Model 4500D

Model 4500D
OPERATION AND SERVICE MANUAL
Hypot  II
MODEL 4500D
500 VA Enhanced
AC Only Hipot With Ground Continuity Check
SERIAL NUMBER
Model
4500D
Item 38088
© Associated Research, Inc. 2002
13860 West Laurel Drive
Lake Forest, Illinois 60045-4546
U.S.A.
Ver 1.08
Printed Feb. 11, 2003
i
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. Options and accessories that are
external to the instrument are warranted for a period of (90) days from date of shipment.
You must return the “Owners Registration Card” provided within (15) days from receipt
of your instrument.
AR recommends that your instrument be calibrated on a twelve month cycle.
Instruments purchased and used in North America only, may have their warranty
extended in one year increments to a maximum of (5) years provided they are returned to
AR at least annually for calibration and inspection. The annual calibration and
inspection must be performed annually every year following receipt of instrument. Any
instrument not calibrated and inspected annually will not be eligible for extended
warranty status. This extended warranty is non-transferable and is offered only to the
original purchaser.
A return material authorization (RMA) must be obtained from AR before
returning this instrument for warranty service. Please contact our Customer Support
Center at
1-800-858-TEST (8378) to obtain an RMA number. It is important that the
instrument is packed in its original container for safe transport. If the original container
in not available please contact our customer support center for proper instructions on
packaging. Damages sustained as a result of improper packaging will not be honored.
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
purchaser of this instrument and all other warranties, express or implied (including,
without limitation, merchantability or fitness for a particular purpose) are hereby
excluded, disclaimed and waived.
Any non-authorized modifications, tampering or physical damage will void your
warranty. Elimination of any connections in the earth grounding system or by-passing
any safety systems will void this warranty. 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
repair of this instrument will void the warranty.
ii
TABLE OF CONTENTS
SECTION I OPERATORS MANUAL.................................................. 1
SAFETY ............................................................................................... 2
INTRODUCTION ................................................................................ 7
SPECIFICATIONS ............................................................................ 13
CONTROLS ....................................................................................... 17
INSTALLATION ............................................................................... 20
QUICKSTART................................................................................... 23
OPERATION...................................................................................... 26
OPTIONS ........................................................................................... 36
SECTION II SERVICE MANUAL ..................................................... 39
CALIBRATION ................................................................................. 40
PARTS LIST ...................................................................................... 42
SCHEMATICS................................................................................... 43
iii
SECTION 1
OPERATORS MANUAL
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.
INSTRUCTION MANUAL SYMBOL. PLEASE REFER TO THE
INSTRUCTION MANUAL FOR SPECIFIC WARNING OR CAUTION
INFORMATION TO AVOID PERSONAL INJURY OR DAMAGE TO
THE PRODUCT.
INDICATES HAZARDOUS VOLTAGES MAY BE PRESENT
CHASSIS GROUND SYMBOL.
WARNING
CAUTION
2
CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR
CONDITION, THAT COULD POSSIBLY CAUSE BODILY INJURY
OR DEATH.
CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR
CONDITION, THAT COULD POSSIBLY CAUSE DAMAGE TO
EQUIPMENT OR PERMANENT LOSS OF DATA.
SAFETY
A Hipot produces voltages and currents that can cause harmful or fatal electric shock. To
prevent accidental injury or death, these safety procedures must be strictly observed when
handling and using the test instrument.
SERVICE AND MAINTENANCE
User Service
To prevent electric shock do not remove the instrument cover. There are no user
serviceable parts inside. Routine maintenance or cleaning of internal parts is not
necessary. Avoid the use of cleaning agents, chemicals, or liquids to clean the cabinet of
the instrument. Some chemicals are corrosive and may damage the finish of the
instrument or may damage plastic parts or lettering. Any external cleaning should be
done with a clean dry or slightly damp cloth. Application or spillage of liquid on the
instrument may penetrate the cabinet through the ventilation holes or damage the controls
and/or switches. Schematics, when provided, are for reference only. Any replacement
cables and high voltage components should be acquired directly from Associated
Research, Inc. Refer servicing to an Associated Research, Inc. authorized service center.
ASSOCIATED RESEARCH, INC.
13860 WEST LAUREL DRIVE
LAKE FOREST, IL 60045-4546 U.S.A.
!PHONE: 1 (847) 367-4077
1 (800) 858-TEST (8378)
FAX: 1 (847) 367-4080
E-MAIL : info@asresearch.com
www.asresearch.com
Service Interval
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.
User Modifications
Unauthorized user modifications will void your warranty. Associated Research will not
be responsible for any injuries sustained due to unauthorized equipment modifications or
use of parts not specified by Associated Research. Instruments returned to Associated
Research with unsafe modifications will be returned to their original operating condition
at your expense.
TEST STATION
Location
Select an area away from the main stream of activity which employees do not walk
through in 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 the test operators should be allowed inside.
3
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.
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. In the event of an emergency,
anyone can cut off the power before entering the test area to offer assistance.
Work Area
Perform the tests on a nonconducting table or workbench, if possible.
There should not be any metal in the work area between the operator and the location
where products being tested will be positioned.
Position the tester so the operator does not have to reach over the product under test to
activate or adjust the tester. If the product or component being tested is small, it may be
possible to construct guards or an enclosure around the device to be tested. Construct the
guards of a non-conducting material such as clear acrylic, so that the item being tested is
within the guards or enclosure during the test. If possible, the guards or enclosure should
also contain safety switches that will not allow the tester to operate unless the guards are
in place or the enclosure closed.
Keep the area clean and uncluttered. All test equipment and test leads not absolutely
necessary for the test should be removed from the test bench and put away. It should be
clear to both the operator and to any observers which product is being tested, and which
ones are waiting to be tested or have already been tested.
Do not perform Hipot tests in a combustible atmosphere or in any area where combustible
materials are present.
TEST OPERATOR QUALIFICATIONS
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.
Safety Procedures
Operators should be thoroughly trained to follow these and all other applicable safety
rules and procedures before they begin a test. Defeating any safety system should be
treated as a serious offense and should result in severe penalties, such as removal from
4
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.
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.
Always connect the return lead first, regardless of whether the item under test is a sample
of insulating material, a component tested with the high voltage test lead, or a cordconnected device with a two or three prong plug. The return lead should be connected
first for any type of hipot testing.
Plug in the high voltage test lead only when it is being used. Handle its clip only by the
insulator---never touch the clip directly. Be certain that the operator has control over any
remote test switches connected to the Hipot. Double-check the return and high voltage
connections to be certain that they are proper and secure.
WARNING
NEVER TOUCH THE ITEM UNDER TEST OR ANYTHING
CONNECTED TO IT WHILE HIGH VOLTAGE IS PRESENT
DURING THE HIPOT TEST.
When testing with DC, always discharge the capacitance of the item under test and
anything the high voltage may have contacted–such as test fixtures–before handling it or
disconnecting the test leads.
HOT STICK probes can be used to discharge any capacitance in the item under test as a
further safety precaution. A hot stick is a nonconducting rod about two feet long with a
metal probe at the end that is connected to a wire. To discharge the device under test, two
hot sticks are required. First, connect both probe wires to a good earth ground. Then
touch one probe tip to the same place that the return lead was connected. While holding
the first probe in place, touch the second probe tip to the same place where the high
voltage lead was connected.
5
SAFETY
KEY SAFETY POINTS TO REMEMBER:
•
•
•
•
•
6
Keep unqualified and unauthorized personnel away from the test area.
Arrange the test station in a safe and orderly manner.
Never touch the product or connections during a test.
In case of any problem, turn off the high voltage first.
Properly discharge any item tested with DC before touching connections.
INTRODUCTION
GLOSSARY OF TERMS
(as used in this manual)
Alternating Current, AC: Current which reverses direction on a regular basis, commonly in the
U.S.A. 60 times per second, in other countries 50 times per second.
Breakdown: The failure of insulation to effectively prevent the flow of current, sometimes evident by
arcing. If voltage is gradually raised, breakdown will begin suddenly at a certain voltage level. Current
flow is not directly proportional to voltage. Once breakdown current has flown, especially for a period of
time, a repeated application of voltage will often show breakdown beginning at a lower voltage than
initially.
Conductive: Having a volume resistivity of no more than 103 ohm-cm or a surface resistivity of no
more than 105 ohms per square.
Conductor: A solid or liquid material which has the ability to let current pass through it, and which has
a volume resistivity of no more than 103 ohm-cm.
Current: The movement of electrons through a conductor. Current is measured in amperes,
milliamperes, microamperes, nanoamperes, or picoamperes. Symbol = I
Dielectric: An insulating material which is positioned between two conductive materials in such a way
that a charge or voltage may appear across the two conductive materials.
Direct Current, DC: Current which flows in one direction only. The source of direct current is said
to be polarized and has one terminal which is always at a higher potential than the other.
Hipot Tester: Common term for dielectric-withstand test equipment.
Hypot®: Registered trademark of Associated Research, Inc., for its dielectric-withstand test equipment.
Insulation: Gas, liquid or solid material which has a volume resistivity of at least 1012 ohm-cm and is
used for the purpose of resisting current flow between conductors.
Insulation Resistance Tester: An instrument or a function of an instrument capable of measuring
resistance’s in excess of 200 megohms. Usually employs a higher voltage power supply than used in
ohmmeters measuring up to 200 megohms.
Leakage: AC or DC current flow through insulation and over its surfaces, and AC current flow through a
capacitance. Current flow is directly proportional to voltage. The insulation and/or capacitance is thought
of as a constant impedance, unless breakdown occurs.
Resistance: That property of a substance which impedes current and results in the dissipation of power
in the form of heat. The practical unit of resistance is the ohm. Symbol = R
Trip Point: The minimum current flow required to cause an indication of unacceptable performance
during a dielectric voltage-withstand test.
Voltage: Electrical pressure, the force which causes current through an electrical conductor.
Symbol = V
7
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.
To meet recognized safety standards, one common test is the “dielectric voltagewithstand test”. Safety agencies which require compliance safety testing at both the
initial product design stage and for routine production line testing include: Underwriters
Laboratories, Inc. (UL), the Canadian Standards Association (CSA), the International
Electrotechnical Commission (IEC), the British Standards Institution (BSI), the
Association of German Electrical Engineers (VDE), the Japanese Standards Association
(JSI). These same agencies may also require that an insulation resistance test and high
current ground bond test be performed.
The Dielectric Withstand (Hipot) Test....
The principle behind a dielectric voltage – withstand test is simple. If a product will
function when exposed to extremely adverse conditions, it can be assumed that the
product will function in normal operating circumstances.
The most common applications of the dielectric-withstand test are:
•
Design (performance) Testing.... determining design adequacy to meet service
conditions.
•
Production Line Testing.... detecting defects in material or workmanship during
processing.
•
Acceptance Testing.... proving minimum insulation requirements of purchased parts.
•
Repair Service Testing.... determine reliability and safety of equipment repairs.
The specific technique varies with each product, but basically, during a dielectric voltage
– withstand test, an electrical device is exposed to a voltage significantly higher than it
normally encounters. The high voltage is continued for a given period of time.
If, during the time the component is tested, stray current flow remains within specified
limits, the device is assumed to be safe under normal conditions. The basic product
design and use of the insulating material will protect the user against electrical shock.
The equipment used for this test, a dielectric-withstand tester, is often called a “hipot”
(for high potential tester). The “rule of thumb” for testing is to subject the product to
twice its normal operating voltage, plus 1,000 volts.
8
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” 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. Design tests usually are
performed on only a few samples of the product. Production tests are performed on each
and every item as it comes off the production line.
The hipot tester must also maintain an output voltage between 100% and 120% of
specification. The output voltage of the hipot must have a sinusoidal waveform with a
frequency between 40 to 70 Hz and has a peak waveform value that is not less than 1.3
and not more than 1.5 times the root-mean-square value.
Advantages and Disadvantages of AC Testing and DC Testing....
Please check with the Compliance Agency you are working with to see which of the two
type of voltages you are authorized to use. In some cases a Compliance Agency will
allow either AC or DC testing to be done. However in other cases the Compliance
Agency only allows for an AC test. If you are unsure which specification you must
comply with please contact our CUSTOMER SUPPORT GROUP at 1-800-858-TEST
(8378).
Many safety agency specifications allow either AC or DC voltages to be used during the
hipot test. When this is the case the manufacturer must make the decision on which type
of voltage to utilize. In order to do this it is important to understand the advantages and
the disadvantages of both AC and DC testing.
AC testing characteristics
Most items that are hipot tested have some amount of distributed capacitance. An AC
voltage cannot charge this capacitance so it continually reads the reactive current that
flows when AC is applied to a capacitive load.
AC testing advantages
1. AC testing is generally much more accepted by safety agencies than DC testing. The
main reason for this is that most items being hipot tested will operate at AC voltages and
AC hipot testing offers the advantage of stressing the insulation alternately in both
polarities which more closely simulates stresses the product will see in real use.
2. Since AC testing cannot charge a capacitive load the current reading remains consistent
from initial application of the voltage to the end of the test. Therefore, there is no need to
gradually bring up the voltage since there is no stabilization required to monitor the
9
INTRODUCTION
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.
3. 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
1. 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. In
many cases the reactive component of the current can be much greater than the real
component due to actual leakage. This can make it very difficult to detect products that
have excessively high leakage current.
2. Another disadvantage of AC testing is that the hipot has to have the capability of
supplying reactive and leakage current continuously. This may require a current output
that is actually much higher than is really required to monitor leakage current and in most
cases is usually much higher than would be needed with DC testing. This can present
increased safety risks as operators are exposed to higher currents.
DC testing characteristics
During DC hipot testing the item under test is charged. The same test item capacitance
that causes reactive current in AC testing results in initial charging current which
exponentially drops to zero in DC testing.
DC testing advantages
1. Once the item under test is fully charged the only current flowing is true leakage
current. This allows a DC hipot tester to clearly display only the true leakage of the
product under test.
2. The other advantage to DC testing is that since the charging current only needs to be
applied momentarily the output power requirements of the DC hipot tester can typically
be much less than what would be required in an AC tester to test the same product.
DC testing disadvantages
1. Unless the item being tested has virtually no capacitance it is necessary to raise the
voltage gradually from zero to the full test voltage. The more capacitive the item the
more slowly the voltage must be raised. This is important since most DC hipots have
failure shut off circuitry which will indicate failure almost immediately if the total current
reaches the leakage threshold during the initial charging of the product under test.
10
INTRODUCTION
2. Since a DC hipot does charge the item under test it becomes necessary to discharge the
item after the test.
3. 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.
4. When performing AC hipot tests the product under test is actually tested with peak
voltages that the hipot meter does not display. This is not the case with DC testing since
a sinewave is not generated when testing with direct current. In order to compensate for
this most safety agencies require that the equivalent DC test be performed at higher
voltages than the AC test. The multiplying factor is somewhat inconsistent between
agencies which can cause confusion concerning exactly what equivalent DC test voltage
is appropriate.
The Ground Continuity Test
The Ground Continuity test is checking to verify that there is low impedance path
between the chassis and the safety ground wire of the line cord. A low impedance ground
system is critical in ensuring that in the event of a product failure a circuit breaker on the
input line will act quickly to protect the user from any serious electrical shock.
International compliance agencies such as CSA, IEC, TÜV, VDE, BABT and others,
have requirements calling out this test. A low current test merely indicates that there is a
safety ground connection. It does not completely test the integrity of the connection that
would be accomplished by using much higher currents in the range from 10 to 30amps.
The high current test is known as a Ground Bond test.
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.
The Insulation Resistance Test....
Some dielectric analyzers come with a built in insulation resistance tester. Typically, the
IR function provides test voltages from 500 to 1,000 volts DC and resistance ranges from
kilohms to gigaohms. This function allows manufacturers to comply with special
compliance regulations. BABT, TÜV and VDE are agencies that may require an IR test
on the product before a Hipot test is performed. This typically is not a production line
test but a performance design test.
The insulation resistance test is very similar to the hipot test. Instead of the go/no go
indication that you get with a hipot test the IR test gives you an insulation value usually in
Megohms. Typically, the higher the insulation resistance value the better the condition of
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
11
INTRODUCTION
between the two points and any component resistance which might also be connected
between the two points.
Although the IR test can be a predictor of insulation condition it does not replace the need
to perform a Dielectric Withstand test.
TYPES OF FAILURES DETECTABLE ONLY WITH A HIPOT TEST
•
•
•
•
Weak Insulating Materials
Pinholes in Insulation
Inadequate Spacing of Components
Pinched Insulation
IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION
OF YOUR INSTRUMENT CALL 1-800-858-TEST(8378) IN THE U.S.A.
12
SPECIFICATIONS
Model 4500D
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, ± 10 % variation
50/60 Hz ± 5%
FUSE
115 VAC, 230VAC – 15A fast acting 250VAC
OUTPUT
Rating AC 0 – 5000V, 10V / step, 100mA
Regulation : ± (1 % of output + 5V)
VOLTAGE SETTING 0V – Max output rating, 10 volts/step
Accuracy: ± (2 % of Setting + 5V) (relative to displayed output)
Can be adjusted during operation via UP and DOWN arrow
keys.
OUTPUT
50 / 60 Hz selectable
FREQUENCY
WAVE FORM
Sinewave, 1.3 < Crest Factor < 1.5
DWELL TIME
0 and 0.2 – 999.9 seconds, 0.1 second / step
SETTING
“0” for continuous running
RAMP TIME
0 and 0.2 – 999.9 seconds, 0.1 second / step
SETTING
0 ramp setting = 0.1 seconds fixed ramp
FAILURE SETTINGS AC mode
High limit : 0.00 – 99.99 mA, 0.01 mA / step
Low limit : 0.00 – 99.99 mA, 0.01 mA / step (0= OFF)
Accuracy : ± (2 % of setting + 0.02 mA)
METERING
Voltmeter (4 digits)
Range
: AC 0.00 – 5.00 KV
Resolution : 0.01 KV
Accuracy : ± (2 % of reading + 10 V)
Ammeter (4 digits)
Range
: AC 0.00 - 99.99 mA
Resolution : 0.01 mA
Accuracy : ± (2 % of reading + 0.02 mA)
TIMER DISPLAY
Range
: 0.0 – 999.9 seconds
Resolution : 0.1 seconds
Accuracy : ± (0.1% of reading + 0.05 sec)
13
SPECIFICATIONS
GROUND
Current : DC 0.1 A ± 0.01A, fixed
CONTINUITY
Max. ground resistance : 1 Ω ± 0.1Ω, fixed
CHECK
GENERAL SPECIFICATIONS
Remote Control and
The following input and output signals are provided through two
Signal Output
9 pin D type connectors;
1. Remote control: test, reset, interlock
2. Outputs: pass, fail, test in process
Program Memory
5 sets
Security
Lockout capability to avoid unauthorized access to test set-up
program.
Line Cord
Detachable 7ft. (2.13m) power cable terminated in a three prong
grounding plug.
Terminations
5ft. (1.52m) high voltage and return leads (2) with clips and a
standard U.S. style (NEMA 5-15) remote receptacle box for
testing items terminated with a line cord. International
receptacles also available.
Mechanical
Tilt-up front feet
Dimensions (W x H x D) 17 x 5.8 x 12 in. (432 x 147 x 305mm)
Weight: 56.70 Lbs. (25.92 kgs)
Environmental
Operating Temperatures: 32°-104°F (0°-40°C)
Relative Humidity : 0 to 80%
Calibration
Traceable to National Institute of Standards and Technology
(NIST). Calibration controlled by software. Adjustments are
made through front panel keypad in a restricted access
calibration mode. Calibration information stored in non-volatile
memory.
14
SPECIFICATIONS
KEY FEATURES & BENEFITS OF MODEL 4500D
1. No load setup of trip current and output voltage.
This provides the operator with an easy and safe way to set trip currents and output
voltages since parameters are set without the high voltage activated.
2. Automatic storage of test program.
The Model 4500D powers up with the parameters that were used during the last test
to avoid operator set-up errors.
3. All parameters for the setups can be adjusted through a simple menu driven
program.
The easy to follow setup screens ensure that the operator correctly sets up all test
parameters.
4. Tamper proof front panel controls.
This makes it possible to limit user access to the setup screens so that only authorized
personnel with a security code can change test parameters.
5. Line and load regulation.
This system maintains the output voltage to within 1% from no load to full load and
over the line voltage range to ensure that test results remain consistent and within
safety agency requirements.
6. The LCD display allows monitoring of current down to 100 microamps AC.
This allows the 4500D to be used even when test requirements only allow a very low
level of acceptable leakage current.
7. Electronic dwell settings.
The electronic dwell control helps keep test results consistent by ensuring that the test
duration is the same for each product tested.
8. PLC remote inputs and outputs.
The standard 9 pin interfaces provide outputs for Pass, Fail, and Test in Process.
Inputs include Test and Reset. This gives the user all the basic remotes required to
configure the 4500D through simple PLC relay control.
9. Front panel LCD displays test parameters and results.
A front panel LCD allows the operator to monitor the test. The display holds the
results after a test item failure so that the operator can easily review the test results.
Indications of high fail and continuity failure are clearly displayed.
10. Maximum output current of 100 milliamps AC.
This instrument offers enough output current to test capacitive loads in AC mode and
allows compliance with standards requiring 500VA output.
15
SPECIFICATIONS
11. Software calibration control.
The 4500D is calibrated through the front panel keypad. All calibration information
is stored in non-volatile memory. This allows the 4500D to be completely calibrated
without removing any covers and exposing the technician to hazardous voltages.
12. User selectable output voltage frequencies of 50 or 60 hertz.
The 4500D is designed for the global market. This feature makes it simple for the
user to select the output frequency in the AC hipot mode so that products can be
tested at the same frequency they will be used at.
13. Output voltage fine adjustment.
To make 4500D usable in all types of applications, the operator can manually bring
the voltage up or down in 10 volt increments by simply pressing the up and down
arrow keys. This makes it very easy to adjust the output voltage even while the
4500D is in the dwell mode so you can analyze test results at different voltages.
14. Built-in Continuity test mode.
The 4500D meets ground continuity test requirements called out by UL and other
safety agencies.
15. Flashing high voltage indicator.
A flashing LED located directly over the high voltage terminal clearly indicates when
high voltage is active to provide maximum operator safety.
16. Comes complete with a test box for products terminated in a line cord.
The standard US style receptacle box allows easy testing of hipot and continuity on
line cord terminated products. As an additional benefit, termination boxes are
available for testing products with line cords configured for other countries.
17. User selectable input voltage.
The 4500D can be switched for either 115 or 230 volt input operation through an easy
access rear panel mounted switch to allow it to be used in any country.
18. Low-current sense.
Monitors the minimum level of current flow, thus ensuring that the DUT is properly
connected and that the hipot test is being performed.
19. Electronic ramping.
Provides a gradual and timed method to increase output voltage to the DUT,
minimizing any damage from quickly over-applying high voltage to sensitive DUTs.
20. Test setup memories.
The operator can store and recall test setups, thus eliminating the need to re-enter
setup information.
21. Built-In Remote Interlock
A remote interlock provides a way to connect a safety enclosure or other safety device
to protect the operator from exposure to high voltage.
16
INSTALLATION
FRONT PANEL CONTROLS
1.
RESET SWITCH: This is a momentary contact switch. If an out-of-range reading
is detected during a hipot test or an IR test or if continuity failure occurs, the red
failure lamp within the switch will light. To reset the system for the next test, press
and release this switch. This switch may also be used to abort a test in progress.
2.
TEST SWITCH: This is a momentary contact switch. Press the green switch to
turn on the high voltage output when in test mode. The indicator lamp within the
switch will light when continuity is “good”, if continuity mode is enabled.
3.
LCD DISPLAY: The Liquid Crystal Display is the main readout for the operator
and programmer of the test settings and test results.
4.
CONTINUITY CHECK OUTPUT JACK: For the connection of the detachable 5
foot (1.52 m) black return test lead or three prong receptacle adapter box. This jack
is always used when performing a continuity test. Please refer to page 35 for details
on connecting the adapter box between Hypot II and the device under test.
5.
POWER SWITCH: Rocker-style switch with international ON ( | ) and OFF (0)
markings.
6.
SET KEY: Use this key to advance forward through the setup menus.
7.
DOWN ARROW (∨): Use this key to decrement numeric values in the setup mode.
This key also used to toggle ON/OFF functions. Also may be used to decrease output
voltage during a test in 10 volt increments.
17
INSTALLATION
FRONT PANEL CONTROLS
8.
UP ARROW (∧): Use this key to increment numeric values in the setup mode. This
key also used to toggle ON/OFF functions. Also may be used to increase output
voltage during a test in 10 volt increments.
9.
EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test.
10. 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.
11. HIGH VOLTAGE ARROW (LED INDICATOR): This indicator flashes to warn
the operator that high voltage is present at the high voltage output terminal.
12. RETURN OUTPUT JACK: For the connection of the detachable 5 foot (1.52 m)
black return test lead. This lead is always used when performing a test.
18
INSTALLATION
REAR PANEL CONTROLS
1.
REMOTE INTERFACE SIGNAL OUTPUT: 9 pin D subminiature female
connector which provides; Pass, Fail and Test in process signals
2.
REMOTE INTERFACE SIGNAL INPUT: 9 pin D subminiature male connector
which provides remote control access over Test, Reset and Interlock.
3.
THERMAL FAN: To cool the instrument.
4.
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.
5.
CONTINUITY CHECK OUTPUT JACK: For the connection of the detachable 5
foot (1.52 m) black return test lead or three prong receptacle adapter box. This jack
is always used when performing a continuity test. Please refer to page 35 for details
on connecting the adapter box between Hypot II and the device under test.
6.
RETURN OUTPUT JACK: For the connection of the detachable 5 foot (1.52 m)
black return test lead. This lead is always used when performing a test.
7.
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.
8.
CHASSIS GROUND (EARTH) TERMINAL: This safety terminal should be
connected to a good earth ground before operation
9.
INPUT POWER RECEPTACLE: Standard IEC 320 connector for connection to a
standard NEMA style line power (mains) cord.
19
INSTALLATION
INSTALLATION
Introduction
This section contains information for the unpacking, inspection, preparation for use and
storage of your Associated Research, Inc., product.
Unpacking and Inspection
Your instrument was shipped in a custom foam insulated container that complies with
ASTM D4169-92a Assurance Level II Distribution Cycle 13 Performance Test Sequence.
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. Please do not return your
product without first notifying us and receiving an RMA (return materials authorization)
number.
Preparation for Use
Power Requirements and Line Voltage Selection
This instrument requires a power source of 115 volts AC ± 10%, 50/60
Hz ± 5% single phase or 230 volts AC ± 10%, 50/60 Hz ± 5% single
phase. Please check the rear panel to be sure the proper switch setting
is selected for your line voltage requirements before turning your
instrument on. In addition, please be sure the correct fuse is selected and installed while
the instrument is in the off position.
CAUTION
Do not switch the line voltage selector switch located on the rear panel while the
instrument is on or operating. This may cause internal damage and represents a safety
risk to the operator.
NOTE
For operation at 115 Volts AC and 230 Volts AC use a 15A fast acting fuse.
20
INSTALLATION
Power Cable
BEFORE CONNECTING POWER TO THIS INSTRUMENT,
THE 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. THIS PROTECTIVE GROUND
(EARTH) MUST NOT BE DEFEATED BY THE USE OF AN EXTENSION CORD
(POWER CABLE) WITHOUT A PROTECTIVE CONDUCTOR (GROUNDING).
WARNING
This instrument is shipped with a three-wire power cable. When this cable is connected
to an appropriate AC power source, this cable connects the chassis to earth ground. The
type of power cable shipped with each instruments depends on the country of destination.
Operating Environment
This instrument may be operated in temperatures from 32° - 104° F (0° - 40° C)
Relative humidity of 0 to 80%.
Altitude up to 15,000 feet (4,600 meters).
STORAGE AND SHIPMENT
Environment
This instrument may be stored or shipped in environments with the following limits:
Temperature......................... -40° to +75°C
Altitude............................ 7,620 meters (25,000 feet)
The instrument should also be protected against temperature extremes that 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. Please do not reuse the original packing material if there appears to be damage
or missing packing material. Contact our customer support department (1-800-858-8378)
for an RGA (return goods authorization) number. Please enclose the instrument with all
options, accessories and test leads. Indicate the nature of the problem or type of service
needed. Also, please mark the container “FRAGILE” to insure proper handling. Upon
receipt your instrument will be issued an AR service number. Please refer to this number
in all correspondence.
21
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.
5. Use a strong double-wall container that is made for shipping instrumentation. 350 lb.
test material is adequate.
6. Use a layer of shock-absorbing material 70 to 100 mm (3 to 4 inch) thick around all
sides of the instrument. Protect the control panel with cardboard.
7. Seal the container securely.
8. Mark the container “FRAGILE” to insure proper handling.
9. Please ship model 4500D via Federal Express or UPS air.
10. Please refer in all correspondence to your AR service number.
Field Installation Of Options
There are no field installable options on the model 4500D.
22
QUICK START
QUICKSTART
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. The default settings will appear in memories 1-5. The instrument default settings
are as follows:
DEFAULTS
•
Input Voltage:
•
Lock:
115 or 230 volts AC country specific
(rear panel switch selectable)
OFF
•
Voltage Output:
1,240 volts AC
•
High Current Trip:
HI-LMT: 10 mA
•
Low Current Trip:
LO-LMT: 0 mA
•
Ramp Timer:
0 second
•
Dwell Timer:
1 second
•
AC Output Frequency:
60Hz
•
Continuity:
OFF
23
QUICK START
1. Unpack this instrument from its special shipping container. Be sure to save all
packaging materials in case you need to return it to the factory for service.
2. 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 set-up in the SAFETY section of this manual. Locate a three prong grounded outlet.
Be sure the outlet has been tested for proper wiring before connecting the instrument to it.
WARNING
3. Check to be sure 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. Connect the male
end of the plug to the outlet receptacle.
CAUTION
Please be sure that the safety ground on the power line cord is
not defeated and that you are connecting to a grounded power
source.
4. Turn on the POWER switch located on the lower left hand side of the front panel. Upon
powering the instrument up a POWER ON SELF TEST (POST) will automatically be
performed. 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.
ARI HYPOT II
4500D
VER: X.X
Current software version
displayed here
You should then see the default parameters on the LCD meter as follows:
Set
M1
1.0s
1.24KVAC 10.00mA
These abbreviated parameters stand for the following:
SET:
M1:
1.0 S:
1.24KVAC:
10.00 mA:
This is the parameter settings review screen.
Indicates the memory location of the current settings.
The dwell timer is set to a test duration of 1 second.
The test voltage is set to 1,240 volts AC.
The high leakage current trip point is set to 10 milliamps.
If you wish to not use any one of these parameters you must change your parameters.
Please refer to the Operation Instructions section in this manual for further details.
24
QUICK START
5. If the instrument 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 this safety ground to a
suitable known good ground before energizing this instrument, connect the return lead first
(black) to the test fixture or item followed by the high voltage output lead (red).
6. Please check your connections to be sure they are making good contact.
WARNING Clear the area of any debris that may create a hazardous situation and ask
any unnecessary personnel to leave the area. DO NOT TOUCH THE
DEVICE UNDER TEST ONCE THE TEST HAS BEEN STARTED. To initiate the test
press the GREEN test button on the front panel. This is a momentary button and does not
need to be held in the pressed position during the test. The instrument will then cycle ON
and begin the automated test sequence using the defaults. If a failure occurs you will
HEAR an audible alarm go off. To stop the alarm you must depress the RED button
marked RESET. This will silence the alarm and reset the instrument to begin another test.
This RESET button may also be used as a safety button to quickly ABORT a test and cut
off the HIGH VOLTAGE.
When HIGH VOLTAGE is present a RED flashing indicator located above
the HV receptacle will remain flashing until the HIGH VOLTAGE is OFF.
If the DUT PASSED the test, you will hear a brief BEEP indicating the
DUT passed and that the test is complete.
In the case of a FAIL condition, the instrument will provide a memory of
the test condition results on the LCD display that will remain until the next test is initiated.
Depressing the reset button will reset the instrument alarm while keeping the last test
results on the display. Depressing the reset button a second time will clear the display.
25
OPERATION
OPERATION INSTRUCTIONS FOR Hypot II
Model 4500D
1. POWER UP:
Check that the correct input line voltage has been
selected on the rear panel, either 115 volts AC or 230
CAUTION
volts AC. Plug the line cord into its socket on the rear
panel of the instrument. Connect the male end of the
plug to the outlet receptacle.
Please be sure that the safety ground on the power line cord is not defeated and
that you are connecting to a grounded power source. Also, connect the rear panel
chassis ground for additional safety.
Turn on the POWER switch located on the lower left-hand side of the front panel.
Upon powering the instrument up a POWER ON SELF TEST (POST) will be
automatically performed. This test will check for the condition of the ram chips,
PCB’s and other critical components. In addition, the display will show the
following message with the model and version number.
ARI HYPOT II
4500D
VER: X.X
Current software version
displayed here
The instrument will recall the last setup that was active and the display will show
the parameters that were programmed into the unit. The instrument is now ready
for operation.
2. SETUP PROCEDURE:
2.1.
To Select the Memory location
Please press the SET key until the display shows
Memory =
X
Use the Up/Down arrow keys to select memory locations 1 through 5. After
selecting the memory, press the SET key to view the settings that have been
recalled from memory or to make any changes to these settings.
To store any changes to the settings press the Exit key. The parameters are
automatically updated into the memory location that was selected, when exiting to
the test mode.
26
OPERATION
2.2.
To set the Output Test Voltage
Please press the SET key until the display shows:
Voltage= X.XX KV
Please use the Up/Down Arrow keys to enter the desired test voltage, then press
the EXIT key to exit to the test mode or toggle to another setting using the SET
key. The maximum voltage, which may be entered, is 5000 volts AC.
2.3.
To set the High Leakage Current Limit
Please press the SET key until the display shows:
HI-LMT =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. The unit of measure is in AC milliamperes with 0.10 milliamperes as
the minimum setting.
2.4.
To set the Low Leakage Current Limit
Please press the SET key until the display shows:
LO-LMT = X.XX mA
Use the Up/Down Arrow keys to enter the leakage current low limit setting, then
press the EXIT key to exit to the test mode or toggle to another setting using the
SET key. The unit of measure is in AC milliamperes with 0.00 milliamperes as
the minimum setting.
2.5.
To set the Ramp Time
Please press the SET key until the display shows:
Ramp-T =
X.X s
Use the Up/Down Arrow keys to enter the ramp time setting then press the EXIT
key to exit to the test mode or toggle to another setting using the SET key. If the
ramp time is set to “0”, the instrument will raise the voltage up to the test voltage
in a fixed ramp time of 0.1 seconds and then begin the dwell cycle. The minimum
ramp time setting is 0.2 seconds with 0.1 second resolution.
27
OPERATION
2.6.
To set the Dwell Time
Please press the SET key until the display shows:
Timer
=
X.X s
Use the Up/Down Arrow keys to enter the dwell time setting, then press the EXIT
key to exit to the test mode or toggle to another setting using the SET key. If the
dwell time is set to “0”, the instrument will operate in a continuous ON mode
when the test button is depressed and released. It will stop when the DUT
(Device Under Test) goes into failure or the manual reset button is pressed. The
minimum dwell time setting is 0.2 seconds with 0.1 second resolution.
2.7.
To setup the Ground Continuity Check
Please press the SET key until the display shows:
Continuity=ON
or
Continuity=OFF
Press the Up/Down Arrow key to select the “ON” or “OFF” function of the
Ground Continuity Check mode, the display will show the set status immediately.
Press the EXIT key to exit to the test mode or toggle to another setting using the
SET key.
If the Continuity Function is set to “ON,” the Ground Continuity cable has to be
connected between the “Cont. Check” connector on the instrument panel and the
chassis of the DUT. The instrument will test the ground connection of the DUT
automatically. If continuity is present a green indicator will be illuminated on the
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.
2.8.
To set the Frequency 50/60 Hz
Please press the SET key until the display shows:
Freq
=60
HZ
or
Freq
=50
HZ
Press the Up or Down Arrow keys to toggle the frequency selection; 50 or 60
hertz, then press the EXIT key to exit to the test mode or toggle to another setting
using the SET key.
28
OPERATION
2.9.
To lock or unlock the front panel keyboard
The Hypot II is equipped with a lockout mode. Within this mode, you can lockout
all front panel control functions except TEST and RESET.
You can toggle this selection only from a power OFF state. Please turn the power
switch to the off position then press and hold the SET key, then turn the power
ON. Momentarily, you will see one of the following screens to indicate if the
keys are locked or unlocked:
Key Lockout
or
Key Unlock
To change the key lock function power down the instrument and repeat the
process.
29
OPERATION
3. OPERATING PROCEDURES:
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. First, connect the return lead to the test fixture or
DUT, then connect the high voltage lead.
Check your connections to be sure they are making good contact. Clear the area
of any debris that may create a hazardous situation and ask any unnecessary
personnel to leave the area.
WARNING
DO NOT TOUCH THE DEVICE UNDER TEST ONCE
THE TEST HAS BEEN STARTED.
Please follow the setup procedures to set the parameters. The display will show
the Dwell or Delay Timer value, the Test Voltage value, and the High Limit
Setting and memory location.
Set
MX XXX.Xs
X.XXKVAC XX.XxmA
3.1.
Ground Continuity Check
If you are performing a Ground Continuity Check, the Ground Continuity must be
set to the “ON (Enabled)” position. The ground check cable has to be connected
properly to the chassis of the DUT and the green indicator on the TEST switch
should be illuminated before activating the Test switch. Otherwise, the
instrument will signal a continuity failure when the test switch is activated.
Please refer to page 35 for the proper test connections using the adapter box, to
test items terminated in a three-prong plug.
The display will show:
CONT. MX XXX.Xs
- .- - KVAC - -.- - mA
If you are not performing a Ground Continuity Check, the Ground Continuity
must be set to the “OFF” (Disabled) position. It is not necessary to connect the
“Cont. Check” cable since this test will not be performed if the circuit is disabled.
The instrument will proceed with the Hipot Test when the “Test” switch is
activated.
30
OPERATION
3.2.
Initiating a Test
To initiate a test, press the TEST switch on the front panel. The red High Voltage
Arrow indicator will flash and the display will immediately show:
Ramp
MX XXX.Xs
X.XXKVAC XX.XxmA
or
Dwell
MX XXX.Xs
X.XXKVAC XX.XxmA
The instrument will continue to output the desired voltage for the duration of the
selected dwell time.
3.3.
Short Circuit
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:
HI-LMT MX XXX.Xs
X.XXKVAC OFL mA
3.4.
Flash Over
If a flash over occurs in the DUT during the test, which results in an OFL
condition due to the current exceeding the maximum metering range, Breakdown
will be indicated as follows. The red indicator light will illuminate on the RESET
switch and an alarm will sound. The display will show:
HI-LMT MX XXX.Xs
X.XXKVAC OFL mA
3.5.
Leakage Current Exceeding the Metering Range
If the leakage current exceeds the metering range and neither a short circuit nor
flash over occurred, the red indicator light will illuminate on the RESET switch
and an alarm will sound. The display will show:
HI-LMT MX XXX.Xs
X.XXKVAC OFL mA
3.6.
High Limit
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:
HI-LMT MX XXX.Xs
X.XXKVAC XX.XxmA
31
OPERATION
3.7.
Low Limit
If the leakage current does not exceed the low limit setting, the red indicator light
will illuminate on the RESET switch and an alarm will sound. The display will
show:
LO-LMT MX XXX.Xs
X.XXKVAC XX.XxmA
3.8.
Resetting the Alarm
To stop the alarm, please press the RESET switch once. The alarm will stop and
the display will retain the failure information. If the RESET switch is pressed
again, the data on the display screen will be cleared and the display will indicate
the setting data from the last test. The instrument is now ready for the next test.
3.9.
Pass
If the DUT passed the test, the instrument will output a short audible beep tone to
indicate the DUT has passed the test. The display will show:
Pass
MX XXX.Xs
X.XXKVAC XX.XxmA
The instrument is now ready to perform another test.
3.10.
Aborting a Test
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:
Abort
MX XXX.Xs
X.XXKVAC XX.XxmA
Press the TEST button to initiate another test.
32
OPERATION
4. CONNECTION OF REMOTE I/O
Two 9 pin “D” type connectors are mounted on the rear panel which 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.
For best performance, a shielded cable should be used. To avoid ground loops the
shield should not be grounded at both ends of the cable. Suggested AMP part
numbers for interconnecting to the Remote I/O are shown below.
205204-4
205203-3
745254-7
745253-7
745171-1
747784-3
4.1.
PLUG SHELL WITH GROUND INDENTS
RECEPTACLE SHELL
CRIMP SNAP-IN PIN CONTACT (for plug)
CRIMP SNAP-IN SOCKET CONTACT (for receptacle)
SHIELDED CABLE CLAMP (for either plug or receptacle)
JACKSCREW SET (2)
Remote Interface Rear Panel:
Signal Outputs on Remote I/O
The rear panel connector provides three output signals to remotely monitor PASS,
FAIL, and PROCESSING conditions. The monitoring signals are provided by
three normally open internal relays, that switch on to indicate the current
condition of the tester. These are normally open free contacts and will 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.
33
OPERATION
Pins 1 and 2 provide the PASS signal.
Pins 3 and 4 provide the FAIL signal.
Pins 5 and 6 provide the PROCESSING signal.
The following describes how the relays operate for each test condition.
PROCESSING – The relay contact closes the connection between pin (5) and pin
(6) while the instrument is performing a test. The connection is opened at the end
of the test.
PASS – The relay contact closes the connection between pin (1) and pin (2) after
detecting that the item under test passed all tests. The connection is opened when
the next test is initiated or the reset function is activated.
FAIL – The relay contact closes the connection between pin (3) and pin (4) after
detecting that the item under test failed any test. The connection is opened when
the next test is initiated, or the reset function activated.
4.2.
Signal Inputs on Remote I/O
The HYPOT II remote connector enables remote operation of the TEST, RESET
and REMOTE INTERLOCK function. When the PLC remote function is (ON)
the test switch on the front panel will be disabled to prevent a test from being
activated through the test switch. 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. For safety, the front panel
RESET switch remains active even when a remote reset switch is connected so
that high voltage can be shut down from either location.
Remote Interlock is a feature that inverts the present reset logic on the instrument
from normally opened (must close contacts to activate the reset) to normally
closed (must open contacts to activate the reset). Hardware and software have
been configured to provide the interlock connections on pins 4 and 5 of the
Remote Interface, Signal Input port. This reset scheme is designed for use with an
external safety interlock device that utilizes a “Fail-When-Open” configuration on
its output interface. The instrument can still be used without the external reset
device as long as the Interlock Connector (provided with unit) is plugged into the
Remote Interface, Signal Input port. If there is nothing connected to the Remote
Interface, Signal Input port to provide a connection to the interlock (reset), then
the instrument will not function.
34
OPERATION
5. ADAPTER BOX CONNECTION:
The following diagram shows how to connect the adapter box to the HYPOT II
and to the device under test.
4500D
36544
CONT
N
L
HV
DUT
RTN
E
CHASSIS
Test Connections
The adapter box allows you an easy way to connect an item that is terminated in a
two or three-prong line cord. If you are testing a product which is terminated in a
three-prong plug, you are also required to perform a continuity or ground bond
test on the ground conductor of the DUT to the chassis or dead metal of the
product. With the HYPOT II, you can perform both the hipot and continuity tests
at the same time by activating the continuity function on the instrument.
When the HYPOT II tests the ground conductor of the line cord, if the resistance
of the ground conductor exceeds 1Ω, 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. When
testing products with two prong plugs, do not activate the continuity circuit.
35
OPTIONS
MODEL 4500D 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. The option label contains an option(s) code that may be crossreferenced to the Options List.
For example your options code would appear as follows:
fitted with option 05
OPT: 05
OPT: 0405
fitted with option 04 and 05
4500D Options
Option List
Code
04
05
06
Description
Arc Detection
Floating Return
Remote Memory Select
Description
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.
Arc Detection Specifications
FAILURE SETTINGS
Arc for AC mode (Option 04 only)
Sensitivity range : 1-9
Arc detection : minimum duration < 10µs
SETUP PROCEDURE
To activate Arc Detection and set the sensitivity level.
Please press the SET key until the display shows:
Arc-Sen=
36
X
OPTIONS
Use the Up/Down Arrow keys to select the arc sensitivity level. The arc sensitivity
level may be set between the values of 1 and 9, 1 being the least sensitive, 9 being
the most sensitive. To deactivate the Arc Detection set the arc sensitivity to 0.
Press the EXIT key to exit to the test mode or toggle to another setting using the
SET key.
OPERATION PROCEDURE
If there is an arcing condition over the Arc sensitivity limit, the red indicator light
will illuminate on the reset switch and an alarm sound. The display will show:
Arc
MX XXX.Xs
X.XXKVAC OFL mA
05 Floating Return
This option separates the Return from the Earth ground. With this option, the
Return lead of instrument is not connected directly to earth ground; this eliminates
monitoring stray leakage currents that flow to earth ground. The metering circuit
monitors only leakage current flowing from the DUT, through the Return test lead
to the Return connector. Therefore, it is crucial that the DUT does not make
direct contact with earth ground or the metering circuit and leakage fail detectors
will be Bypassed.
06 Remote Memory Select
This option enables remote operation of three pre-programmed test setups
(Memories 1-3) through the rear panel input connector. This gives the user the
capability to quickly change parameters and initiate a test remotely. The three
memory setups can be accessed by connecting pins 7, 8 and 9 in different
combinations.
ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH
THE REMOTE CONNECTOR SELECTS THE PROGRAM AND
STARTS THE TEST THAT IS PREPROGRAMMED INTO THAT MEMORY
IMMEDIATELY.
WARNING
37
OPTIONS
MEMORY ONE – Momentarily connecting pin 7 to pin 8 immediately begins the
test program that is stored in memory one.
MEMORY TWO – Momentarily connecting pin 7 to pin 9 immediately begins the
test program that is stored in memory two.
MEMORY THREE – Momentarily connecting pin 7 to pins 8 and 9 immediately
begins the test program that is stored in memory three.
SIGNAL INPUT
RESET
TEST
INTERLOCK
1
6
5
9
MEMORY 1
MEMORY 2
MEMORY 3
38
SECTION 2
SERVICE MANUAL
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. AR recommends you use "Calibration Standards" that are
NIST traceable, or traceable to agencies recognized by NIST to keep this
instrument within published specifications. End user metrology standards or
practices may vary. These metrology standards determine the measurement
uncertainty ratio of the calibration standards being used.
Calibration Equipment Required:
The following equipment will be needed to properly calibrate your instrument.
1). Digital Multimeter with the minimum ranges;
AC Voltage: 5,000 volts
AC Current: 100mA range.
2). 10KΩ/100Watt resistor
100KΩ/10Watt resistor
1. CALIBRATION PROCEDURE:
Model 4500D
To enter the calibration mode the instrument must be in the OFF position. Using
a pen or small screwdriver, press and hold the recessed calibration key on the rear
panel, then turn on the Input Power Switch.
For model 4500D the display will show:
CAL Mode
SET:V ∨:A
Press the SET key for kilovolts calibration, Down Arrow key (∨) for milliamps.
1.1.
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.
40
CALIBRATION
Then press the SET key on the front panel. The instrument will provide around
5000VAC on the output connectors and the display will show:
Voltage=
XXXX V
Please use the Up/Down Arrow keys to enter the reading off the AC Voltmeter,
into the instrument. Then press the SET key to store the voltage setting. Press the
EXIT or RESET key to return to the calibration menu without changing the
calibration setting.
The instrument will output two short “beeps” when attempting to save a missing
or bad parameter and will not allow return to the calibration menu.
1.2.
Calibration of Dielectric Withstand Current
Equipment needed: STANDARD AC MILLIAMMETER with a range of 100mA
and a fixed Resistor 10K Ohms, 100 watts.
Please connect a 10KΩ resistor in series with the standard ac milliammeter and
connect these across the output leads of the instrument. Press the Down Arrow
key. The instrument will provide around 1000VAC on the output and the display
will show:
Current= X.XX mA
Please use the Up/Down Arrow keys to enter the reading of the standard AC
milliammeter, into the instrument. Then press the SET key to store the current
setting. Press the EXIT or RESET key to return to the calibration menu without
changing the calibration setting.
The instrument will output two short “beeps” when attempting to save a missing
or bad parameter and will not allow return to the calibration menu.
1.3.
Save Calibration
After the calibration, the instrument has to be turned off to save the calibration
parameters. The power must be turned off and on again to switch from the
calibration mode to the run mode.
41
PARTS LIST
Replacement Parts List HYPOT II
Model 4500
ECO 4834 REV B
Part Number
Qty.
38111
37593
38135
38110
38112
38113
37571
35999
37478
38101
38102
37800
37801
37999
37554
38109
37806
37807
38075
38108
38107
38071
04040A-08
02100A-13
37697
38009
37605
1
1
1
1
1
1
1
4
2
1
4
2
2
1
1
1
1
1
1
1
1
1
1
2
1
1
2
42
Reference
Designator
CHV-4500
CKB-02
CSW-05
4500
AMP-510
REC-19
T-4500-T2
T-4500-T1
U9
U10
FAIL,READY
Description
High Voltage Control Board
Key Board Assembly
Input Protection Board
Main Control Board
Power Amplifier Board
Rectifier Board
Earth Connector
Black Banana Jacks
High Voltage Connector
Feet Kit w/o Rubber Inserts
Rubber Insert for Feet
3U Rack Mount Bracket
3U Rack Mount Handle
Fuse 15A, 250V, Fast Blow, 20 mm
LCD Display 16 x 2 Characters
Power Switch 2P 10A/250V
Test Switch, Green
Reset Switch, Red
Interlock Connector Std. M/F
Output High Voltage Transformer
Input Transformer
Input Power Cable 15A/6Ft.
High Voltage Output cable
Return cable
Microcontroller 8 Bit P89C52
IC W27E257 EEPROM
Bulbs
SCHEMATICS
SCHEMATIC INDEX
Drawing Number
Description
Pages
S04500D
Wiring Diagram
1
4500
Main Control Board
5
AMP-510
Power Amplifier Board
1
REC-19
Rectifier Board
1
CHV-4500
HV Control Board AC/DC
1
CKB-02
Keypad Board
1
CSW-05
Input Protection Board
1
43
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