Associated Research Hypot II Operation And Service Manual

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OPERATION AND SERVICE MANUAL

Hypot



MODEL 3500D (AC ONLY HIPOT WITH GROUND CONTINUITY CHECK)

MODEL 3505D (ENHANCED AC ONLY HIPOT WITH GROUND CONTINUITY CHECK)

MODEL 3565D (ENHANCED AC/DC HIPOT WITH GROUND CONTINUITY CHECK)

MODEL 3570D (ENHANCED AC/DC HIPOT WITH IR AND GROUND CONTINUITY)

SERIAL NUMBER

M ode ls

13860 West Laurel Drive

3 5 0 0 D/3 5 0 5 D

Lake Forest, Illinois, 60045-4546

U.S.A.

3 5 6 5 D/3 5 7 0 D

Printed Nov 6, 2000

Item 37589

Ver 3.18

www.valuetronics.com

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Summary of Contents for Associated Research Hypot II

Page 1 MODEL 3565D (ENHANCED AC/DC HIPOT WITH GROUND CONTINUITY CHECK) MODEL 3570D (ENHANCED AC/DC HIPOT WITH IR AND GROUND CONTINUITY) SERIAL NUMBER M ode ls © Associated Research, Inc., 2000 13860 West Laurel Drive 3 5 0 0 D/3 5 0 5 D Lake Forest, Illinois, 60045-4546 U.S.A.
Page 2 Transportation costs for the return of the instrument for warranty service must be prepaid by the customer. AR will assume the return freight costs when returning the instrument to the customer. The return method will be at the discretion of Associated Research. Except as provided herein, Associated Research makes no warranties to the...
Page 3 TABLE OF CONTENTS SECTION I OPERATORS MANUAL ................1 SAFETY ...........................2 INTRODUCTION ......................6 SPECIFICATIONS......................12 CONTROLS ........................18 INSTALLATION ......................21 QUICK START ......................24 OPERATION........................27 OPTIONS ........................42 SECTION II SERVICE MANUAL................45 CALIBRATION ......................46 PARTS LIST........................49 SCHEMATICS.......................50 www.valuetronics.com...
Page 4 www.valuetronics.com...
Page 5 SECTION 1 OPERATORS MANUAL www.valuetronics.com...
Page 6 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 the Hipot 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 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 11 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 12 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 13 INTRODUCTION required to monitor the 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. 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 14 The Ground Continuity test verifies that the ground circuit between the Continuity and Return panel jacks on the Hypot II is below 1ohm while test at a current of 100mA. This function can be enabled or disabled through software, when a ground circuit is not provided on the device under test or test requirement are not needed.
Page 15 INTRODUCTION the insulation. The connections to perform the IR test are the same as the hipot test. The measured value represents the equivalent resistance of all the insulation which exists between the two points and any component resistance which might also be connected between the two points.
Page 16 SPECIFICATIONS Model 3500D, 3505D, 3565D and 3570D Functional Specifications Unless otherwise stated, accuracy's are relative to a laboratory standard measurement. DIELECTRIC WITHSTAND TEST MODE Descriptions Specifications INPUT VOLTAGE 115 / 230V selectable, ± 15 % variation 47 - 63 Hz FUSE 115 VAC, 230VAC -- 3.15A fast acting 250VAC OUTPUT...
Page 17 SPECIFICATIONS Descriptions Specifications METERING Voltmeter (4 digits) Range : AC 0.00 - 5.00 KV : DC 0.00 - 6.00 KV Resolution : .01 KV Accuracy : ± (2 % of reading + 10 V) Ammeter (4 digits) Range : AC 0.10 - 12.00 mA : DC 0.02 - 5.00 mA Resolution : 0.01 mA Accuracy...
Page 18 SPECIFICATIONS Descriptions Specifications High Resistance Limit Range: 0 - 1000 MΩ (0 = Off) Low Resistance Limit Range: 1 - 1000 MΩ Delay Timer Range: 0, 0.5 - 999.9 sec (0 = Constant) Resolution: 0.1 sec/step Accuracy: ± (0.1% + 0.05 sec) GENERAL REMOTE CONTROL The following input and output signals are provided through...
Page 19 6. The LCD display allows monitoring of current down to 100 microamps AC and 20 microamps DC. This allows the Hypot II to be used even when test requirements only allow a very low level of acceptable leakage current. 7. Electronic dwell settings.
Page 20 10 volt increments by simply pressing the up and down arrow keys. This makes it very easy to adjust the output voltage even while Hypot II is in the dwell mode so you can analyze test results at different voltages. 14. Built-in Continuity test mode.
Page 21 SPECIFICATIONS 21. Insulation Resistance Test Mode ** This allows the operator to perform an Insulation Resistance test independently or in sequence with the Dielectric Withstand (Hipot) test, thus eliminating the need for a separate piece of test equipment when IR testing is required. 22.Insulation Resistance Adjustable Output ** The Insulation Resistance test mode provides an adjustable output range of 100-1000 volts DC.
Page 22 Please refer to page 41 for details on connecting the adapter box between Hypot II and the device under test. POWER SWITCH: Rocker-style switch with international ON ( | ) and OFF (0) markings.
Page 23 CONTROLS FRONT PANEL CONTROLS ∧ ∧ ∧ ∧ ) : Use this key to increment numeric values in the setup mode. This UP ARROW ( key also used to toggle ON/OFF functions. Also may be used to increase output voltage during a test in 10 volt increments. EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test.
Page 24 CONTROLS REAR PANEL CONTROLS Cal. THERMAL FAN: To cool the instrument. INPUT POWER SWITCH: Line voltage selection is set by the position of the switch. In the down position it is set for 115 volt operation, in the up position it is set for 230 volt operation.
Page 25 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 26 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 27 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. 2). Use a strong double-wall container that is made for shipping instrumentation. 350 lb. test material is adequate.
Page 28 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 29 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 30 QUICK START These abbreviated parameters stand for the following: This is the parameter settings review screen. SET: This is the parameter settings review screen for Dielectric Withstand test W - SET: mode. Indicates the memory location of the current settings. Indicates that an Insulation Resistance test will execute after the Dielectric M1_: Withstand test is completed successfully.
Page 31 OPERATION OPERATION INSTRUCTIONS FOR Hypot II Model 3500D, 3505D, 3565D and 3570D 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 32 OPERATION 2. To set the test type and sequence for model 3570D only On model 3570D only the Insulation Resistance (I) and Dielectric Withstand (W) test can be run independently or as a sequence of tests. When “W” or “I” is selected the instrument executes only the test selected.
Page 33 OPERATION 5. To set the High Leakage Current Limit Please press the SET key until the display shows: Models 3500D, 3505D, and 3565D Model 3570D H I - L M T = XX.XX mA W - H i g h XX.XX mA Use the Up/Down Arrow keys to enter the leakage current high limit setting, then press the EXIT key to exit to the test mode or toggle to another setting using the SET key.
Page 34 TEST switch and the operator may proceed with the hipot test. The Hypot 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 35 OPERATION 11. To Set Key Lock or Memory Lock The Hypot II is equipped with two different lockout selections. The first selection is Key Lock. Within this selection, you can lockout all front panel control functions except TEST and RESET. The second selection is Memory Lock and is used in conjunction with the Key Lock.
Page 36 OPERATION 13. To set the High Resistance Limit on model 3570D only Please press the SET key until the display shows: I - H i g h XXXX MΩ Use the Up/Down Arrow keys to enter the resistance high limit setting, then press the EXIT key to exit to the test mode or toggle to another setting using the SET key.
Page 37 OPERATION C. OPERATING PROCEDURES: 1. 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. Then connect the return lead first to the test fixture or the DUT followed by the high voltage lead.
Page 38 OPERATION The display will show: models 3500D models 3505D and 3565D C O N T - F a i l . 0 . 0 s C O N T . 0 . 0 s - . - - K V A C - - .
Page 39 OPERATION 5. If there is a short circuit in the DUT during the test, the red indicator light will illuminate on the RESET switch and an alarm will sound. The display will show: models 3500D models 3505D and 3565D H I - F A I L XXX .
Page 40 OPERATION 8. If the leakage current exceeds the high limit setting, but does not exceed the metering range, the red indicator light will illuminate on the RESET switch and an alarm will sound. The display will show: models 3500D models 3505D and 3565D H I - F A I L XXX .
Page 41 OPERATION 12. If the operator elects to abort a test in process this can be accomplished by pressing the RESET switch at anytime. The instrument will stop the test process immediately and the display will show: models 3500D models 3505D and 3565D A b o r t XXX .
Page 42 OPERATION 16. If the insulation resistance exceeds the high limit setting, but does not exceed the metering range, the red indicator light will illuminate on the RESET switch and an alarm will sound. The display will show: I - H i g h XXX .
Page 43 OPERATION D. CONNECTION OF REMOTE I/O: A 9 pin “D” type connector is mounted on the rear panel which provides REMOTE- INPUT-OUTPUT control and information. This connector mates with standard 9 pin “D” subminiature connector provided by the user. The Remote I/O mates to a female (receptacle) connector.
Page 44 2. SIGNAL INPUTS OF REMOTE I/O The Hypot II remote connector enables remote operation of the TEST and RESET functions. A normally open momentary switch can then be wired across pins 3 and 5 to allow remote operation of the TEST function. A normally open momentary switch can also be wired across pins 2 and 5 which allows remote operation of the RESET function.
Page 45 OPERATION E. ADAPTER BOX CONNECTION: The following diagram shows how to connect the adapter box to the HYPOT II and to the device under test. Never connect the adapter box to the hipot while the high voltage WARNING outputs are energized.
Page 46 OPTIONS MODEL 3500D, 3505D, 3565D and 3570D 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 which can be referenced on the model option label on the rear panel of the unit when options are present.
Page 47 OPTIONS OPTIONAL REAR PANEL CONTROLS 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 48 OPTIONS 04 Arc Detection This option provides the user with the capability of detecting low level arcing. The arc detection circuit has nine preset sensitivity levels. The specifications for the Arc Detection option are as follows: FAILURE SETTINGS Arc for AC and DC mode (Option 04 only) Sensitivity range : 1-9 Arc detection : minimum duration <...
Page 49 SECTION 2 SERVICE MANUAL www.valuetronics.com...
Page 50 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 1. Calibration of Voltage Equipment needed: STANDARD AC VOLTMETER capable of measuring 5000VAC. Please connect a standard ac voltmeter with 5000V minimum full scale range to the high voltage and return connectors. Then press the SET key on the front panel. The instrument will provide around 5000VAC on the output connectors and the display will show: V o l t a g e = __ Please use the Up/Down Arrow keys to enter the reading off the AC Voltmeter into the...
Page 52 CALIBRATION 3. Calibration of Insulation Resistance Current model 3570D only Equipment needed: STANDARD DC MILLIAMMETER with a range of 2000uA and a fixed Resistor 500K Ohms, 50 watts. Please connect a 500KΩ resistor in series with the standard DC microammeter and connect these across the output leads of the instrument.
Page 53 CALIBRATION Replacement Parts List HYPOT II Model 3500D, 3505D, 3565D and 3570D Rev I. ECO 4671 Part Number Qty. Reference Description Designator 37961 CGC-03 Ground Continuity Board (3500 - 3565D only) 37903 CGC-03 Ground Continuity Board (3570D only) 37590 CHV-04...
Page 54 PARTS LIST SCHEMATIC INDEX Drawing Number Description Pages S03500D Wiring Diagram S37917 Main Control Board S37961 Ground Continuity Check Board S37903 Ground Continuity Check Board w/IR test S37590 HV Control Board AC/DC S37593 Keypad Board S37515 Input Protection Board S38220 ROM Conversion Board www.valuetronics.com...

This manual is also suitable for:

3500d 3505d 3565d 3570d