧...
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Page 42: Parts List
PARTS LIST Replacement Parts List HYAMP jr. Model 3030D Rev. B 2-4-99 ECO 4697 Part Number Reference Description Designator 37515 CSW-01 PCB Assy Input Protection Board 37593 CKB-02 PCB Assy Keyboard Assembly 37955 3030 PCB Assy Main Control Board 37956... -
Page 43: Schematics
SCHEMATICS SCHEMATIC INDEX Drawing Number Description Reference Pages Designator S03030D Wiring Diagram S37955 Main Control Board 3030 S37956 Power Amplifier Board AMP-260 S37593 Keypad Board CKB-02 S37515 Input Protection Board CSW-01 S37957 Rectifier Board REC-18 S38220 ROM Conversion Board 82147...
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