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1. 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 e ASSOCIATED 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
2. 37554 1 LCDDisplayl6x2Characters 37555 1 PowerSwitch2P10A 250Y_ 37556 1 rest Switch Green 37557 1 Reset Switch Rd _ _ _ 37561 1 RS 232 Cable 20 cm RS 232 Female One End and Ribbon Female on Other End 37562 1 RS 232 Cable 23 cm RS 232 Male One End and Ribbon Female on Other End 37563 2 Handle for Mounting Bracket 2U __ 37564 2 9 Mounting Bracket 33189 1 Input Power Cable l0A 7Ft 04040A 08 1 High Voltage Output cable _ _ 021004 13 1 Returncable 54 e ASSOCIATED SCHEMATIC INDEX Drawing Number Description Pages Alternate or Additional Schematics note These schematics apply only to HypotPLUS II with installed options Some optional hardware changes are refered to on standard schematics Options Drawing Description 01 03 0102 0103 Pages Number S05500DT 25 10 Volt Analog Option x x x 2 37546 01 10 Volt Main Control rel IN A replace S37546 ia facea EEE 37546 03 Real Current Main Control MIN E replace S37546 S37546 0103 Real Current 10 Volt Main x 5 Control replace S37546 55
3. FAIL symbol will illuminate and the alarm will sound The display will show LO LMT MX XXX Xs X XXKVAC XX XX mA 38 DY ASSOCIATED RESEARCH INC OPERATION 11 If there is an arcing condition over the Arc sensitivity limit the red FAIL symbol will illuminate and the alarm will sound The display will show Arc MX XXX Xs X XXKVAC XX XX mA 12 To stop the alarm please press the RESET switch once The alarm will stop and the display will retain the failure information Ifthe 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 13 Ifthe DUT passed all of the tests the green PASS symbol on the front panel will illuminate and the instrument will output a short audible beep tone to indicate the DUT has passed the tests The Ready light will also illuminate and the display will show Pass MX XXX Xs X XXKVAC XX XX mA The instrument is now ready to perform another test 14 Ifthe 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 XX mA Please press the Test switch to initiate another test 39 DY ASSOCIATED RESEARCH INC OPERATION D CONNECTION OF REMOTE
4. ACCESSORIES A set of rack mount handles rear output jacks and a receptacle box for testing products terminated with a line cord are standard 10 MICROAMP READING RESOLUTION The reading resolution on the HypotPLUS II allows the user to monitor and set trip points down to 10 microamps ADVANCED DIAGNOSTICS The LCD provides the user with more information on test results The display indicates whether the DUT failed due to Arcing Breakdown Excessive Leakage or a Short Circuit 17 e ASSOCIATED FRONT PANEL CONTROLS 1 234567891011 12 13 14 15 16 17 18 19 20 AC DC WITHSTAND VOLTAGE TESTER SOSODT t 21 22 23 24 25 2627 1 RESET SWITCH This is a momentary contact switch If out of range leakage current or an arc breakdown is detected during the hipot test or continuity failure occurs the red Failure lamp 20 will light 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 2 TEST SWITCH This is a momentary contact switch Press the green switch to turn on the high voltage output when in test mode 3 RAMP KEY Dedicated key used to select voltage Ramp time entry The numeric keypad 23 is used to enter the value The Enter key 16 is used to save the new value 4 HI LIMIT KEY Dedicated key used to select Upper leakage limit threshold entry The numeric keypad 23 is used to enter the value The Enter
5. Analog option The following specifications apply to the 10 Volt analog option 10Volt Analog Option with Real Current Ratios are relative to the display V Set Input Range 0 10VDC Ratio 10V 3 KVAC Accuracy 2 of Reading KV Meter Output Range 0 10VDC Ratio 10V 3KVAC Accuracy 2 of Reading mA Meter Output Range 0 10VDC Ratio 10V 40 mA Total 10V 10 mA Real Accuracy 2 of Reading 5mV 47 DY ASSOCIATED RESEARCH INC OPTIONS 04 8KVAC 10mA AC Only The 8K VAC option increases the output voltage of the unit to 8K VAC but reduces the output current to 10mA with both hardware and software control The trip points are adjusted to a maximum of 10mA and the hardware has been modified so the high speed maximum current shutdown is fixed at 10mA All other specifications remain the same The specifications for the 8K VAC option are as follows Descriptions Specifications OUTPUT Rating AC 0 8000V 2V step 10mA FAILURE SETTINGS AC mode High limit 0 05 10 00 mA 0 01 mA step Low limit 0 00 and 0 05 10 00 mA 0 01 MA step METERING Voltmeter 4 digits Range AC 0 00 8 00 KV Resolution 0 01 KV Accuracy 2 ofreading 10 V Ammeter 4 digits Range AC 0 05 10 00 mA Resolution 0 01 mA Accuracy 2 of reading 0 02mA 07 Remote Interlock Option 07 is a Remote Interlock feature that inverts the present reset logic on the instrument from n
6. FAIL LED INDICATOR When a failure occurs during a hipot test or ground continuity test this indicator will light and the LCD meter will display the type of failure present such as High Current Failure Low Current Failure Breakdown Short Continuity and Arc Failure POWER SWITCH Rocker style switch with international ON and OFF 0 markings AC DC KEY Dedicated key used to enter AC DC select mode This key available on 5560DT only The enter key toggles from AC to DC mode DATA ENTRY NUMERIC KEYPAD For numeric entry or change of testing parameters during the Setup mode Keypad entry is unavailable if the Key Lockout indicator on the front panel is on Press and hold one of these keys until the second tone is heard to store parameters in memory Also used to recall test parameters stored in memory DY ASSOCIATED RESEARCH INC CONTROLS FRONT PANEL CONTROLS 1 234567891011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 2627 24 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 25 HIGH VOLTAGE ARROW LED INDICATOR This indicator flashes to warn the operator that high voltage is present at the high voltage output terminal 26 RETURN OUTPUT JACK For the connection of the detachab
7. 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 PLUG SHELL WITH GROUND INDENTS 205203 3 RECEPTACLE SHELL 745254 7 CRIMP SNAP IN PIN CONTACT for plug 745253 7 CRIMP SNAP IN SOCKET CONTACT for receptacle 745171 1 SHIELDED CABLE CLAMP for either plug or receptacle 747184 3 JACKSCREW SET 2 REMOTE INTERFACE REAR PANEL REMOTE 1 0 SIGNAL OUTPUT SIGNAL INPUT L MEMORY PROCESSING MEMORY MEMORY 1 SIGNAL OUTPUTS ON REMOTE I O The rear panel connector provides output signals to remotely monitor PASS FAIL and PROCESSING conditions These signals are provided by three normally open internal relays that switch on to indicate the current condition ofthe 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 act
8. OF DATA fk Ob DY ASSOCIATED RESEARCH INC SAFETY A Hipot produces voltages and currents which 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 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 ventillation 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 aquired directly from Associated Research Inc Refer servicing to an Associated Research Inc authorized service center PHONE 1 847 367 4077 ASSOCIATED RESEARCH INC 1 800 858 TEST 8378 13860 WEST LAUREL DRIVE FAX 1 847 367 4080 LAKE FOREST IL 60045 4546 U S A 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 component
9. Options There are no field installable options on the model 5500DT or 5560DT 25 e ASSOCIATED A quiexsrarr QUICK START This quick start guide assumes the operator has some familiarity with automated hipot testing and desires to use the default settings on the instrument The default settings shown will remain in memory unless you choose to override them with your own test program The instrument default settings are as follows DEFAULTS e Input Voltage 115 volts AC rear panel switch selectable e Communications local front panel key selectable e Mode set up e Voltage Output 1 240 volts AC e Current Trip W UPPER 10 mA W LOWER 0 00 mA e Dwell Timer 1 second e Ramp Time 1 second e Voltage Type AC e AC Output Frequency 60Hz Arc detection ON e Arc sensitivity 3 e Continuity OFF e Buzzer Volume Level 5 e Contrast LCD contrast level 5 e Remote OFF e Lock OFF 26 e ASSOCIATED A _ osat 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 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 CAUT
10. VOLTAGE is OFF If the device under test PASSED the test then no audible alarm will sound You will hear a brief BEEP to let you know the item was successfully tested and it PASSED 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 28 e ASSOCIATED OPERATION INSTRUCTIONS FOR HypotPLUS II Model 3500DT and 5560DT A POWER UP CAUTION 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 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 pcb s and other critical components All of the front panel led s will light temporarily then go out In additi
11. 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 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 1 Digital Multimeter with the minimum ranges ac voltage 5 000 volts ac current 25mA range 2 500KQ 50Watt resistor CALIBRATION PROCEDURE To enter the calibration mode the instrument must be in the OFF position Press and hold the 0 key then turn on the Input Power Switch The display will show Calibration Mode 2 KV 3 mA 7 Lock Press 2 for kilovolts calibration 3 for milliamps and 7 for the password and lock mode settings 1 Calibration of Voltage Equipment needed STANDARD AC VOLTMETER capable of measuring 5000V AC Please connect a standard ac voltmeter with 5000V minimum full scale range to the high voltage and return connectors Then press the 2 key on the front panel The instrument will provide around 5000VAC on the output connectors and the display will show Volta
12. 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 Ifthe 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 such that the item being tested is within the guards or enclosure during the test and fit them 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 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 which can cause harmful or fatal electric shock and must only be operated by a skilled
13. the return and high voltage connections to be certain that they are proper and secure 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 WARNING 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 which 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 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 KEY SAFETY POINTS TO REMEMBER 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 DN ASSOCIATED GLOSSARY OF TERMS as used in this manual Alternating Current AC Current which reverses direction on a regular basis commonly in the U
14. 9 is the maximum sensitivity After the Enter key is pressed the display will show the following message Arc Func ON or Arc Func OFF Press the Enter key to toggle the judgment function of arc leakage current from ON to OFF then press the Exit key to exit from the set mode and to go to the test mode If the arc sensitivity setting is satisfactory and you only want to change the judgment function press the Exit key directly then press the Enter key to toggle between ARC ON and ARC OFF In the arc ON position excessive arcing over your setting will stop the test and light the Arc indicator on the front panel and the alarm will sound In the arc OFF position an arcing condition will light the Arc led indicator only and no alarm will be indicated if the arcing was over your setting 7 To lock or unlock the keyboard of the front panel The HypotPLUS II is equipped with two lockout modes one requires a password to deactivate the lockout feature the other does not require a password Within each mode you can selectively lockout all front panel control functions except TEST and RESET or you may allow the operator to select from the pre programmed memories A Setup of Password and Lock Functions To setup a PASSWORD or change the MEMORY LOCK functions you must power up the instrument in the calibration mode To do this you must do the following 31 DY ASSOCIATED RE
15. CD screen will show the set point immediately Level 0 will turn off the alarm Level 1 produces the lowest volume and level 9 is the loudest Press the EXIT key to exit to the test mode or toggle to another program using the arrow keys 10 To store and recall the memory programs HypotPLUS II is equipped with a total of 10 memory programs numbered 0 to 9 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 Program memories can also be accessed through the remote control PLC port so that a manufacturer can quickly toggle through the various programs without going into the setup menu 35 e ASSOCIATED A Storage of Memory Program Once you have entered all the test parameters such as Voltage HI Limit Trip Current Ramp Time Dwell Time etc as outlined in the above procedures you may store your setup into one of the 10 memories The display will show Set M XXX Xs X XXKVAC XX XXmA Select one of the memory positions 0 to 9 to store the data which was just entered This is done by pressing and holding a Numerical key in for approx 2 seconds HypotPLUS II will respond with two beep tones one short tone when you select the key and one longer tone when the data is stored into that memory position Please select the correct memory position as you may inadvertently overwrite a previou
16. D DISPLAY The Liquid Crystal Display is the main readout for the operator and programmer of the test settings and test result EXIT KEY Use this key when you desire to enter the Run Mode to initiate a test or use this key when you enter numeric data during a Setup routine and you wish to clear the information ARC MENU KEY Used to enter arc menu for Arc threshold settings Exit key moves to Arc On Off selection mode DOWN ARROW y FUNCTION KEY Use this key to advance forward through the setup menus continuity remote volume contrast Also may be used to decrease output voltage during a test in 10 volt increments ENTER KEY Use the enter key after entering new data through the keypad to save it This key also used to toggle ON OFF functions 19 1 17 18 19 20 21 22 23 20 e ASSOCIATED FRONT PANEL CONTROLS 234567891011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 2627 LOCK KEY Used to enter the security lock menu This menu may or may not ask for a password depending on how the Lock function was configured in the calibration mode UP ARROW AN FUNCTION KEY Use this key to advance backwards through the setup menus continuity remote volume contrast Also may be used to increase output voltage during a test in 10 volt increments PASS LED INDICATOR This indicator lights at the end of a hipot test if no failure has occurred during the test
17. Electronic ramp and dwell settings The electronic ramp control helps keep test results consistent as well as reduces damage to sensitive products by providing a method to gradually bring up the test voltage and eliminate high voltage spikes The dwell timer also has a count down feature so the operator can clearly see how much time is left on a test 13 10 11 12 13 14 15 16 e ASSOCIATED PLC remote inputs and outputs The standard 9 pin interfaces provide outputs for Pass Fail and Test in Process Inputs include Test Reset and Program Select This gives the user all the basic remotes required to configure the HypotPLUS II through simple PLC relay control 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 short breakdown low fail high fail arc fail and continuity failure are clearly displayed Maximum output current 20 milliamps AC and 6 milliamps DC This makes this instrument a true hipot tester with enough output current to test capacitive loads in AC mode and allows the instrument to comply with the UL 120 K ohm requirements Digitally controlled arc detection system Many tests require the monitoring of arcing levels even if they do not exceed the maximum trip current level HypotPLUS II allows the operato
18. 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 Ifyou 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
19. ION c 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 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 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 HYPOTPLUS II 5560 DT VER Bs Current software version displayed here You should then see the default parameters on the LCD meter as follows SET MI 1 0S 1 24KVAC 10 00mA These abbreviated parameters stand for the following 27 e ASSOCIATED A ue starr SET This is the parameter settings review screen M 1 The instrument is using the default set ups contained in memory 1 1 0 S The dwell timer is set to a test duration of 1 second 1 24KVAC The test voltage is set to 1 240 volts AC 10 00 mA The high leakage current trip point is set to 10
20. OPERATION AND SERVICE MANUAL HypotPLUS II MODEL 5500DT AC ONLY HIPOT WITH GROUND CONTINUITY CHECK MODEL 5560DT AC DC HIPOT WITH GROUND CONTINUITY CHECK SERIAL NUMBER ESA ALGA O Associated Research Inc 2003 Mo del Ss 13860 West Laurel Drive 5500DTI5560DT Lake Forest Illinois 60045 4546 U S A Item 37545 Ver 1 45 Printed Oct 16 2003 CE DECLARATION OF CONFORMITY Manufacturer Associated Research Inc Address 13860 W Laurel Dr Lake Forest IL 60045 USA Product Name HypotPLUS II Dielectric Withstand Voltage Tester Model Number 5500DT 5560DT Conforms to the following Standards Safety EN 61010 1 1993 A2 EN 61010 031 1994 EMC EN 50082 1 1992 EN 50081 1 1992 IEC 801 2 1984 IEC 801 3 1984 IEC 801 4 1988 EN 55022 1994 EN 60555 2 1987 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 ib bam Joseph Guerriero Vice President General Manager Associated Research Inc Lake Forest Illinois USA May 19 1998 ii WarrantyPolicies Associated Research Inc certifies that the instrument listed in this manua
21. 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
22. SEARCH INC OPERATION 1 Place the power switch in the off position 2 Press and hold in the 0 key then turn on the power switch The display will indicate the following Calibration Mode 2 KV 3 mA 7 Lock 3 Press the 7 key the display will show P W XXXX or P W 0 4 Ifthe password is not to be changed please press the Exit key The program will go to the Memory Lock Function setting Please refer to item 7 listed below 5 Ifa password for the Lock Function is not required please use the numerical key to enter 0 and press the Enter key The program will go to the Memory Lock Function setting 6 Ifa password for Lock Function is required please use the numerical keys to enter a four digit Numerical Code and press the Enter key The program will go to the Memory Lock Function Once the password is set the password has to be entered to activate or deactivate the Lock function 7 After setting the password press the Exit key the display will show MR Lock O N or MR Lock OFF Press the Enter key to select Memory Lock ON or OFF If the MR Lock is in the ON position all the memory programs will be locked along with keyboard functions The operator will be locked out of recalling memory programs while in the lock mode If the MR Lock is in the OFF position the instrument will not lock the memory programs even if t
23. atios are relative to the display V Set Input Range 0 10VDC Ratio 10V 5 KVAC or 6 KVDC Accuracy 2 of Reading KV Meter Output Range 0 10VDC Ratio 10V 6KV Accuracy 2 of Reading mA Meter Output Range 0 10VDC Ratio 10V 5 mA Accuracy 2 of Reading 45 e ASSOCIATED 03 Real Current The Real Current option allows the user to monitor only the real portion of the leakage current and ignore any reactive components due to capacitance in the device under test It is Important to recognize that the total current is the vector sum of the reactive and real current not the direct addition of the two components As in a right triangle the total current is the square root of the sum of the squares of the real and reactive currents Since the real component is usually much smaller than the reactive current a doubling of the real current increases the total current by only a small amount Unless the two components are separated a doubling of the real leakage current can go virtually undetected by a total current measurement The Associated Research Real Current option allows the operator to view either real or total current The real current and total current cannot be measured or monitored simultaneously Independent failure settings for Real and Total current are provided but only one fail detector is active depending on the metering mode of operation The selection must be made in the menu before the test is run To ma
24. be connected to a good earth ground before operation 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 INPUT POWER RECEPTACLE Standard IEC 320 connector for connection to a standard NEMA style line power mains cord FUSE RECEPTACLE To change the fuse unplug the power mains cord and turn the fuse cap counter clockwise to remove the fuse 22 DN ASSOCIATED RESEARCH INC 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 Y our 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 Ifthe 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 RGA return goods authorization number Preparation for Use Power Re
25. 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 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 models 5500DT and 5560DT via Federal Express or UPS air 7 Please refer in all correspondence to your AR service number Field Installation Of
26. e 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 The HypotPLUS II also allows access to three MEMORY PROGRAMS through the remote control connector This gives the user the capability to quickly change parameters and initiate a test remotely The HypotPLUS II basically operates in a PLC mode by responding to simple switch or relay contact closures the built in memory programs of the instrument are used to accomplish this Three internal memory programs can be accessed by connecting terminals 7 8 and 9 in different combinations the user can select the correct memory program ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE REMOTE CONNECTOR SELECTS THE PROGRAM AND STARTS THE TEST THAT IS PREPROGRAMMED INTO THAT MEMORY WARNING DO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY CAUTION 4l e ASSOCIATED MEMORY ONE Momentarily connecting terminal 7 to 8 signals the instrument to immediately begin the test program that is stored in memory one MEMORY TWO Momentarily connecting terminal 7 to 9 signals the instrument to immediately begin the test program that is stored in memory two MEMORY THREE Momentarily connecting terminal 7 t
27. e warranty ili TABLE OF CONTENTS SECTION I OPERATORS MANUAL visssssssssssssssssssssssssssssssssssssssssssssssssssssssssssesssssessses 1 o atollo ai 2 INTRODUCE ON alal A La 6 SPEGINICA NONE scala oi ala e al 11 O 16 AA A 18 AS E AOE 23 A A rino no di ih i dii i RE aa cuties sei een aie 26 OPERATION cada ed ori 29 A II E Mareen 43 SECTION Il SERVICE MANUAL vesssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssesssssssseee 51 O nC nC TO eee E 52 PARTE Leal 54 SCHEMATICS en a alata ii 55 SECTION 1 OPERATORS MANUAL e ASSOCIATED 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 CALLS ATTENTION TO A PROCEDURE PRACTICE OR CONDITION THAT COULD POSSIBLY CAUSE BODILY WARNING INJURY OR DEATH CALLS ATTENTION TO A PROCEDURE PRACTICE OR CAUTION CONDITION THAT COULD POSSIBLY CAUSE DAMAGE TO EQUIPMENT OR PERMANENT LOSS
28. et for 0 the display will show Dwell MX XXX Xs X XXKVAC XX XX mA The instrument will continue to output the set dwell voltage for the duration of the selected dwell time The count down timer will display the time remaining on the test NOTE H the alarm volume is set to 0 OFF no audible alarm will be heard 37 DY ASSOCIATED RESEARCH INC OPERATION during a failure condition 6 If there is a short circuit in the DUT during the test the red FAIL symbol will illuminate and an alarm will sound The display will show Short MX XXX Xs X XXKVAC OFL mA 7 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 FAIL symbol will illuminate and the alarm will sound The display will show BRKDWN MX XXX Xs XXXKVAC OFL mA 8 Ifthe leakage current exceeds the metering range and neither a short circuit nor flash over occurred the red FAIL symbol will illuminate and the alarm will be activated The display will show HI LMT MX XXX Xs X XXKVAC OFL mA 9 If the leakage current exceeds the high limit setting but does not exceed the metering range the red FAIL symbol will illuminate and the alarm will sound The display will show HI LMT MX XXX Xs X XXKVAC XX XX mA 10 If the leakage current does not exceed the low limit setting the red
29. ge __ V 52 e ASSOCIATED Please use the numerical keys to enter the reading off the ac voltmeter into the instrument Then press the Enter key to store the voltage setting If an incorrect value is entered press the EXIT key Then the correct value may be re entered 2 Calibration of Current Equipment needed STANDARD AC MILLIAMMETER with a range of 25mA anda fixed Resistor 500K Ohms 50 watts Please connect a 500KOQ resistor in series with the standard ac milliammeter and connect these across the output leads of the instrument Press the 3 key The instrument will provide around 5000VAC on the output and the display will show Current _ mA Please use the numerical keys to enter the reading of the standard ac milliammeter into the instrument Then press the Enter key to store the current setting If an incorrect value is entered press the EXIT key The correct value may be re entered 3 Setup of the Password and Lock Function Please refer to the setup procedures section of this manual 53 e ASSOCIATED Replacement Parts List HYPOTPLUS II Model 5500DT 5560DT Rev F 12 07 99 ECO 4742 Designator 37s 1 f arth Connector gt gt gt 35999 4 Black Banana Jacks _ _ 37478 2 HighVoltageComector ______ 38101 1 Feet Kit w o Rubber Inserts 38102 4 Rubber Insert 37857 1 FuseSA250VSlo Blo5x20mm 37781 1 Fuse Holder 5x20mm _________
30. ge 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 However specific products may be tested at much higher voltages than 2X operating DY ASSOCIATED 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
31. he keyboard is locked The memory programs may be recalled while in the lock mode but the test parameters within each setup cannot be changed 32 DY ASSOCIATED RESEARCH INC OPERATION B Turning the LOCK function ON or OFF with no password activated Press the Lock key the display will show Lock ON or Lock OFF Press the Enter key to select the Lock ON or Unlock OFF mode then press the Exit key to exit and return to the test mode If the Lock mode is selected the Lock indicator on the front panel will light and the keyboard will be locked If the Lock indicator is not lit the keyboard will be operational C Turning the LOCK function ON or OFF with a Password Press the Lock key the display will show Please use the Numerical keys to enter the four numeral password If the current position of the lock function is OFF the status will be changed to ON and the Lock indicator on the front panel will be illuminated In the reverse case the status will be changed to OFF and the Lock indicator will be off 8 To set the AC DC mode for MODEL 5560DT Press the AC DC key the display will show Mode AC or Mode DC Press the Enter key to toggle the output function AC or DC then press the Exit key to exit from the setting mode and to return to the test mode 33 e ASSOCIATED 9 T
32. his 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 Program memories can also be accessed through the remote control PLC port so that a manufacturer can quickly toggle through the various programs without going into the set up menu All parameters for the setups can be adjusted through a simple menu driven program by using quick access front panel keys The easy to follow setup screens ensure that the operator correctly sets up all test parameters 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 password can change test parameters Passwords are programmable this ensures that the required test parameters can not be tampered with 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 Posi Test M current sensing system This capability makes it possible to ensure that a test item was properly connected since the HypotPLUS II can be set to monitor minimum and maximum levels of current during a hipot test The LCD display allows monitoring of current down to 50 microamps AC and 20 microamps DC Many tests only allow a very low level of acceptable leakage current
33. ivate each pin When a terminal becomes active the relay closes thereby allowing the external voltage to operate an external device 40 e ASSOCIATED 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 8 and9 are blank 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 2 SIGNAL INPUTS OF REMOTE I O AND MEMORY PROGRAMS The HypotPLUS II remote connector enables remote operation of the TEST and RESET functions or allows the operator to select one of three pre programmed test When the 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 th
34. ke the selection of Real or Total current press the up arrow key to scroll through the menu You will see or Press the Enter key to toggle between Real and Total mode After you have made the selection press the Exit key to return to the run mode You will see Set M_ X Xs Set M_ X Xs XXXKV XX XXmAR or X XXKV XX XXmAT The letter R or T after the current reading XX XXmA indicates whether the Hypot PLUS II is in Real or Total current reading mode All other operation remains the same please refer to the Operation section page 29 46 DY ASSOCIATED RESEARCH INC OPTIONS The specifications for the Real Current option are as follows Voltmeter Range 0 00 3 00 KVAC Resolution 01 KV Accuracy 2 of reading 10 V Current Meter Total mode Range 0 05 35 00mA Resolution 01 mA Accuracy 2 of reading 02mA Real mode Range 0 05 10 00mA Resolution 01 mA Accuracy 3 of reading 05mA Failure Settings Total mode High limit 0 05 35 00 mA 0 01 mA step Low limit 0 00 and 0 05 35 00 mA 0 01 mA step Accuracy 2 of setting 0 02 mA Real mode High limit 0 05 10 00 mA 0 01 mA step Low limit 0 00 and 0 05 10 00 mA 0 01 mA step Accuracy 2 of setting 0 02 mA Please allow a ten minute warm up time after power up before operation A 30 minute warm up time is necessary to guarantee these accuracy s If the Real Current option is installed with option 01 10 Volt
35. key 16 is used to save the new value 5 VOLTAGE KEY Dedicated key used to select output voltage mode entry The numeric keypad 23 is used to enter the value The Enter key 16 is used to save the new value 6 DWELL KEY Dedicated key used to select Test Voltage time duration entry The numeric keypad 23 is used to enter the value The Enter key 16 is used to save the new value 7 LO LIMIT KEY Dedicated key used to select Lower leakage limit threshold entry The numeric keypad 23 is used to enter the value The Enter key 16 is used to save the new value 8 50 60 KEY Dedicated key used to enter 50 60 Hz select mode Active only when AC mode is selected The enter key 16 toggles from 50 to 60 Hz 1 10 11 12 13 14 15 16 DN ASSOCIATED RESEARCH INC CONTROLS FRONT PANEL CONTROLS 234567891011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 2627 KEY LOCKOUT LED When the Key Lockout light is ON the password software lockout has been enabled This means that the operator will be unable to access the program mode of the instrument to change any settings ARC LED The Arc LED always illuminates when arcing events exceed the Arc threshold during a test READY LED LED will illuminate when the system is ready to execute the next test When the Continuity Check feature is enabled this LED will illuminate when continuity is present on the DUT LC
36. l 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 complete the on line registration at www asresearch com register or call 1 800 858 TEST ext 210 to register over the phone 5 Year Program 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 Ifthe original container in not available please contact our customer support center for proper instruc
37. le 5 foot 1 52 m black return test lead This lead is always used when performing a test 27 CONTINUITY CHECK 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 continuity test 21 CONTROLS DY ASSOCIATED RESEARCH INC REAR PANEL CONTROLS RETURN CONT eHeck SIGNAL OUTPUT pigwa INPUT FAIL PASS Pa RESET ST z 1 1 115V 230V gt 54 2 54 50Hz 60Hz 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 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 CONTINUITY CHECK OUTPUT JACK For the connection of the detachable 5 foot 1 52 m return test lead This lead is always used when performing a continuity test THERMAL FAN Runs continuously to cool the instrument REMOTE OUTPUT 9 pin D subminiature female connector for monitoring PASS FAIL and PROCESSING output relay signals REMOTE INPUT 9 pin D subminiature male connector for remote control of test and reset funtions as well as program memory selection 1 2 or 3 CHASSIS GROUND EARTH TERMINAL This safety terminal should
38. milliamps 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 Then connect the return lead first black to the test fixture or item followed by the high voltage output lead red WARNING D Please check your connections to be sure they are making good contact and that the test station or area is clear of debris and other personnel 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 Ifa 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
39. o setup the Ground Continuity Check Remote Control LCD Contrast and Alarm Volume A Ground Continuity Check Press the UP or DOWN arrow key to toggle the programs until the display shows Continuity ON or Continuity OFF Press the Enter 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 arrow keys 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 ofthe DUT The instrument will test the ground connection of the DUT automatically If continuity is present the Ready indicator will be illuminated and the operator may proceed with the hipot test The HypotPLUS II will continue to test the ground connection of the DUT during other tests Ifno continuity is present while the operator tries to initiate a test the instrument will signal a continuity failure B Status of Remote Control setting Press the UP or DOWN arrow key to toggle the programs until the display shows Remote ON or Remote OFF Press the Enter key to select the ON or OFF function of the Remote Control mode the display will show the status immediately Press the Exit key to exit to the test mode or toggle to another se
40. o terminals 8 and 9 signals the instrument to immediately begin the test program that is stored in memory three E ADAPTER BOX CONNECTION The following diagram shows how to connect the adapter box to the HypotPLUS II and to the device under test 5500DT and 5560DT Test Connections The adapter box allows you an easy way to connect an item which 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 HypotPLUS II you can perform both the hipot and continuity tests at the same time by activating the continuity function on the instrument When the HypotPLUS II tests the ground conductor of the line cord if the resistance of the ground conductor exceeds 10 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 42 DN ASSOCIATED RESEARCH INC OPTIONS MODEL 5500DT 5560DT 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 wi
41. olarity 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 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 IF YOU SHOULD HAVE ANY QUESTIONS RELATING TO THE OPERATION OF YOUR INSTRUMENT CALL 1 800 858 TEST 8378 IN THE U S A e ASSOCIATED Model 5500DT and 5560DT Functional Specifications DIELECTRIC WITHSTAND TEST MODE Unless otherwise stated accuracies are relative to a laboratory standard measurement Specifications INPUT VOLTAGE 115 230V selectable 15 variation 47 63 Hz FUSE 115 VAC 230VAC SA slow blo 250VAC OUTPUT Rating AC 0 5000V 2V step 20mA DC 0 6000V 2V step 6mA 5560DT only Regulation 1 of output 5V VOLTAGE SETTING OV 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 ke
42. on the country of destination Test Leads The test leads provided are designed specifically for use with this instrument The Red High Voltage lead will mate with the white front panel connector and should only be installed when the user is completely familiar with the operation of the instrument and is ready to perform a test The black test leads will install into the black Return and Continuity jacks The Return lead will be used for all test but the Continuity lead is only necessary for continuity testing The test lead ratings are as follows HV output lead 04040A 08 10 KVAC 1A Black test leads 02100A 13 2 KVAC 1A Operating Environment This instrument may be operated in temperatures from 32 113 F 0 45 C Relative humidity of 0 to 95 Altitude up to 15 000 feet 4 600 meters Ventillation 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 STORAGE AND SHIPMENT Environment This instument may be stored or shipped in environments with the following limits doo o MAA 40 to 75 C 24 e ASSOCIATED Altitude 7 620 meters 25 000 feet 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
43. on the display will show the following message ARI HYPOTPLUS II ARI HYPOTPLUS II 5500D T VER X X 5560D T VER X X The instrument will recall the last memory program which was active and the display will show the parameters which were programmed into that memory The instrument is now ready for operation B SETUP PROCEDURE 1 To set the output test voltage Please press the Voltage key the display will show Voltage XXXX V Please use the Numerical keys to enter the desired test voltage then press the Enter key to store the voltage setting If an incorrect value is entered press the Exit key then the correct value may be re entered The maximum voltage which may be entered is 5000 volts AC or 6000 volts DC Any value above these will produce an ERROR message 29 DN ASSOCIATED RESEARCH INC OPERATION 2 To set the high leakage current limit Please press the HIGH LIMIT key the display will show HI LMT XXXX mA Use the Numerical keys to enter the leakage current high limit setting then press the Enter key to store the setting The unit of measure is in milliamperes with 0 05 AC and 0 02 DC milliamperes as the minimum setting 3 To set the low leakage current limit Please press the LO Limit key the display will show LO LMT XX XX mA Please use the Numerical keys to enter the leakage current low limit setting then press the Enter key to store the se
44. 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 l 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 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 Since a DC hipot does charge the item under test it becomes necessary to discharge DY ASSOCIATED RESEARCH INC INTRODUCTION the item after the test DC testing unlike AC testing only charges the insulation in one p
45. ormally opened must close contacts to activate the reset to normally closed must open contacts to activate the reset Hardware and software have been reconfigured to provide the interlock connections on pins 2 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 38037 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 Please refer to page 40 for further information about the remote interface 48 DY ASSOCIATED RESEARCH INC OPTIONS 08 7 Remote Memories Select The 7 Remote Memories Select option increases the number of memory programs that may be accessed through the remote control connector from 3 to 7 This gives the user the capability to quickly change parameters and initiate a test remotely The HypotPLUS II basically operates in a PLC mode by responding to simple switch or relay contacts closures the built in memory programs of the instrument are used to accomplish this Seven internal memory programs can be accessed by connecting terminals 3 7 8 and 9 in different combinations The binary truth table sho
46. ould be at least 100KQ Remote Interface Pinouts bold for 10 Volt Option SIGNAL OUTPUTS SIGNAL INPUTS DESCRIPTION DESCRIPTION PASS V SET PASS REM RESET FAIL REM TEST FAIL V SET SELECT PROCESS TEST RESET COM PROCESS V SET COM VOLTAGE PRGM COM CURRENT PRGMI VOLT CURRENT COM REMOTE 1 0 SIGNAL OUTPUT SIGNAL INPUT L FAIL PASS ac ao Ue a o alo No MEMORY 1 MEMORY 2 MEMORY 3 PROCESSING VOLTS AMPS COM 44 DY ASSOCIATED RESEARCH INC OPTIONS Analog Interface Specifications Descriptions Specifications Ratios are relative to the display V Set Input Range 0 10VDC Ratio 10V 5 KVAC or 6 KVDC Accuracy 2 of Reading KV Meter Output Range 0 10VDC Ratio 10V 6KV Accuracy 2 of Reading mA Meter Output Range 0 10VDC Ratio 10V 20 mA Accuracy 2 of Reading Note Specifications subject to change with other installed options See appropriate options section 02 SmA Output The SmA Output option limits the output current with both hardware and software control The trip points are adjusted to a maximum of SmA and the hardware has been modified so the high speed maximum current shutdown is fixed at SmA All other specifications remain the same If this option is installed with option 01 10 Volt Analog option The following specifications apply to the 10Volt Analog option 10Volt Analog Option with 5 mA Option R
47. ovide maximum operator safety SPECIFICATIONS 18 Easily configurable into an automated test system HypotPLUS II comes standard with rear output connectors and rack mount handles to make it simple to build into an automated system 19 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 15 WHAT S NEW DY ASSOCIATED RESEARCH INC WHAT S NEW IN HypotPLUS II vs HypotPLUS STORAGE OF UP TO 10 DIFFERENT TEST SETUPS Allows users who test many different products to access various test setups through the keypad or through PLC remote MICROPROCESSOR CONTROLLED The easy to follow menu screens ensure that the user will set all parameters through the keypad correctly Also dedicated HOT keys for fast direct access to most parameter settings PLC REMOTES Two 9 pin interfaces provide the user with all the necessary remotes required to configure HypotPLUS II through simple PLC control Outputs include Pass Fail Test in Process Inputs include Test Reset and Program Select NO LOAD SETUP This feature gives the user the ability to safely set the output voltage and trip currents without the high voltage activated DWELL TIMER COUNTDOWN The countdown timer allows the user to clea
48. quirements and Line Voltage Selection This instrument requires a power source of either 115 volts AC CAUTION 15 47 63 Hz single phase or 230 volts AC 15 47 63 Hz 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 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 5A slow blo fuse 23 DY ASSOCIATED RESEARCH INC INSTALLATION Power Cable BEFORE CONNECTING POWER TO THIS INSTRUMENT THE PROTECTIVE GROUND EARTH TERMINALS OF THIS WARNING 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 instruments depends
49. r to select whether low level arcs should be detected and provides the operator with the ability to digitally select and program multiple sensitivity levels This makes HypotPLUS II flexible enough to test any product Software calibration control HypotPLUS II is calibrated through the front panel keypad All calibration information is stored in non volatile memory This allows HypotPLUS II to be completely calibrated without removing any covers and exposing the technician to hazardous voltages User selectable output voltage frequencies of 50 or 60 hertz HypotPLUS II was 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 Output voltage fine adjustment To make HypotPLUS II 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 HypotPLUS II is in the dwell mode so you can analyze test results at different voltages Built in Continuity test mode HypotPLUS II meets ground continuity test requirements called out by UL and other safety agencies DY ASSOCIATED RESEARCH INC 17 Flashing high voltage indicator A flashing LED located directly over the high voltage terminal clearly indicates when high voltage is active to pr
50. 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 e Design performance Testing determining design adequacy to meet service conditions e Production Line Testing detecting defects in material or workmanship during processing Acceptance Testing proving minimum insulation requirements of purchased parts e 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 volta
51. rly see how much time is left on the test TAMPER PROOF CONTROLS With the user programmable password access to setup screens can be limited to authorized personnel only METER MEMORY This standard feature holds results of failed tests on the LCD allowing the user to further review test results DIGITALLY CONTROLLED ARC DETECTION This provides the user with the ability to select whether low level arcs should be detected With a range of 2 20mA peak the HypotPLUS II can be DY ASSOCIATED RESEARCH INC WHAT S NEW set to multiple sensitivity levels HIGHER OUTPUT CURRENT Increased output current of 20mA in AC and 6mA in DC provide the HypotPLUS II with enough output to meet most applications FRONT PANEL LCD WITH ADJUSTABLE DIMMER HypotPLUS II utilizes an enhanced LCD to display setups and test results For easier reading of the screen the user can set the contrast to 10 different levels using the keypad ALARM VOLUME CONTROL The user can change the volume of the failure alarm to fit a variety of environments From level 1 through 9 0 OFF FREQUENCY SELECTION This feature allows the user to toggle between 50hz and 60hz so products can be tested at the same frequency they will be used FRONT PANEL CALIBRATION By going into the restricted access calibration mode the user can calibrate the unit through the keypad with out the need to remove any panels or covers which could expose the technician to hazardous voltages STANDARD
52. s 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 DY ASSOCIATED RESEARCH INC 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
53. 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 current reading This means that unless the product is sensitive to a sudden application of voltage the operator can immediately apply full 3 f ASSOCIATED voltage and read current without any wait time Another advantage of AC testing is that since AC voltage cannot charge a load there is no need to discharge the item under test after the test 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 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
54. sly stored program The display will show Set MX XXX Xs X XXKVAC XX XX mA B Recall ofa Memory Program Please press the Numerical key of the Memory Program that you wish to recall The instrument will respond with a short beep tone and the display will indicate the test parameters stored in that program To start a test press the TEST key C OPERATING PROCEDURES 1 Please follow the Setup Procedures to set the general status of Ground Continuity Remote Control LCD Contrast and the Alarm Volume If the instruments defaults are acceptable then be sure to connect the appropriate test leads to the device under test DUT or test fixture Be sure to connect the safety ground on the rear panel to a suitable known good ground before energizing this instrument Then connect the return lead first to the test fixture or the DUT followed by the high voltage lead 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 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 ofthe DUT and the Cont Check indicator READY LIGHT should be illuminated before activating the Test 36 DY ASSOCIATED RESEARCH INC OPERATION s
55. th options there will be an option label on the rear panel of the unit The option label contains an option s code that may be cross referenced to the Options List For example your options code would appear as follows fitted with Option OPT 01 fitted with option dl andrai OPT 0102 5500DT 5560DT Options Option List 8KVAC 10mA AC ONLY Remote Interlock C 7 Remote Memories Select 43 DN ASSOCIATED RESEARCH INC OPTIONS Description 01 10 Volt Analog Interface For a description of standard remote I O see page 40 The 10 Volt Analog Interface option allows the user to remotely set the Voltage applied to the item under test and measure the actual test voltage and leakage current during the test Voltage Input When the V Set select contacts pins 4 and 6 are connected menu driven voltage setting is disabled The output voltage is controlled by the voltage applied to the Remote Voltage Set inputs pins 1 and 6 A 0 to 10 VDC input will set the high voltage from 0V to its maximum rated output level The input impedance is approximately 20KQ Meter Outputs The remote meter outputs generate a DC voltage proportional to the actual test voltage pins 7 and 9 and leakage current pins 8 and 9 present at the item under test These outputs are used to monitor actual test conditions in a computer controlled test system These outputs are floating relative to the hipot chassis The input resistance of the measuring device sh
56. tions 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 3 Year Program A 3 Year warranty is also available for instruments purchased and used in North America All costs for this warranty are paid with the initial purchase and include warranty coverage annual calibration and standard ground return freight for three years However unlike our 5 year program annual calibration and inspection by Associated Research is not required 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 bypassing 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 th
57. tors OUTPUT 1 Remote control test and reset 2 Remote recall of memory program 1 2 and 3 3 Outputs pass fail and test in process SECURITY Password lockout capability to avoid unauthorized access to test set up program Detachable 7 ft 2 13m power cable terminated in a three prong grounding plug TERMINATIONS Sft 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 Bench or rack mount 2U height with tilt up front feet Dimensions w x h x d 17 x 3 5 x 16 5in 432 x 88 x 419mm Weight 5500DT 20 lbs 9kgs 5560DT 24 lbs 11Kgs ENVIRONMENTAL Operating Temperature 32 113 F 0 45 C Relative Humidity 0 to 95 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 12 e ASSOCIATED EY FEATURES amp BENEFITS OF HypotPLUS II 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 Storage of up to 10 different test programs A real benefit for manufacturers that test different products T
58. tting If set for 0 the low leakage current limit will be disabled The unit of measure is in milliamperes with with 0 05 AC and 0 02 DC milliamperes as the minimum low limit current setting without disabling the low limit detector 4 To set the dwell time Please press the Dwell key the display will show Dwell T XXX X s Use the Numerical keys to enter the dwell time setting then press the Enter key to store the dwell time setting 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 5 To set the ramp time Please press the Ramp key the display will show Ramp T XXX Xs Use the Numerical keys to enter the ramp time setting then press the Enter key to store the ramp time setting Ifthe ramp time is set to 0 the ramp up function is disabled The minimum ramp time setting is 0 5 seconds with 0 1 second resolution 30 DY ASSOCIATED RESEARCH INC OPERATION 6 To set the sensitivity of the arc detection circuit Please press the Arc key the display will show Use the Numerical keys to enter the arc sensitivity setting then press the Enter key to store the arc sensitivity setting There are ten Arc detector sensitivity settings from 0 through 9 0 is the minimum sensitivity and
59. tting using the arrow keys Ifthe Remote Control is set to ON the Test function will be controlled by the Remote Control via the remote connectors located on the rear panel The Test switch on the front panel is locked out but the Reset switch will still be functional Ifthe Remote Control is set to OFF the operation will be controlled by the Test and Reset switches on the front panel 34 e ASSOCIATED C LCD Contrast setting Press the UP or DOWN arrow keys to toggle the programs to the display shown Contrast X Please use the Numerical keys to enter the range of Contrast from 0 to 9 Then press the Enter key to store the Contrast range A total of10 ranges are available The LCD will change the Contrast immediately and the display will show the set value on the screen The Contrast number 0 is the weakest and 9 is the strongest Toggle the arrow keys to another setting or press the Exit key to exit from the setting mode and enter the testing mode D Alarm volume setting Press the UP or DOWN key to toggle the programs until the display shows Use the Numerical keys to enter the range of alarm volume from 0 to 9 A total of 10 levels Then press the Enter key to store the selected alarm volume setting The instrument will emit a tone signal as a sample of the alarm volume selected and the L
60. witch Otherwise the instrument will signal a continuity failure when the test switch is activated 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 3 Please follow the setup procedures to set or recall setups from memory programs The display will show the number of the Memory Program time of Dwell value of Test Voltage and the value of the High Limit Leakage Current as follows Set M XXX Xs Set MX XXX Xs X XXKVAC XX XX mA X XXKVAC XX X XmA 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 4 To initiate a test press the Test switch on the front panel If the ramp time is set the red High Voltage symbol will flash and the display will immediately show Ramp MX XXX Xs X XXKVAC XX XXmA The instrument will output the set voltage from 0V to the set voltage according to the ramp time selected The instrument starts to test the DUT from ramp up When the ramp up cycle is completed the instrument will go directly to dwell 5 Ifthe ramp time is s
61. 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 the Hipot testing job Allowing unauthorized personnel in the area during a test should also be dealt 4 DY ASSOCIATED RESEARCH INC SAFETY 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 Then Connect the return lead first for any test regardless of whether the item under test is a sample of insulating material tested with electrodes a component tested with the high voltage test lead or a cord connected device with a two or three prong plug 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
62. ws the different combinations of momentary switch relay closures and which memory programs that will be selected as the result It may be necessary to OR the momentary switches relay contacts to prevent incorrect program selection due to timing errors 7 MEMORIES SELECT TRUTH TABLE MEMORY BIT3 BIT2 BIT 1 OR 0 0 1 1 0 1 0 2 0 1 1 3 1 0 0 4 1 0 1 5 1 1 0 6 1 1 1 7 1 Momentary Contact closure between BIT and COMMON 0 No Contact closure between BIT and COMMON ACTIVATING MEMORY PROGRAM FUNCTIONS THROUGH THE REMOTE CONNECTOR SELECTS THE PROGRAM AND STARTS THE TEST THAT IS PREPROGRAMMED INTO THAT MEMORY NOTE The remote Test switch CAN NOT be used but is no longer necessary if this option has been installed The remote Reset switch CAN still be used in this configuration WARNING PO NOT CONNECT VOLTAGE OR CURRENT TO THE SIGNAL INPUTS THIS COULD RESULT IN DAMAGE TO THE CONTROL CIRCUITRY 49 DY ASSOCIATED RESEARCH INC 50 This page is intentionally left blank OPTIONS SECTION 2 SERVICE MANUAL DY ASSOCIATED RESEARCH INC 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
63. ys OUTPUT Model 5500DT 50 60 Hz selectable 5560DT DC and 50 60 Hz selectable 0 and 0 5 999 9 seconds 0 1 second step SETTING 0 for continuous running RAMP TIME 0 and 0 5 999 9 seconds 0 1 second step SETTING 0 setting 2 seconds FAILURE SETTINGS AC mode High limit 0 05 20 00 mA 0 01 mA step Low limit 0 00 and 0 05 20 00 mA 0 01 mA step Accuracy 2 of setting 0 02 mA DC mode High limit 0 02 6 00 mA 0 01 mA step Low limit 0 00 and 0 02 6 00 mA 0 01 mA step Accuracy 2 of setting 0 02 mA Arc for AC and DC mode Sensitivity range 0 9 Arc detection minimum duration lt 10 us 11 DY ASSOCIATED RESEARCH INC SPECIFICATIONS METERING Voltmeter 4 digits Range AC 0 00 5 00 KV DC 0 00 6 00 KV Resolution 0 01 KV Accuracy 2 ofreading 10 V Ammeter 4 digits Range AC 0 05 20 00 mA DC 0 02 6 00 mA Resolution 0 01 mA Accuracy 2 of reading 0 02mA TIMER DISPLAY Range 0 0 999 9 seconds Resolution 0 1 second Accuracy 0 1 of reading 0 05 seconds Ramp 0 0 2 seconds MAXIMUM luF lt 1KV 0 08uF lt 4KV CAPACITIVE LOAD 0 75uF lt 2KV 0 04uF lt S5KV DC MODE 0 5uF lt 3KV 0 0luF lt 6KV GROUND Current DC 0 1 A 0 01A fixed CONTINUITY CHECK Max ground resistance 1 Q 0 1Q fixed PROGRAM MEMORY REMOTE CONTROL The following input and output signals are provide through two AND SIGNAL 9 pin D type connec

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