Model 2630 and 2660

OPERATION AND SERVICE MANUAL

Model 2630 and 2660

MODEL 2630 GROUND BOND TESTER

MODEL 2660 GROUND BOND TESTER

SERIAL NUMBER

Model

2630, 2660

Item 99-10125-01 Ver 2.11

© Slaughter Company, Inc., 2011

28105 N. Keith Drive

Lake Forest, Illinois, 60045-4546

U.S.A.

Printed December 13, 2011

Manufacturer:

Address:

DECLARATION OF CONFORMITY

Slaughter Company, Inc.

28105 N. Keith Drive

Lake Forest, IL 60045

USA

Ground Bond Tester

2630

Product Name:

Model Number:

Conforms to the following Standards:

Safety:

EN 61010-1: 1993 + A2

EMC:

EN 55022:1998 Class A

Supplementary Information

The product herewith complies with the requirements of the Low

Voltage Directive 73/23/EEC as amended by 93/68/EEC and the EMC

Directive 89/336/EEC as amended by 92/31/EEC.

The CE marking has been affixed on the device according to article 10 of the EMC Directive 8/336/EEC.

The technical file and other documentation are on file with

Associated Research, Inc.

______________________________

Joseph Guerriero

Vice President / General Manager


Lake Forest, Illinois USA

October 22, 2002

DECLARATION OF CONFORMITY

Manufacturer:

Address:

Associated Research, Inc.

13860 W. Laurel Dr.

Lake Forest, IL 60045

USA

Product Name:

Model Number:

2660 Ground Bond Tester

2660

Conforms to the following Standards:

Safety:

EN61010-1:2001

EMC:

EN 50022-1:1998/A1:2000 Class A and

EN61326:1997+A1:1998 (EN61000-4-2:1995, EN61000-

4-3:1996, EN61000-4-4:1995, EN61000-4-5:1995,

EN61000-4-6:1996, EN61000-4-8:1993, EN61000-4-

11:1994)

Supplementary Information

The product herewith complies with the requirements of the Low

Voltage Directive 73/23/EEC as amended by 93/68/EEC and the EMC

Directive 89/336/EEC as amended by 92/31/EEC.

The CE marking has been affixed on the device according to article 10 of the EMC Directive 8/336/EEC.

The technical file and other documentation are on file with

Associated Research, Inc.

______________________________

Joseph Guerriero

Vice President / General Manager


Lake Forest, Illinois USA

July 4, 2003

Warranty Policy

Slaughter Company, 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. You must return the “Owners Registration

Card” provided within (15) days from receipt of your instrument.

Slaughter Company recommends that your instrument be calibrated on a twelve-month cycle. A return material authorization (RMA) must be obtained from Slaughter Company.

Please contact our Customer Support Center at 1-800-504-0055 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. Slaughter Company will assume the return freight costs when returning the instrument to the customer. The return method will be at the discretion of Slaughter Company.

Except as provided herein, Slaughter Company 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 bypassing any safety systems will void this warranty. This warranty does not cover batteries or accessories not of Slaughter Company manufacture. Parts used must be parts that are recommended by

Slaughter Company as an acceptable specified part. Use of non-authorized parts in the repair of this instrument will void the warranty.

TABLE OF CONTENTS

SECTION I OPERATORS MANUAL ......................................................................... 1

SAFETY ......................................................................................................................... 2

INTRODUCTION ......................................................................................................... 5

SPECIFICATIONS ....................................................................................................... 8

CONTROLS ................................................................................................................ 14

INSTALLATION ........................................................................................................ 20

QUICK START ........................................................................................................... 23

OPERATION............................................................................................................... 30

OPTIONS .................................................................................................................... 45

SECTION II SERVICE MANUAL ............................................................................ 48

CALIBRATION .......................................................................................................... 49

PARTS LIST ............................................................................................................... 51

PARTS LIST ............................................................................................................... 52

SCHEMATICS ............................................................................................................ 53

SECTION 1

OPERATORS MANUAL

SAFETY

SAFETY PRECAUTIONS

GENERAL:

This product and its related documentation must be reviewed for familiarization with safety markings and instructions before operation.

This product is a Safety Class I instrument (provided with a protective earth terminal).

Before applying power verify that the instrument is set to the correct line voltage (115 or

230) and the correct fuse is installed.

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

CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR

CONDITION, THAT COULD POSSIBLY CAUSE BODILY

INJURY OR DEATH.

2

CAUTION

CALLS ATTENTION TO A PROCEDURE, PRACTICE, OR

CONDITION THAT COULD POSSIBLY CAUSE DAMAGE TO

EQUIPMENT OR PERMANENT LOSS OF DATA.

SAFETY

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. Any external cleaning should be done with a clean dry or slightly damp cloth.

Avoid the use of cleaning agents or chemicals to prevent any foreign liquid from entering the cabinet through ventilation holes or damaging controls and switches, also some chemicals may damage plastic parts or lettering. Schematics, when provided, are for reference only. Any replacement cables and high voltage components should be acquired directly from Slaughter Company, Inc. Refer servicing to a Slaughter Company, Inc.

authorized service center.

SLAUGHTER COMPANY, INC.

28105 N. KEITH DRIVE

LAKE FOREST, IL 60045-4546 U.S.A

.

(PHONE: 1 (847) 932-3662

1 (800) 504-0055

FAX: 1 (847) 932-3665

E-MAIL : [email protected]

www.hipot.com

Service Interval

The instrument and its power cord, test leads, and accessories must be returned at least once a year to a Slaughter Company authorized service center for calibration and inspection of safety related components. Slaughter Company 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. Slaughter Company will not be responsible for any injuries sustained due to unauthorized equipment modifications or use of parts not specified by Slaughter Company. Instruments returned to Slaughter Company 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 TESTING. No employees other than the test operators should be allowed inside.

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 - TEST IN PROGRESS -

UNAUTHORIZED PERSONNEL KEEP AWAY."

3

SAFETY

Power

Ground Bond Test Equipment must be connected to a good ground. Be certain that the power wiring to the test bench is properly polarized and that the proper low resistance bonding to ground is in place.

Power to the test station should be arranged so that it can be shut off by one prominently marked switch located at the entrance to the test area. 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, made of a non-conducting material such as clear acrylic. The item being tested is then within the guards or enclosure during the test, and may be fitted with switches so that the tester will not 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 what product is being tested, and which products are waiting to be tested or have already been tested.

Do not perform Ground Bond Tests in a combustible atmosphere or in any area where combustible materials are present.

TEST OPERATOR

Qualifications

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 the Ground

Bond 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 that could accidentally complete a circuit.

Medical Restrictions

Personnel with heart ailments or devices such as pacemakers should not operate this instrument.

4

INTRODUCTION

GLOSSARY OF TERMS

(As used in this manual)

Alternating Current, AC:

Current that reverses direction on a regular basis, commonly in the

U.S.A. 60 times per second, in other countries 50 times per second.

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 that 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 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.

Hipot Tester:

Common term for 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.

Resistance:

That property of a substance that 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 resistance required causing an indication of unacceptable performance during a ground bond test.

Voltage:

Electrical pressure, the force which causes current through an electrical conductor.

Symbol = V

5

6

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 voltage-withstand 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 devise 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 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.

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.

Why Perform a Ground Bond Test.....

Ground bond testing is done to insure that a low resistance path exists between the safety ground pin of a three-wire line cord and exposed metal of the item under test. If a live wire inside the item under test came loose and contacted the chassis, the fault current would flow through the low resistance safety ground, and protect the user.

The need for high current bonding (i.e. 30A or 60A) as apposed to low current go-no go type testers, results from the nature of line voltage breakers’ high current characteristics.

to maintain safe voltage potentials on the chassis of the faulty device. Verifying the integrity of the grounding circuit at high currents insures that the line breaker will open before the grounding circuit wires fail. This insures that the power will be de-energized at the device while maintaining safe voltage levels on the chassis.

IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION

OF YOUR INSTRUMENT CALL 1 (800) 504-0055 IN THE U.S.A.

7

8

SPECIFICATIONS

Model 2630 Functional Specifications

GROUND BOND TEST MODE

Unless otherwise stated, accuracies are relative to a laboratory standard measurement.

INPUT

Input voltage

Frequency

Fuse

115 / 230V

±

10

%

, user selectable

50/60 Hz

±

5

%

6.3A slow blow 250VAC

TEST MODE

Output Rating

Output Frequency

Dwell Time Setting

High Limit Setting*

Offset Capability

Current:

Resolution:

Regulation

Voltage:

3.0 – 30.0 Amps AC

0.1Amp

±

(2

%

of setting

+

0.02 Amps)

6 Volts AC, fixed

50 / 60 Hz user selectable

Range:

Resolution:

Accuracy:

Range:

Current:

Resolution:

Accuracy:

Range:

Resolution:

Accuracy:

Range:

0 and 0.5 – 999.9 seconds,

0 for continuous running

0.1 second

±

(0.1

%

of setting

+

0.05 seconds)

0 – 510 m

Ω

0 – 510 m

Ω

for 0.0 – 10.0 Amps

0 – 200 m

Ω

for 10.1 – 25.0 Amps

0 – 150 m

Ω

for 25.1 – 30.0 Amps

1 m

Ω

+(2

%

of setting

+

2m

Ω

)

0 – 100 m

Ω

1 m

Ω

±

(2

%

of setting

+

2 m

Ω

)

0.0 – 30.0 Amps Current Display

Ohmmeter Display

Timer Display

Resolution:

Accuracy:

Range:

Resolution:

Accuracy:

Range:

0.1 Amp

±

(3

%

of reading

+

0.03 Amps)

0 – 510 m

Ω

1 m

Ω

±

(2

%

of reading

+

2 m

Ω

)

0.0 – 999.9 seconds

Resolution:

Accuracy:

0.1 seconds

±

(0.1

%

of reading

+

0.05 seconds)

*Even though it is possible to set the High Limit trip point to the maximum of 510 m

Ω

for all current settings, the usable resistance range will be reduced according to the test current that has been selected due to the limits on the output voltage.

SPECIFICATIONS

GENERAL

Remote Control And Signal

Output

Program Memory

Security

Line Cord

Terminations

Mechanical

Environmental

Calibration

The following input and output signals are provided through two 9 pin D type connectors;

1. Remote control: Test, Reset, and Withstand

Processing.

2. Outputs: Pass, Fail, Test-in-Process, Start Out, and

Reset Out.

5 sets

Key Lock capability to avoid unauthorized access to all test parameters. Memory Lock capability to avoid unauthorized access to memory locations.

Detachable 6 ft. (1.80m) power cable terminated in a three prong grounding plug.

5ft. (1.52m) high current and return leads with clips.

Tilt up front feet.

Dimensions: (w x h x d) 11 x 3.5 x 14.56 in. (280 x 89 x

370mm)

Weight: 20 lbs. (9 kg)

Operating Temperature: 32

°

- 104

°

F (0

°

- 40

°

C)

Relative Humidity - 20 to 80%

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.

9

SPECIFICATIONS

Model 2660 Functional Specifications

GROUND BOND TEST MODE

Unless otherwise stated, accuracies are relative to a laboratory standard measurement.

INPUT

Input voltage

Frequency

Fuse

115 / 230V

±

10

%

, user selectable

50/60 Hz

±

5

%

15A slow blow 250VAC

TEST MODE

Output Rating

Output Frequency

Dwell Time Setting

High Limit Setting*

Offset Capability

Current:

Resolution:

Regulation

Voltage:

3.0 – 60.0 Amps AC

0.1 Amp

±

(2

%

of setting

+

0.02 Amps)

12 Volts AC, fixed

50 / 60 Hz user selectable

Range:

Resolution:

Accuracy:

Range:

Current:

Resolution:

Accuracy:

Range:

Resolution:

Accuracy:

Range:

0 and 0.5 – 999.9 seconds,

0 for continuous running

0.1 second

±

(0.1

%

of setting

+

0.05 seconds)

0 – 600 m

Ω

0 – 600 m

Ω

for 0.0 – 15.0 Amps

0 – 300 m

Ω

for 15.1 – 30.0 Amps

0 – 150 m

Ω

for 30.1 – 60.0 Amps

1 m

Ω

+(2

%

of setting

+

2m

Ω

)

0 – 100 m

Ω

1 m

Ω

±

(2

%

of setting

+

2 m

Ω

)

0.0 – 60.0 Amps Current Display

Ohmmeter Display

Resolution:

Accuracy:

Range:

Resolution:

Accuracy:

Accuracy:

0.1 Amp

±

(3

%

of reading

+

0.03 Amps)

0 – 600 m

Ω

1 m

Ω

±

(3

%

of reading

+

3 m

Ω

) for 3 – 5.9 Amps

±

(2

%

of reading

+

2 m

Ω

) for 6 – 60 Amps

0.0 – 999.9 seconds Timer Display Range:

Resolution:

Accuracy:

0.1 seconds

±

(0.1

%

of reading

+

0.05 seconds)

*Even though it is possible to set the High Limit trip point to the maximum of 600 m

Ω

for all current settings, the usable resistance range will be reduced according to the test current that has been selected due to the limits on the output voltage.

10

SPECIFICATIONS

GENERAL

Remote Control And Signal

Output

Program Memory

Security

Line Cord

Terminations

Mechanical

Environmental

Calibration

The following input and output signals are provided through two 9 pin D type connectors;

3. Remote control: Test, Reset, and Withstand

Processing.

4. Outputs: Pass, Fail, Test-in-Process, Start Out, and

Reset Out.

5 sets

Key Lock capability to avoid unauthorized access to all test parameters. Memory Lock capability to avoid unauthorized access to memory locations.

Detachable 6 ft. (1.80m) power cable terminated in a three prong grounding plug.

5ft. (1.52m) high current and return leads with clips.

Tilt up front feet.

Dimensions: (w x h x d) 16.875 x 5.25 x 15.625 in. (430 x

130 x 400mm)

Weight: 44.1 lbs. (20 kg)

Operating Temperature: 32

°

- 104

°

F (0

°

- 40

°

C)

Relative Humidity - 20 to 80%

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.

11

SPECIFICATIONS

KEY FEATURES & BENEFITS OF 2630 and 2660

1. All parameters for the setups can be adjusted through a simple menu driven program by using front panel keys.

The easy to follow setup screens ensure that the operator correctly sets up all test parameters.

2. Tamper proof front panel controls.

This makes it possible to limit user access to the setup screens.

3. Milliohm offset capability.

The milliohm offset function allows the use of longer test leads and test fixtures without compromising the test results.

4. Storage of up to 5 different test programs.

A real benefit for manufacturers that test different products. This makes it possible to store all the various test parameters required and quickly recall them for each of the different products that needs to be tested.

5. Versatile PLC control.

Interconnection of the 2630 or 2660 to one of the 2900 family of Hipots makes a true semi-automated test system. The test system can be configured to test Ground Bond first and then advance to the Dielectric Withstand test and Insulation Resistance tests.

6. 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.

7. User selectable output voltage frequencies of 50 or 60 hertz.

2630 and 2660 were designed for the global market. This feature makes it simple for the user to select the output frequency in the Ground Bond mode so that products can be tested at the same frequency they will be used.

8. Adjustable output current and milliohm trip ranges.

This capability makes the 2630 and 2660 versatile enough to meet all safety agency specifications for ground bond test requirements.

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.

10. PLC remote inputs and outputs.

The standard 9 pin interfaces provide outputs for Pass, Fail, and Test in Process,

Start Out and Reset Out. Inputs include Test, Reset, and Withstand Processing.

12

SPECIFICATIONS

11. Test indicator.

An LED located directly over the high current terminal clearly indicates when high current is active to provide maximum operator safety.

12. Withstand processing indicator.

The front panel display indicates when the high voltage from a hipot is being applied to the item under test for greater operator safety.

13. Software calibration control.

2630 and 2660 are calibrated through the front panel keypad. All calibration information is stored in non-volatile memory. This allows 2630 and 2660 to be completely calibrated without removing any covers and exposing the technician to hazardous voltages.

13

2630 FRONT PANEL CONTROLS

1 2

INSTALLATION

3

4 5 6 7

8

9 10 11

1.

LCD DISPLAY: The Liquid Crystal Display is the main readout for the operator and programmer of the test settings and test results.

2.

RESET SWITCH: This is a momentary contact switch. To reset the system for the next test, press and release the red Reset switch (1). This switch may also be used to abort a Test in Progress.

3.

TEST SWITCH: This is a momentary contact switch. Press the green switch to turn on the high current output when in the test mode.

4.

POWER SWITCH: Rocker-style switch with international ON (l) and OFF (0) markings.

5.

SET KEY: Use this key to advance forward through the setup menus.

6.

DOWN ARROW (

∨

):

Use this key to decrement numeric values in the setup mode.

This key may also be used to toggle ON/OFF functions.

7.

UP ARROW (

∧

)

: Use this key to increment numeric values in the setup mode. This key may also be used to toggle ON/OFF functions.

8.

EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test.

This key may also be used to save settings into memory.

9.

TEST LED INDICATOR: This red LED lights to indicate to the operator that a test is in process.

14

INSTALLATION


1 2 3

4 5

6

7

8

9 10 11

10. CURRENT OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) red high current test lead or adapter box. This jack is always used when performing a

Ground Bond test. Please refer section F. Adapter Box connection for details on connecting the adapter box between the instrument and the device under test.

11. RETURN OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) black return test lead. This jack is always used when performing a test.

15

1

2630 REAR PANEL CONTROLS

2 3 4 5

INSTALLATION

6 7 8 9

1. THERMAL FAN: Runs continuously to cool the instrument.

2. INTERCONNECT JACK: For the connection of the return lead from the hipot tester used when performing both Hipot and Ground Bond tests on the same test item.

3. INPUT POWER SWITCH: Line voltage selection is set by the position of the switch. In the left position it is set for 115-volt operation, in the right position it is set for 230-volt operation.

4. CHASSIS GROUND (EARTH) TERMINAL: This safety terminal should be connected to a good earth ground before operation.

5. FUSE RECEPTACLE: To change the fuse unplug the power (mains) cord and unscrew the fuse cap counter clockwise to remove the fuse.

6. REMOTE OUTPUT: 9 pin D subminiature female connector for monitoring PASS,

FAIL, and PROCESSING output relay signals, as well as remote START and RESET outputs.

7. CALIBRATION ENABLE: This recessed switch when depressed allows access to the calibration control program.

8. REMOTE INPUT: 9 pin D subminiature male connector for remote control of test and reset functions as well as withstand processing input.

9. INPUT POWER RECEPTACLE: Standard IEC 320 connector for connection to a standard NEMA style line power (mains) cord.

16


1 2

INSTALLATION

3

4 5 6 7 8 9

10

11

1.

DISPLAY: The Liquid Crystal Display is the main readout for the operator and programmer of the test settings and test results.

2.

RESET SWITCH: This is a momentary contact switch. To reset the system for the next test, press and release the red Reset switch (1). This switch may also be used to abort a Test in Progress.

3.

TEST SWITCH: This is a momentary contact switch. Press the green switch to turn on the high current output when in the test mode.

4.

POWER SWITCH: Rocker-style switch with international ON (l) and OFF (0) markings.

5.

SET KEY: Use this key to advance forward through the setup menus.

6.

DOWN ARROW (

∨

):

Use this key to decrement numeric values in the setup mode.

This key may also be used to toggle ON/OFF functions.

7.

UP ARROW (

∧

)

: Use this key to increment numeric values in the setup mode. This key may also be used to toggle ON/OFF functions.

8.

EXIT KEY: Use this key when you desire to enter the Run Mode to initiate a test.

This key may also be used to save settings into memory.

17


1 2

INSTALLATION

3

4 5 6 7 8 9 10 11

9.

CURRENT OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) red high current test lead or adapter box. This jack is always used when performing a

Ground Bond test.

10. TEST LED INDICATOR: This red LED lights to indicate to the operator that a test is in process.

11. RETURN OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) black return test lead. This connector may also be used to interconnect a Hipot to this instrument. This jack is always used when performing a test.

18

INSTALLATION

2660 REAR PANEL CONTROLS

1 2 3 4

5

1. THERMAL FAN: Thermally switched fans provide cooling when needed.

6 7

2. REMOTE OUTPUT: 9 pin D subminiature female connector for monitoring PASS,

FAIL, and PROCESSING output relay signals, as well as remote START and RESET outputs.

3. CALIBRATION ENABLE: This recessed switch when depressed allows access to the calibration control program.

4. REMOTE INPUT: 9 pin D subminiature male connector for remote control of test and reset functions as well as withstand processing input.

5. INPUT POWER RECEPTACLE: Standard IEC 320 connector for connection to a standard NEMA style line power (mains) cord.

6. INPUT POWER SWITCH: Line voltage selection is set by the position of the switch. In the left position it is set for 115-volt operation, in the right position it is set for 230-volt operation.

7. CHASSIS GROUND (EARTH) TERMINAL: This safety terminal should be connected to a good earth ground before operation.

19

INSTALLATION

INSTALLATION

Introduction

This section contains information for the unpacking, inspection, preparation for use and storage of your Slaughter Company, 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

Slaughter Company customer support department immediately. Please save the shipping 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 RGA (return goods authorization) number.

Preparation for Use

Power Requirements and Line Voltage Selection

This instrument requires a power source either 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

2630: For operation at 115 Volts AC and 230 Volts AC, use a 6.3A 250VAC slow blow fuse.

2660: For operation at 115 Volts AC and 230 Volts AC, use a 15A 250VAC slow blow fuse.

20

INSTALLATION

Power Cable

WARNING

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).

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 instrument depends on the country of destination.

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 connect to the black Return jack.

The test lead ratings are as follows:

Description

2630 Test Leads

Part Number

Return lead 99-10008-01

Current 99-10009-01

Rating

30 A, 600V

30 A, 600V

Description

Return lead

2660 Test Leads

Part Number

99-10238-01

Current 99-10239-01

Rating

60 A, 600V

60 A, 600V

Operating Environment

This equipment is intended for indoor use only. The equipment has been evaluated according to Installation Category II and Pollution Degree 2 as specified in IEC 664.

This instrument may be operated within the following environmental conditions:

Temperature… … … … .32° - 104° F (0° - 40° C)

Relative humidity … … .0 - 80%

Altitude … … … … … … 6,560 feet (2,000 meters)

Ventilation: When choosing a bench location, or in rack mount applications, insure that there is at least 6 inches (15 cm) of space from the rear panel to any wall or obstruction behind the unit.

21

INSTALLATION

STORAGE AND SHIPMENT

Environment

This instrument may be stored or shipped in environments with the following limits:

Temperature.................-40° - 167° F (-40° - 75°C)

Altitude............................ 50,000 feet (15,240 meters)

The instrument should also be protected against temperature extremes, which may cause condensation within the instrument.

Packaging

Original Packaging: Please retain all original packaging materials if you do not have an alternate method of repackaging. If you are returning your instrument to us for servicing please repackage the instrument in its original container or use an alternate packaging solution. Please do not reuse the original packing material if there appears to be damage or missing packing material. Contact our customer support department (1-800-504-0055) for an RMA (return materials 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.

Please refer to the RMA number for all correspondence.

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.

3). 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.

4). Seal the container securely.

5). Mark the container "FRAGILE" to insure proper handling.

6). Please ship model 2630 or 2660 via Federal Express or UPS air.

7). Please reference in all your correspondence your RMA number.

Field Installation of Options

There are no field installable options on the model 2630 or 2660.

22

QUICK START

QUICK START

This quick start guide assumes the operator has some familiarity with automated Ground Bond testing and desires to use the default settings on the instrument. The default settings shown will remain in memory unless you choose to override them with your own test program. The instrument default settings are as follows:

DEFAULTS

•

Memory Position:

•

Input Voltage:

•

Current Output:

•

Resistance Trip (High):

•

Dwell Timer:

•

Frequency:

•

Offset:

•

Lock:

1

115 volts AC (rear panel switch selectable)

25.00 Amps

100m

Ω

1 second

60Hz

20m

Ω for 2630, 4m

Ω

for 2660

Key Unlock a). 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.

WARNING

b). 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.

CAUTION

c). Check to be sure that the correct input line voltage has been selected on the rear panel, either 115 volts AC or 230 volts AC. Connect the power-input plug into its socket on the rear panel of the instrument. Connect the male end of the plug to the outlet receptacle.

23

QUICK START

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.

d). 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, name and Model Number briefly appear on the LCD readout and then clear itself.

SLAUGHTER

2630 VERXX or SLAUGHTER

2660 VERXX

You should then see the default parameters on the LCD meter as follows:

Set M1 1.0s

25.00A 100m

Ω

These abbreviated parameters stand for the following:

Set:

M1:

This is the parameter settings review screen.

The instrument is using the default set ups contained in memory 1.

1.0s:

25.00A:

100m

Ω

:

The dwell timer is set to test duration of 1 second.

The test current is set to 25.00 Amps.

The high resistance trip point is set to 100 milliohms.

If you wish to not use any one of these parameters, you must overwrite the memory 1 position or change your parameters and save them in a different memory such as memory position 2.

e). If the instrument defaults are acceptable then be sure to connect the appropriate test leads to the device under test (DUT) or test fixture. Be sure to connect this safety ground to a suitable known good ground before energizing this instrument, and then connect the

Return lead first (black) to the test fixture or item followed by the High Current output lead (red).

WARNING

f). Please 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. 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. 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 CURRENT.

24

QUICK START

When HIGH CURRENT is present, a green TEST indicator located to the left of the

CURRENT receptacle will light until the HIGH CURRENT is shut OFF. If the device under test PASSED, then a single beep will sound. In the case of a FAIL condition, the

RESET SWITCH will illuminate and the LCD will display a failure

TEST condition along with an audible alarm. 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.

Quick Guide to Interconnecting 2630 to the 2900 Family of Hipots

Using the optional Interface Cable Kit part number 99-10006-01.

The following illustrations should be used to configure the 2630 for integrated operation with a 2925, 2935 or 2945 series Hipot:

HV

OPTIONAL ADAPTER BOX 99-10005-01

FRONT PANEL 29XX REAR PANEL 29XX

LINECORD

DUT

I.E. AC FAN

DUT

CHASSIS

99-10003-01(SEQ) or

99-10004-01(SIM)

99-10007-01

(INTERCONNECT)

RED MARKER

BLUE MARKER

FRONT PANEL 2630

CURRENT

REAR PANEL 2630

99-10007-01

RETURN

Cable number

99-10003-01

Method

Sequential

Operation

2630 first then 2925,2935,2945

99-10004-01 Simultaneous 2630 and 2925,2935,2945 at the same time.

For a more detailed description on interconnecting your system, see page 36.

25

QUICK START


HV



LINECORD

DUT

I.E. AC FAN

DUT

CHASSIS

99-10007-01

(INTERCONNECT)

RED MARKER

BLUE MARKER

99-10608-01(SEQ) or

99-10609-01(SIM)


REAR PANEL 2630

CURRENT 99-10007-01

RETURN

Cable number

99-10608-01

Method

Sequential

Operation

2630 first then 2955,2965,2975

99-10609-01 Simultaneous 2630 and 2955,2965,2975 at the same time.

For a more detailed description on interconnecting your system, see page 36.

26

QUICK START

Quick Guide to Interconnecting 2660 to the 2900 Family of Hipots

Using the optional Interface Cable Kit part number 99-10006-01.


Front Panel Connections

LINE

102-055-913

HV

99-10007-01

(INTERCONNECT)

NEUTRAL

GND

99-10239-01

CURRENT

99-10238-01

RETURN

DUT

I.E. AC FAN

DUT

CHASSIS

Rear Panel Connections

RED MARKER

BLUE MARKER

99-10003-01(SEQ) or

99-10004-01(SIM)

Cable number

99-10003-01

99-10004-01

Method

Sequential

Operation

2630 first then 2925, 2935,2945

Simultaneous 2630 and 2925, 2935,2945 at the same time.

The optional adapter box 99-10005-01 is not designed to be used with 2660.

27

QUICK START



DUT

I.E. AC FAN

LINE

102-055-913

HV

99-10007-01

(INTERCONNECT)

NEUTRAL

GND

99-10239-01

CURRENT

99-10238-01

RETURN

DUT

CHASSIS


RED MARKER

BLUE MARKER

99-10608-01(SEQ) or

99-10609-01(SIM)

Cable number

99-10608-01

99-10609-01

Method

Sequential

Operation

2630 first then 2955, 2965,2975

Simultaneous 2630 and 2955, 2965,2975 at the same time.


28

QUICK START

NOTE: When interconnecting 2630/2660 to one of the 2900 family Hipots, 2630/2660 will automatically sense when high voltage is active. The display on the 2630/2660 will change to show a “W-On” indicating that the Dielectric Withstand test is processing. An example of this display is shown below. The initialization of the AC or DC Dielectric

Withstand test will now be controlled by the 2630/2660 through the interconnect cables.

Set M1 1.0s

25.00A W-On 0m

Ω

29

OPERATION

OPERATION INSTRUCTIONS FOR 2630 and 2660

A. POWER UP:

Check to be sure that the correct input line voltage has been selected on the rear panel, either 115 volts AC or 230 volts AC. Connect the power-input plug into its socket on the rear panel of the instrument. 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.

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, led indicators, PCBs and other critical components. In addition, the display will show the following message.

SLAUGHTER

2630 VERXX or SLAUGHTER

2660 VERXX

The instrument will recall the last memory program that was active and the display will show the parameters that were programmed into that memory. The instrument is now ready for operation.

B. SETUP PROCEDURE:

1. Output Current Setting

Please press the SET key, the display will show:

CURRENT = XX.XA

Please use the Up (

∧

) or Down (

∨

) arrow keys to adjust the Current setting, then press the

EXIT key to store the current setting and return to the Run mode, or press the SET key to advance to the next parameter. The maximum current which may be entered is 30.0 Amps for 2630 and 60.0Amps for 2660. Any value above this will produce an ERROR message.

2. High Limit Setting

Please press the SET key until arriving at the HI-LMT setting. The display will show:

HI-LMT = XXX m

Ω

Please use the Up (

∧

) or Down (

∨

) arrow keys to adjust the value of the High Limit resistance trip point then press the EXIT key to store the setting and return to the Run mode, or press the SET key to advance to the next parameter. The unit of measure is in milliohms with a range from 0-510m

Ω for 2630 and 0-600m

Ω

for 2660 .

3. Dwell Time Setting

30

OPERATION

Please press the SET key until arriving at the Timer setting. The display will show:

T i m e r = XXX . X s

Use the Up (

∧

) or Down (

∨

) arrow keys to adjust the Timer setting, then press the EXIT key to store the Timer setting and return to the Run mode, or press the SET key to advance to the next parameter. The range is 0 to 999.9 seconds, if the Timer 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.

4. Frequency Setting

Please press the SET key until arriving at the Frequency setting. The display will show:

Freq = 50 HZ or Freq = 60 HZ

Use the Up (

∧

) or Down (

∨

) arrow keys to change the Frequency setting to 50Hz or

60Hz, then press the EXIT key to store the frequency setting and return to the Run mode, or press the SET key to advance to the next parameter.

5. Offset Setting

Please press the SET key until arriving at the Offset setting. The display will show:

Offset = XXX m

Ω

TEST to Auto Set

Please use the Up (

∧

) or Down (

∨

) arrow keys to adjust the setting of the offset manually, then press the EXIT key to store the setting and return to the Run mode, or press the SET key to advance to the next parameter. To automatically set the Offset, press the TEST button when the test leads or test fixture is connected across the 2630/2660 outputs. The

2630/2660 will measure the resistance that is present and enter this value into the Offset setting. This offset will be automatically subtracted from the actual resistance reading before the reading is displayed. The unit of measure is in milliohms with a range from 0-

100m

Ω

.

31

OPERATION

6. Memory Storage and Recall

2630 and 2660 are equipped with 5 memory programs numbered 1 through 5. This makes it possible to store all the various test parameters required, and quickly recall them for each of the different products that need to be tested.

(A). Storage of a Memory Program

Please press the SET key until the display shows

M e m o r y

=

X

Use the Up (

∧

) or 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. Once you have entered all the test parameters such as Current, Hi-Limit Trip Resistance, Dwell Time, etc., as outlined in the above procedures, press the Exit key to store any changes to the settings. The parameters are automatically updated into the memory location that was selected, when exiting to the test mode.

S e t MX XXX . X s

XX . XA XXX m

Ω

(B). Recall of a Memory Program

Please press the SET key until the Memory Program is displayed then press the Up (

∧

) or

Down (

∨

) arrow keys until the specific memory you wish to recall is displayed. Pressing the EXIT key will activate this memory position. To start a test, press the TEST button.

7. To Set Key Lock or Memory Lock

The 2630 and 2660 are 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. Within this selection, you can lockout all front panel control functions except TEST, RESET and memory select.

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 Lock = ON or

Key Lock = OFF

To toggle the Key Lock function on and off use the up or down arrow keys, then press exit to select, or press the set key again to reach the Memory Lock screens.

32

OPERATION

The memory lock screens appear as follows:

Memory Lock = ON or

Memory Lock = OFF

To toggle the Memory Lock function on and off use the up or down arrow keys, then press exit to select, or press the set key again to reach the Key Lock screens.

Use the following chart to set the Key Lock and Memory Lock for your application.

Key Lock Memory Lock Accessible keys

Off Off All

Off

On

On

On

Off

On

All

TEST, RESET, and up-down arrows for memory selection

TEST and RESET

C. OPERATING PROCEDURES:

1. If the 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 current lead.

Check your connections to be sure they are making good contact and that the test station or area is clear of debris or other personnel.

DO NOT TOUCH THE DEVICE UNDER TEST ONCE THE TEST HAS BEEN

STARTED.

WARNING

2. Please follow the setup procedures to set or recall setups from memory programs. The display will show the number of the Memory Program and the value of Dwell time, Test Current and High Limit resistance trip point as follows:

S e t M __ XXX. Xs

XX . XA XXX m Ω

or

S e t MX XXX . X s

XX . XA XXX m Ω

If the set data is to be stored in the memory program, please follow the procedure outlined in the setup procedures on Storage of Memory Program.

3. To initiate a test press the TEST switch on the front panel.

The instrument will output the set current for the length of time set on the dwell timer.

The display will show:

D w e l l MX XXX . X s

X X.XX A XXX m Ω

33

OPERATION

4. If the resistance exceeds the high limit trip setting but does not exceed the metering range, the red RESET switch will illuminate and the alarm will be activated.


HI - LMT MX XXX . X s

XX . XA XXX m Ω

If the resistance exceeds the high limit trip setting and exceeds the metering range, the red

RESET switch will illuminate and the alarm will sound. The display will show:

HI - LMT MX XXX . X s

XX . XA OFL m

Ω

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.

5. If the test leads are left open or the resistance is so large that the test current generates more that the maximum limit of 6VAC for 2630 or 12VAC for 2660, then the red RESET switch will illuminate and the alarm will sound. The display will show:

2630 2660

V-OVLD MX XXX . X s

XX . XA >6VAC or

V-OVLD MX XXX . X s

XX . XA >12VAC

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.

6. If the DUT passed all of the tests, the LCD will indicate a pass condition and the instrument will output a short audible beep tone to indicate the DUT has passed the tests.

The instrument is now ready to perform another test.


Pass MX XXX . X s

XX . XA XXX m Ω

7. 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.


Abort MX XXX . X s

XX . XA XXX m Ω

34

OPERATION

Please press the TEST switch to initiate another test.

D. CONNECTION OF REMOTE I/O:

Two 9-pin D type connectors are mounted on the rear panel that provide REMOTE-

INPUT-OUTPUT control and information. These connectors mate with standard 9 pin D subminiature connector provided by the user. The output mates to a male (plug) connector while the input mates to a female (receptacle) connector. 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

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, and it also provides a RESET OUT pulse signal and a

START OUT pulse signal. The monitoring signals are provided by three normally open internal relays that switch on to indicate the current condition of the tester. The RESET

OUT signal and the START OUT pulse signal are also provided by a normally open internal relay. The RESET OUT gives a signal whenever the reset function is activated.

This can be used to abort a Dielectric Withstand test while the units are interfaced as a test system. The START OUT gives a momentary output pulse at the end of the Ground

Bond test that can be used to start the Hipot test. These are normally open free contacts

35

OPERATION 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.

Pins 1 and 2 provide the PASS signal.

Pins 3 and 4 provide the FAIL signal.

Pins 5 and 6 provide the PROCESSING signal.

Pins 7 and 8 provide the RESET OUT signal.

Pins 7 and 9 provide the START OUT pulse 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 is activated.

RESET OUT - The relay contact closes the connection between pin (7) and pin (8) while the reset function is activated. This is only a continuous closure dependent on the length of time the reset button is held in an active state.

START OUT - The relay contact closes the connection between pin (7) and pin (9) momentarily after the completion and pass of the Ground Bond test. This is only a momentary closure, and therefore, the contact does not stay closed.

With the 2630/2660 and one of the 2900 series Hipots being used as a test system, the processing signal from the Hipot tester will be sent across pin (6) and pin (7) of the 2630 remote input. This signal will add to the LCD display a W-On Withstand Processing indicator that notifies the operator that high voltage is enabled.

E. 2630/2660 AND 2900 FAMILY HIPOT INTERCONNECTION:

The two instruments have been designed to interface and work as one test system. The tests may be performed in sequence, where the Ground Bond test is run to verify the ground integrity and then the Hipot test is run after a good ground is indicated. The two tests can also be run simultaneously. Instructions regarding connections are provided in the next section. Also, refer to the end of section E for a complete diagram of a basic test setup.

36

OPERATION

After configuring the required test parameters for both instruments and connecting the cables, the test cycle can be initiated by activating the front panel test button on

2630/2660. The Hipot test will be controlled by the 2630/2660 automatically, through the interconnecting control cables.

1. INSTRUCTIONS FOR USER-FABRICATED INTERCONNECT CABLES.

The following diagrams show how to connect to the Remote I/O of both units. The associated pin numbers are given for the connectors on both units and the pins to be wired together. Refer to section D of this manual for the required parts to make these cables.

A. Simultaneous Testing 2925, 2935 and 2945

2630/2660 to 29XX Simultaneous Connection

2

•

3

•

4

•

5

•

6

•

7

•

8

•

9

•

2630/2660 Out 29XX In 2630/2660 IN

1

•

1

•

•

2

•

4

•

•

•

•

•

•

3

5

6

7

8

9

•

1

•

2

•

3

•

4

•

5

•

6

•

7

•

8

•

9

Male Plug Female Plug Female Plug

B. Simultaneous Testing 2955, 2965 and 2975

2630/2660 to 29XX Simultaneous Connection

2

•

3

•

4

•

5

•

6

•

7

•

8

•

9

•

2630/2660 Out 29XX In 2630/2660 IN

1

•

1

•

•

2

•

1

•

2

•

3

•

3

•

4

•

4

•

5

6

•

•

7

•

8

•

9

•

5

•

6

•

7

•

8

•

9

Male Plug Female Plug Female Plug

37

OPERATION

C. Sequential Testing 2925, 2935, 2945

2630/2660 to 29XX Sequential Connections

2630/2660 Out

1

•

2

•

3

•

4

•

5

•

6

•

7

•

8

•

9

•

Male Plug

29XX In 2630/2660 In

1

•

•

2

•

3

4

•

•

5

•

6

•

7

•

8

•

9

•

1

•

2

•

•

•

•

•

•

•

3

4

5

6

7

8

9

Female Plug Female Plug

D. Sequential Testing 2955, 2965, 2975

2630/2660 to 29XX Sequential Connections

2630/2660 Out

1

•

2

•

3

•

4

•

5

•

6

•

7

•

8

•

9

•

Male Plug

29XX In 2630/2660 In

1

•

•

2

•

3

•

4

•

5

•

1

•

2

•

3

•

4

•

5

6

• •

6

•

7

•

8

•

9

•

•

•

7

8

9

Female Plug Female Plug

RETURN CABLE CONNECTION

For the return cable connection, it is suggested that two insulated banana plugs be used with 18AWG stranded wire. For proper connection, one end of the return cable should be connected to the RETURN jack on the front panel of the Hipot and the other end connected to the INTERCONNECT jack on the rear panel of the 2630 or the RETURN jack in the case of the 2660. The suggested E.F. Johnson part number for the banana plug is as follows:

108-0303-001 Banana Plug Insulated (2)

38

OPERATION

2. INTERCONNECTING WITH THE 99-10006-01 ACCESSORY CABLES

Accessory kit 99-10006-01 includes the rear interface cables needed for interfacing the

2630/2660 with the 2900 family Hipot. The following table lists the kit contents.

99-10007-01 Cable Assembly

99-10003-01

(2925, 2935 and

2945)

Cable Assembly R/P Interface Sequential

Cable Assembly R/P Interface Simultaneous 99-10004-01

(2925, 2935 and

2945)

99-10608-01

(2955, 2965 and

2975)


99-10609-01

(2955, 2965 and

2975)

Cable Assembly R/P Interface Simultaneous

Qty.

1

1

1

1

1

The following sections describe the procedures for interconnecting your units. Please refer to the test method you require for specific cable connection instructions.

Cable Connections.

First, locate the 99-10007-01 return cable, identified by its double banana plug connectors.

Connect one end to the RETURN jack on the front panel of the Hipot and the other end to the INTERCONNECT jack on the rear panel of the 2630 or the RETURN jack on the

2660.

Determine whether you want to run the Ground Bond and Hipot test simultaneously or sequentially then select the appropriate cable assembly for your needs, using the descriptions in the table above.

1. For sequential testing, use the following cable connections. Locate the cable marked

“99-10003-01 SEQUENTIAL” for the 2925, 2935 and 2945 units. Locate the cable marked “99-10608-01” for the 2955, 2965 and 2975 units. Attach the male connector

(male connector with blue tubing) with two cables coming from it, to the female input connector of the 2630/2660. Attach the shorter of the two remaining cables with female connectors (female connector with blue tubing), to the male output connector of the 2630/2660 and the longer cable to the male signal input/output connector

(female connector with red tubing) on the rear panel of the Hipot.

2. For simultaneous testing, use the following cable connections. Locate the cable marked “99-10004-01 SIMULTANEOUS” for the 2925, 2935 and 2945 units.

Locate the cable marked “99-10609-01” for the 2955, 2965 and 2975 units. Attach the male connector (male connector with blue tubing) with two cables coming from it, to the female input connector of the 2630/2660. Attach the shorter of the two remaining cables with female connectors (female connector with blue tubing), to the male output connector of the 2630/2660 and the longer cable to the male signal input/output connector (female connector with red tubing) on the rear panel of the

39

OPERATION

Hipot.

Interconnecting 2630 to the 2945 Family of Hipots


HV



LINECORD

DUT

I.E. AC FAN

DUT

CHASSIS

99-10003-01(SEQ) or

99-10004-01(SIM)

99-10007-01

(INTERCONNECT)

RED MARKER

BLUE MARKER


CURRENT

REAR PANEL 2630

99-10007-01

RETURN

40

OPERATION



HV



LINECORD

DUT

I.E. AC FAN

DUT

CHASSIS

99-10608-01(SEQ) or

99-10609-01(SIM)

99-10007-01

(INTERCONNECT)

RED MARKER

BLUE MARKER


CURRENT

REAR PANEL 2630

99-10007-01

RETURN

41

OPERATION




LINE

102-055-913

HV

99-10007-01

(INTERCONNECT)

NEUTRAL

GND

99-10239-01

CURRENT

99-10238-01

RETURN

DUT

I.E. AC FAN

DUT

CHASSIS


RED MARKER

BLUE MARKER

99-10003-01(SEQ) or

99-10004-01(SIM)

42

OPERATION




LINE

102-055-913

HV

99-10007-01

(INTERCONNECT)

NEUTRAL

GND

99-10239-01

CURRENT

99-10238-01

RETURN

DUT

I.E. AC FAN

DUT

CHASSIS


RED MARKER

BLUE MARKER

99-10608-01(SEQ) or

99-10609-01(SIM)

43

OPERATION

F. ADAPTER BOX CONNECTION (For connecting to 2630 only)

The adapter box is an optional accessory and is not provided as standard equipment with the 2630. If you would like to acquire an adapter box for use with your 2630, please contact The Slaughter Company using the contact information provided in the Safety section of this manual.

The following diagram shows how to connect the adapter box to the 2630 and the Device

Under Test. This adapter box allows the user an easy way to connect an item that is terminated in a three-prong line cord. The high current is wired to the ground pin of the receptacle box and from there the test is performed on the ground conductor of the DUT to the chassis or dead metal of the product. If the high voltage lead is not used, it should be secured out of the way.

If the 2630 and a 2900 family Hipot are being used as a test system, the high voltage lead should be plugged into the high voltage jack on the front panel of the 29XX. The return lead from the 29XX should be connected to the 2630 as described in the previous section

(Cable Connections). This configuration would allow you to do both the Ground Bond and Hipot tests by pushing a single test button on the 2630 once all connections are made and the test parameters are set up.


2630

99-10005-01

H.V.

CURRENT RETURN

E

N

L

DUT

CHASSIS

Test Connections

44

OPTIONS

MODEL 2630/2660 OPTIONS

Introduction

This section contains a list with 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 2630/2660 Options List.

The option(s) code would appear as follows: fitted with option 02 .............................................................. OPT: 02 fitted with option 02 and 03.................................................... OPT: 0102

2630/2660 Options List

Code Description

01 Rear Outputs

Description

01 Rear Outputs

The Rear Outputs option gives the user the capability to access the High Current and

Return in addition to the existing Interconnect outputs from the rear panel for use in automated systems. The configuration and descriptions are as follows.

2630 OPTIONAL REAR PANEL CONTROLS

1 2 3

1. CURRENT OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) red test lead or adapter box. This jack is always used when performing a Ground

Bond test. Please refer section F. Adapter Box connection for details on connecting the adapter box between the instrument and the device under test.

45

OPTIONS

2. INTERCONNECT JACK: For the connection of the return lead from the Hipot tester used when performing both Hipot and Ground Bond tests on the same test item.

3. RETURN OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) black return test lead. This jack is always used when performing a test.

2660 OPTIONAL REAR PANEL CONTROLS

1 2

1. CURRENT OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) red test lead. This jack is always used when performing a Ground Bond test.

2. RETURN OUTPUT JACK: For the connection of the detachable 5-foot (1.52 m) black return test lead. This connector may also be used to interconnect a Hipot to this instrument. This jack is always used when performing a test.


46

This page is intentionally left blank.

OPTIONS

47

48

SECTION 2

SERVICE MANUAL

OPTIONS

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. Slaughter

Company, Inc. 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 adjustments can only be made in the Calibration mode, calibration checks can only be made in the Test mode of operation.

Calibration Equipment Required:

The following equipment will be needed to properly calibrate your instrument.

A Standard AC Voltmeter and a Standard AC Ammeter with the minimum ranges specified in the table:

Required Meters

Standard AC Voltmeter

Standard AC Ammeter

2630 min range

Voltage 6VAC

Current 30AAC

2660 min range

Voltage 12VAC

Current 60AAC

CALIBRATION PROCEDURE:

To enter the calibration mode the instrument must be in the OFF position. Using a pen or small screwdriver, press and hold the rear panel recessed calibration key, then turn on the

Input Power Switch. The display will show

:

C a l i b r a t i o n M o d e

S e t : V

v: A

Press the SET key for volts calibration or the Down (

∨

) arrow key for amps.

1. Calibration of Voltage

Equipment needed: Standard AC Voltmeter.

Please connect the standard ac voltmeter to the current and return connectors. Then press the SET key on the front panel. The instrument will provide approximately 6.0VAC for the 2630 or 12.0VAC for the 2660 on the output connectors and the display will show:

V o l t a g e = __ V

Please use the Up (

∧

) or Down (

∨

) arrow keys to enter the reading from the ac voltmeter into the instrument, then press the SET key to store the voltage setting. To exit without changing the calibration, press the EXIT key.

49

CALIBRATION

2. Calibration of Current

Equipment needed: Standard AC Ammeter.

Please connect the standard ac ammeter across the output leads of the instrument. Press the Down (

∨

) arrow key. The instrument will provide around 30A for the 2630 or

60Amps for the 2660 on the output and the display will show:

C u r r e n t = __ A

Please use the Up (

∧

) or Down (

∨

) arrow keys to enter the reading of the standard ac ammeter into the instrument, then press the SET key to store the current setting. To exit without changing the calibration, press the EXIT key.

3. Exit Calibration Mode

After the calibration is complete, turn the input power switch to OFF (0) to exit the

Calibration Mode. Turn the power switch to ON (l) to return to standard operating test mode for calibration verification.

50

PARTS LIST

Part Number Qty

99-10014-01

99-10222-01

99-10115-01

99-10117-01

99-10118-01

99-10016-01

99-10103-01

99-10031-01

175-974-002

175-946-013

99-10057-01

125-013-001

330-112-001

99-10017-01

330-113-002

330-113-001

99-10122-01

99-10106-01

150-135-003

99-10008-01

99-10009-01

99-10112-01

99-10113-01

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

4

1

1

1

1

1

1

2630 Replacement Parts List

Rev B ECO 5477

Description

-

-

-

-

-

-

T1

-

-

-

-

Reference

Designator

CSW-01

CKB-06

3030

AMP-260

REC-18

-

-

-

-

-

-

-

PCB Assy Input Protection Board

PCB Assy Keyboard Assembly

PCB Assy Main Control Board

PCB Assy Main Power Amplifier Board

PCB Assy Rectifier Board

Earth Connector

Diode Rectify Bridge 50V/50A

IC 89C52 Microcontroller 8-bit

Rubber Insert

Feet Kit w/o Rubber Inserts

LCD Display 16 x 2 Characters

Line Cord (Mains)

Power Switch 2P 10A/250V

Return Connector Black Banana Jack

Switch Reset, Red

Switch Test, Green

Transformer Input, Toroidal

Fuse 6.3A 250V, Slow Blow, 20mm

Fuse Holder, 20mm

Cable Assy High Current Return Lead

Cable Assy High Current Output Lead

High Current Return Jack

High Current Output Jack

Accessory Kit 99-10006-01

Part Number

99-10007-01

99-10003-01

Qty.

1

1

99-10004-01

99-10608-01

99-10609-01

1

1

1

Description

Cable Assembly Return Interconnect


(2925, 2935, 2945)


(2925, 2935, 2945)


(2955, 2965, 2975)


(2955, 2965, 2975)

Optional Adapter Box

Part Number

99-10005-01

Qty.

1

Description

Adapter Box High Voltage High Current

51

PARTS LIST

Part Number Qty

99-10221-01

99-10222-01

99-10240-01

99-10220-01

99-10016-01

99-10031-01

175-974-002

175-946-013

99-10057-01

99-10164-01

330-118-001

330-113-002

330-113-001

99-10230-01

99-10210-01

99-10238-01

99-10239-01

99-10203-01

99-10204-01

99-10458-01

99-10459-01

1

1

1

1

1

1

1

2

2

1

1

1

4

1

1

1

1

1

1

1

1

2660 Replacement Parts List

Rev. C ECO 5477

Description

-

-

-

-

T1

-

-

-

-

Reference

Designator

PWR-2660

CKB-06

3030

AMP-3160

-

-

-

-

-

-

-

-

PCB Assy Input Power Select Board

PCB Assy Keyboard Assembly

PCB Assy Main Control Board

PCB Assy Main Power Amplifier Board

Earth Connector

IC 89C52 Microcontroller 8-bit

Rubber Insert

Feet Kit w/o Rubber Inserts

LCD Display 16 x 2 Characters

Line Cord (Mains)

Power Switch 2P 10A/250V

Switch Reset, Red

Switch Test, Green

Transformer Input, Toroidal

Fuse 15A 250V, Slow Blow, 20mm

Cable Assy High Current Return Lead

Cable Assy High Current Output Lead

High Current Return Jack

High Current Output Jack

3U Handle Rack Mount

3U Bracket Rack Mount

Accessory Kit 99-10006-01

Part Number

99-10007-01

99-10003-01

Qty.

1

1

99-10004-01 1

99-10608-01

99-10609-01

1

1

Description

Cable Assembly Return Interconnect


(2925, 2935, 2945)


(2925, 2935, 2945)


(2955, 2965, 2975)


(2955, 2965, 2975)

52

REAR PANEL

INTERCONNECT

SCHEMATICS

SCHEMATIC INDEX

Drawing Number

S02630

S02660

S99-10115

S99-10117

S99-10220

S99-10222

S99-10014

S99-10221

S99-10118

S99-10036

Description

Wiring Diagram

Reference

Designator

-

Pages

1

Wiring Diagram

Main Control Board

-

3030

Amplifier AMP-260

1

3

1

Amplifier AMP-3160

Keypad Board

Input Protection Board(2630)

CKB-06

CSW-01

Input Power Board(2660)

Rectifier Board(2630)

ROM Conversion Board

PWR-2660

REC-18

82147

2

1

1

1

1

1

53

Model 2630 and 2660

Model

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

Warranty Policy

TABLE OF CONTENTS

SECTION 1

OPERATORS MANUAL

SAFETY PRECAUTIONS

GENERAL:

GLOSSARY OF TERMS

Model 2630 Functional Specifications

Model 2660 Functional Specifications

∨

):

∧

)

∨

):

∧

)

Preparation for Use

SECTION 2

SERVICE MANUAL

2630 Replacement Parts List

Accessory Kit 99-10006-01

Optional Adapter Box

2660 Replacement Parts List

Accessory Kit 99-10006-01

SCHEMATIC INDEX

Related manuals

Table of contents

Model 2630 and 2660

Model

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

Warranty Policy

TABLE OF CONTENTS

SECTION 1

OPERATORS MANUAL

SAFETY PRECAUTIONS

GENERAL:

GLOSSARY OF TERMS

Model 2630 Functional Specifications

Model 2660 Functional Specifications

∨

):

∧

)

∨

):

∧

)

Preparation for Use

SECTION 2

SERVICE MANUAL

2630 Replacement Parts List

Accessory Kit 99-10006-01

Optional Adapter Box

2660 Replacement Parts List

Accessory Kit 99-10006-01

SCHEMATIC INDEX

Related manuals

Slaughter

4320

Slaughter

6330

Slaughter

2935

Slaughter

4320

Slaughter

2550

Table of contents