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Associated Research 3130 Operation And Service Manual

Ground bond tester
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OPERATION AND SERVICE MANUAL
®
HYAMP
III
MODEL 3130 GROUND BOND TESTER
SERIAL NUMBER
© Associated Research, Inc., 2013
Model 3130
13860 West Laurel Drive
Lake Forest, Illinois 60045-4546
U.S.A.
Item 38301
Ver 3.04
Printed October 30, 2013

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  • Page 1 OPERATION AND SERVICE MANUAL ® HYAMP MODEL 3130 GROUND BOND TESTER SERIAL NUMBER © Associated Research, Inc., 2013 Model 3130 13860 West Laurel Drive Lake Forest, Illinois 60045-4546 U.S.A. Item 38301 Ver 3.04 Printed October 30, 2013...
  • Page 2 The product herewith complies with the requirements of the Low Voltage Directive 2006/95/EC and the EMC Directive 2004/108/EC. Last two digits of the year the CE mark was first affixed: 02 The technical file and other documentation are on file with Associated Research, Inc. ______________________________ Joseph Guerriero Vice President / General Manager Associated Research, Inc.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1. INTRODUCTION ....................1 1.1. Warranty Policies ..................1 1.2. Safety Symbols ..................3 1.2.1. Product Marking Symbols ............... 3 1.2.2. Caution and Warning Symbols ............3 1.3. Glossary of Terms ..................3 1.4. Safety ......................5 1.4.1.
  • Page 4 4.3.3. Default Parameters ................ 30 4.3.4. Setting Up a Test ................30 5. OPERATING INSTRUCTIONS ............... 32 5.1. Instrument Connections ................32 5.1.1. Test Leads ..................32 5.1.2. Adapter Box Connections (Adapter box is sold separately) ..32 5.1.3. Interlock Connector................ 33 5.2.

  • Page 5: Introduction

    5-Year Program All Associated Research instruments include the opportunity to extend the standard warranty for up to a period of 5 years. Returning instruments to Associated Research for their annual calibration and inspection will extend the instrument's warranty for an additional year.
  • Page 6 Elimination of any connections in the earth grounding system or bypassing any safety systems will void this warranty. This warranty does not cover accessories not of Associated Research, Inc. manufacture. Parts used must be parts that are recommended by Associated Research, Inc. as an acceptable specified part. Use of non-authorized parts in the repair of this instrument will void the warranty.

  • Page 7: Safety Symbols

    1.2. Safety Symbols 1.2.1. Product Marking Symbols Product will be marked with this symbol when it is necessary to refer to the operation and service manual in order to prevent injury or equipment damage. Product will be marked with this symbol when hazardous voltages may be present.
  • Page 8 Direct Current, DC: Current that flows in one direction only. The source of direct current is said to be polarized and has one terminal that is always at a higher potential than the other. Frequency: The number of cycles an AC waveform repeats over time. Usually given in Hertz (Hz). Ground: Refers to the point of low potential in a circuit to which all other voltages are referenced.

  • Page 9: Safety

    FAX: 1 (847) 367-4080 LAKE FOREST, IL 60045-4546 U.S.A. info@asresearch.com E-MAIL: Service Interval Associated Research, Inc. will not be held liable for injuries suffered if the instrument is not properly maintained and safety checked annually. See section 1.1. Warranty Policies for more information.

  • Page 10: Test Station

    1.4.2. Test Station Location Select an area away from the mainstream of activity where employees do not walk while performing their normal duties. If this is not practical because of production line flow, then the area should be roped off and marked for HIGH VOLTAGE TESTING. No employees other than test operators should be allowed inside.

  • Page 11: Test Operator

    1.4.3. Test Operator This instrument generates voltages and currents that can cause harmful or fatal electric shock and must only be operated by a skilled worker trained in its use. The operator should understand the electrical fundamentals of voltage, current, and resistance. DO NOT TOUCH THE DEVICE UNDER TEST, TEST LEADS, ALLIGATOR CLIP, OR CLIP INSULATOR ONCE THE TEST HAS BEEN STARTED.
  • Page 12 currents generated by the instrument are very dangerous. If contacted, the instrument may cause heart-related problems. Please have the test operator consult a physician for recommendations.

  • Page 13: Key Features And Benefits

    1.5. Key Features and Benefits: HYAMP III Provides the operator with an easy-to-use THE FIRST MANUAL interface, eliminating the need to decipher cryptic GROUND BOND abbreviations. The graphic display makes testing INSTRUMENT WITH AN safer, easier and more reliable than ever before. ENHANCED GRAPHIC LCD Limit user access so that only authorized SECURITY ACCESS...

  • Page 14: Getting Started

    2. GETTING STARTED Introduction This section contains information for the unpacking, inspection, preparation and storage of your Associated Research, Inc., product. 2.1. Unpacking and Inspection 2.1.1. Packaging Your instrument was shipped in a custom foam insulated container. If the shipping carton is damaged, inspect the contents for visible damage such as dents, scratches or a broken display.

  • Page 15: Returning The Instrument For Service Or Calibration

    Please include all accessories and test leads. Mark the container “ FRAGILE” to ensure proper handling. Before shipping, contact an Associated Research, Inc. customer support representative at 1-800-858-TEST (8378) to indicate and explain the reason for service.

  • Page 16: Installation

    2.2. Installation 2.2.1. Work Area Locate a suitable testing area and be sure you have read all safety instructions for the operation of the instrument and suggestions on the test area setup in section 1.4. Safety. Make sure the work area you choose has a three-prong grounded outlet capable of supplying the necessary input current to the power source.

  • Page 17: Basic Connections

    2.2.3. Basic Connections Power Cable The instrument is shipped with a line cord containing a protective earth ground. When the line cord is connected to an appropriate AC power source the cable will connect the chassis to earth ground. The main plug shall only be inserted in a socket outlet with a protective ground (earth) contact.
  • Page 18 More Information For more information on test operator and workstation safety please visit the Events and Training section of our website at http://www.asresearch.com/events- training/Default.aspx...

  • Page 19: Specifications And Controls

    3. SPECIFICATIONS AND CONTROLS 3.1. HYAMP III Functional Specifications INPUT 115/230 VAC ± 10%, user selectable Voltage 50/60 Hz ± 5% Frequency Fuse 6.3 Amp, slow-blow 250 VAC TEST MODE Output Rating Current: 1.00 – 30.00 Amps AC Resolution: 0.01 Amp/step ±...
  • Page 20 GENERAL Remote Control And Signal The following input and output signals are provided Output through two 9 pin D type connectors; 1. Remote control: Test, Reset, Interlock, and Withstand Processing. 2. Remote recall of memory program #1, #2 and #3. 3.

  • Page 21: Instrument Controls

    3.2. Instrument Controls 3.2.1. Front Panel Controls 1. RESET BUTTON: Momentary contact switch used to reset the instrument. If a failure condition occurs during a test, you will need to reset the system to shut off the alarm and signal the system that you are aware of a failure condition. The reset button must be pressed before you can proceed to the next test or change any of the set-up parameters.

  • Page 22: Rear Panel Controls

    8. TEST LED INDICATOR: This red indicator flashes to warn the operator that voltage or current is present at the output terminal, and a test is in process. 9. INTERCONNECT JACK: Connector used to attach the return lead from the Hipot tester when performing both Hipot and Ground Bond tests on the same test item.
  • Page 23 8. REMOTE SIGNAL OUTPUT: 9-Pin D subminiature female connector for monitoring PASS, FAIL, PROCESSING, and RESET output relay signals. 9. REMOTE SIGNAL INPUT: 9-Pin D subminiature male connector for remote control of TEST, RESET, and INTERLOCK functions, as well as remote program memory selection and withstand processing input.

  • Page 24: Programming Instructions

    4. PROGRAMMING INSTRUCTIONS 4.1. Power Up The HYAMP III automatically defaults to the Perform Tests screen upon power up. The Perform Tests screen will appear as follows: The Perform Tests screen is the main operational screen of instrument. From this screen, all test parameters are monitored while the test is being performed.

  • Page 25: Results, Tests And System Selections

    The Main Menu will now be displayed. From the Main Menu screen, three software controls may be accessed: Menu, Memory and Step. Pressing the “ Exit” soft key at any time will return you to the Perform Tests screen. Menu Pressing the “...

  • Page 26: System Setup

    Test Pressing the “ Test” soft key from this menu will allow you to access the Parameter Review screen. For specific instructions for reviewing and editing test parameters, refer to section 4.3. Test Parameters. System Pressing the “ System” soft key from this menu will allow you to access the Setup System screen.

  • Page 27: System Setup Soft Keys

    You can control your I/O. If you attempt to start a test from the Associated Research, Inc. TEST button on the front panel when the instrument using basic PLC PLC Remote function is turned ON, a pop- inputs and outputs.
  • Page 28 connected test step. Each time the TEST button is pressed the next connected test step will execute. If you press the RESET button before completing all connected test steps, it will return you to the original starting test step. If a step fails and you wish to continue to the next test step press TEST.
  • Page 29 When P/F is selected, it is not possible to see the test results directly at the end of the test. In order to review the test results refer to section 4.2.3. Reviewing Test Results. When Last is selected, the results of the last test step performed will be displayed on the Perform Tests screen.
  • Page 30 The Hipot Start parameter is only used when connecting the HYAMP III with an Associated Research Hipot tester. If G→W is selected, the Hipot test will run after the HYAMP III has completed its test. If G + W is selected, the Hipot test will run at the same time as the HYAMP III.
  • Page 31 the “ +” soft key to change the numeric value. Once you change the value it is automatically stored. Time Within the Set Time parameter are three fields: hours, minutes, and Military or Standard time. Use the “ >” soft key to select the field within the time parameter you want to edit.

  • Page 32: Default System Parameters

    4.2.3. Default System Parameters Setup System PLC Remote Single Step Alarm Contrast Results Last Lock Mem Lock Hipot Start G→W Date Format mdy (month, day, year) Cal Alert Alert Date Cal Date + 11 months 4.2.4. Memory, Step, and Default System Parameter Restore Restoring the instrument’...

  • Page 33: Test Setup Soft Keys

    4.3.1. Test Setup Soft Keys Directional soft keys ∧,∨, > The “ ∧,∨, > ” soft keys are used to scroll the cursor to the different system parameters. +/- keys The “ +” and “ -“ soft keys are used to increase or decrease numerical values or toggle settings ON and OFF.

  • Page 34: Default Parameters

    Offset The Offset function may be used to compensate for test lead and test fixture resistance during the test. Using the up and down arrow keys, scroll the cursor to the Offset parameter and press the “ Edit” soft key. You may now manually or automatically set an Offset value.
  • Page 35 From the Parameter Review screens the following parameters may be selected for editing: Current, Max Lmt, Min Lmt, Dwell, Frequency, Offset, and Connect.

  • Page 36: Operating Instructions

    5. OPERATING INSTRUCTIONS 5.1. Instrument Connections 5.1.1. Test Leads The test leads provided are designed specifically for use with this instrument. The red High Current lead will mate with the red Current jack. The black Return lead will mate with the black Return jack. The test lead ratings are as follows: DESCRIPTION PART NUMBER...

  • Page 37: Interlock Connector

    5.1.3. Interlock Connector HYAMP III is equipped with a Remote Interlock feature. Remote Interlock utilizes a set of closed contacts to enable the instrument’ s output. If the Remote Interlock contacts are open the output of the instrument will be disabled. To disable the Remote Interlock feature connect the Interlock Key into the Signal Input port located on the back of the tester.

  • Page 38: Results Screens

    5.4. Results Screens The HYAMP III may be configured to display one of three different types of Results screens (see section 4.2. Setup System for more information). To access the results screen use one of the following methods: Method 1, Hot key Pressing the bottom soft key at the Perform Tests screen will display the Results screen.
  • Page 39 Abort: This message appears on the display, if the test in process is aborted with the RESET button or remote Reset control. Max-Fail: This message appears on the display if the measured reading exceeds the Max Lmt current setting of the Ground Bond test, or Max Lmt resistance setting of the Insulation Resistance test.

  • Page 40: Connection Of Remote I/O

    6. CONNECTION OF REMOTE I/O Two 9 pin D-type connectors mounted on the rear panel provide REMOTE-INPUT- OUTPUT control and information. These connectors mate with a standard 9 pin D- type subminiature connector provided by the user. The output mates to a male (plug) connector while the input mates to a female (receptacle) connector.

  • Page 41: Signal Inputs Of Remote I/O And Memory Access

    The Hipot Start parameters main purpose is to control the sequential timing between HYAMP III and a connected Associated Research Hipot. The parameter controls if the Hipot will run after the HYAMP III has completed its test, G→W, or if the Hipot will run at the same time as the HYAMP III, G + W.
  • Page 42 When the PLC Remote mode is on, the HYAMP III will respond to simple switch or relay contacts closures. A normally open momentary switch can be wired across pins 3 and 5 to allow remote operation of the TEST function. A minimum pulse width or contact DID YOU KNOW? closure of 20mS is required to guarantee a test start.
  • Page 43 could also be referred to as a remote system lockout, utilizing “ fail when open” logic. If the Remote Interlock contacts are open and the TEST button is pushed, a pop-up message will be displayed on the screen for two seconds. The message will appear as follows: If the Remote Interlock contacts are opened during a test, the pop-up message will be displayed and the test will abort.
  • Page 44 If the Hipot start signal is set to G+W then a small “ W-T” indicator will appear in the upper right of the display. PLC Remote Pop-up message If you attempt to start a test from the front panel TEST button and the PLC remote function is turned “...

  • Page 45: System 3100, Hyamp Iii Integrated With Hypot Iii

    6.3. System 3100, HYAMP III Integrated with HYPOT III The following illustration should be used to configure the HYAMP III for integrated operation with Hypot III: If you order the HYAMP III interconnect kit you will receive the following items. INTERCONNECT KIT PART NUMBER DESCRIPTION...
  • Page 46 The Hipot Start parameter is only used when connecting the HYAMP III with an Associated Research Hypot III. The parameter determines if the Hypot will run after the HYAMP III has completed its test, G→W. If the Hypot will run at the same time as the HYAMP III, G + W.

  • Page 47: Options

    7. OPTIONS Introduction This section contains a list and descriptions of available factory installed options at the time of this printing. The list of options contains an option code number that can be referenced on the data plate on the rear panel of the unit. Option Label On the rear panel of the instrument, you will find a label that contains the option code.
  • Page 48 resistance drops below the Max Lmt setting or above the Min Lmt setting, or until the RESET button is pressed to de-energize the output. This operation emulates basic audible Continuity testers found on many multi-meters, and is useful for doing multi-point Ground Bond tests on the DUT. 04 PLC Ready Output The PLC Ready Output Option creates a signal that acts as an instrument power-on indicator.
  • Page 49 If you order the HYAMP III with External RS-232 Converter option you will receive the following items: RS-232 External Module Part # 39050 includes: Part Number Description Qty. 39057 Cable 16 inch 9 Pin Male to 9 Pin Female Connector 38606 Cable Assembly RS-232 2 meter 37845...
  • Page 50 This interface does not support XON/XOFF protocol or any hardware handshaking. The controller should be configured to ignore the handshaking lines DTR (pin 4), DSR (pin 6) CTS (pin 8) and RTS (pin 7). If the port cannot be configured through software to ignore these lines the handshake lines should be jumpered together in two different sets.
  • Page 51 RESET Stop or abort a test. Also used to reset a latched failure condition. AOFF Set the offset for the ground bond test. The cables and any test fixture should be connected before executing the command. This command will perform an actual test and all safety precautions should be observed when using this command.
  • Page 52 Test Parameter Editing Commands These commands are used to modify the test parameter within each step. These commands require a parameter value to be included with the command. The writing of the parameter requires that the unit not be included with the value, only the numeric value should be included with the command.
  • Page 53 parameter is separated by commas and includes step number, test status, and metering. The syntax for this command response is {memory - step, status, meter 1, meter 2, meter 3}. For example: M1-1,Pass,25.00A,100m ,1.0s RD <step number>? Read the results for an individual step. The step number is the actual step number that has been saved within the file, not the order of which the steps were executed.

  • Page 54: Instrument Verification

    8. INSTRUMENT VERIFICATION Verification is the process by which an instrument’ s failure detectors are proven to be functioning properly by performing basic tests in open and short circuit conditions. Verifying the failure detection circuitry of the electrical safety tester is required by safety agencies such as CSA, UL, and TÜV.
  • Page 55 Ground Bond Verification From the Verification screen, press the TEST button to begin the verification process. At the end of the Verification process, a message will appear indicating the outcome of the process. If the instrument passes the Verification (test failure, indicating the fail detectors are working properly) the RESET button will illuminate, the alarm will sound and the following message will appear: If the instrument fails the Verification (test pass, indicating the fail detectors are...

  • Page 56: Calibration Procedure

    Associated Research, Inc. offers a standard one-year manufacturer’ s warranty. This warranty can be extended an additional four years provided that the instrument is returned each year to Associated Research, Inc. for its annual recertification. In order to be eligible for the extended warranty instruments must be returned to Associated Research, Inc.

  • Page 57: Calibration Of Parameters

    9.2.1. Calibration of Parameters From the Calibration screen, use the “ ∨ “ soft key to scroll the cursor to the parameter you wish to calibrate. Once the cursor is pointing to the parameter you wish to calibrate, press the “ Select” soft key. A calibration prompt screen will now appear. The following is a list of the calibration parameters and an example of the prompt screen with the details that will be displayed for each parameter (screen shown at left).

  • Page 59: Replacement Parts List

    128 x 64 Graphic Display ICs and PCB Assemblies 38262 IC16 Microcontroller 78E516B PLCC 38367 CON 3670 Main Control Board 38325 AMP 3130 Power Amplifier Board 38331 KEY 3670 Keypad Board 38268 PWR 3670 Input Voltage Select PCB 39050 RS232...

  • Page 60: Schematic Index

    11. SCHEMATIC INDEX Drawing Reference Description Pages Number Designator S03130 Wiring Diagram 3130 S38367 Main Control Board CON 3670 S38325 Power Amplifier Board AMP 3130 S38267 Keypad Board KEY 3670 S38268 Input Voltage Select PCB PWR 3670 S39013 RS232 Interface Board...
  • Page 61 Index Adapter Box 17, 32, 41, 55 3, 31 Benefits Breakdown 3, 4 Calibration 11, 26, 52 Calibration Alert Alert Date Cal Alert 22, 26, 27, 28 Cal Date 22, 26, 28 Cal Due 22, 26, 28 Date 22, 26, 28 Time 22, 27, 28, 31 Calibration Procedure...
  • Page 62 Test Parameters 9, 16, 20, 22, 29 22, 23, 28, 38 Power 4, 6, 12 Power Factor Programming Rear Panel Controls 12, 18 Receptacle 18, 36 Regulation Remote 9, 16, 19, 22, 23, 28, 33, 35, 36, 37, 38, 39, 40, 41, 50 Remote Interlock 33, 35, 38, 39 Resistance...

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