Amptec Research 630ES Manual
RESEARCH
AMPTEC
PHONE (512) 858-4045; 800-350-5105
website http://www.amptec.com
FAX (512) 858-4340; TOLL FREE IN USA
Revision D
AMPTEC 630ES
SAFETY IGNITER TESTER
OPERATION/MAINTENANCE MANUAL
1
TABLE OF CONTENTS
_______________________________________________________________
SECTION A: UNPACKING AND INSPECTION
A-1 Introduction to the AMPTEC 630ES
A-2 Unpacking and Inspection
A-3 Opening the 630ES Ohmmeter and Removal of the Lid
A-4 AC Adaptor/ Battery Charger- Power Requirements
A-5 Setup and Use
SECTION B: 630ES Explosive Safety Igniter Tester
SPECIFICATIONS
Table B-2. Specifications
SECTION C: REPLACEMENT, OPTIONAL AND ACCESSORY
ITEMS
C-1 Available Accessories and Options
C-2 Test Lead Sets
SECTION D: OPERATION AND USE
D-1 General
D-2 Front Panel Features and Operation
D-3 Fuse Holder
D-4 4-Wire Resistance Measurement
D-5 Connections
D-6 Failsafe Operation
D-7 Battery Monitoring Circuitry
D-8 Zero Pot
1
SECTION E: THEORY OF OPERATION
E-1 General
E-2 Troubleshooting
E-3 Circuit Descriptions
E-4 Analog-to-Digital Converter
E-5 Ohms-to-DC Converter
E-6 Failsafe Design
E-7 Ultra-Safe Power Supply Scheme
Figure E-1. Model 630ES Block Diagram
Figure E-1B Analog-to-Digital Converter Timing Diagram
Figure E-2 Analog Section of IC1 and IC2
Figure E-3. Constant Diagram (Simplified)
Figure E-4. LED Display Pin Functions
SECTION F: ROUTINE MAINTENANCE
F-1 General
F-2 Required Test Equipment
F-3 Calibration Procedure
F-4 Battery Replacement Instructions
A
E-7B Failsafe Current Limiting Circuit
A-1. Introduction to the AMPTEC 630ES
The AMPTEC Series 620A and now the 630
Series Igniter Testers are becoming the
standard in the Explosive Safety Igniter
Circuit Test industry, and are designed to
provide extremely safe and reliable
resistance testing of explosive or volatile
devices. Safety Approvals from various
Safety Boards include, the U.S. Air Force (
620A-4) for generic use on Non-Nuclear
munitions. Some of the devices the 630ES
Failsafe Ohmmeter may be used on include:
fuses, squibs, igniters, explosive bolts,
automobile airbag initiators and many
others.
Essentially, a AMPTEC 630ES is a 4-wire
failsafe digital ohmmeter which has been
designed to reliably use very low test
currents for its resistance measurement.
Additional circuitry proprietary to
AMPTEC RESEARCH is used to ensure
that test current levels do not exceed the
specified "failsafe current" even in a worst-
case component failure situation. The
failsafe feature is tested in every instrument
before shipment.
The 620A and the newer 630 series
represent the latest in ultra-safe Igniter
Tester measurements. The 630ES uses the
same main printed circuit board (PCB) as
the AMPTEC 620A Igniter Tester. The
630ES has been made water-resistant and
has many features which make it useful in a
variety of applications. Please check the
front of this manual for any addendums that
may apply to new 630ESs and 630AN
conversions.
SECTION A: UNPACKING AND INSPECTION
A standard feature of the 630ES is a battery
monitoring circuit that alerts the user it is time to
recharge the batteries. Refer to section D-7 for
more details.
A-2. Unpacking and Inspection
If the shipping carton (box)
appears damaged, request that the
carrier's agent (i.e. UPS) be present
when the unit is unpacked. If the instrument
appears damaged, the carrier's agent should
authorize repairs before the unit is returned to the
factory. Even if the instrument appears
undamaged, it may have suffered internal damage
in transit that may not be evident until the unit is
operated or tested to verify conformance with its
specifications. You may refer to the Functional
Test section of Section D of this manual to help
identify the problem (i.e Test leads etc.) The
630ES has a set of test resistors built-in the
Functional Test Section that can quickly help the
user figure out where the problem is most of the
time. If the unit fails to operate or fails to meet the
performance specifications of Section B, notify
the carrier's agent and the nearest AMPTEC Sales
Office. Retain the shipping carton for the carrier's
inspection. DO NOT return equipment to
AMPTEC RESEARCH or any of its sales offices
prior to obtaining an (RMA) Return Material
Authorization number.
R M A
1
A-3. Opening the 630ES Igniter Tester
and removal of the Lid
When closed, the 630ES Explosive Safety
Igniter Tester has two large O-rings that
provide a very water resistant and on
occasion even an air tight seal. By
pressing down with your palm as
diagramed above you compress the O-ring
in the lid of the 630ES.. This makes it
easier to flip up the release latch. Repeat the
palm press step on the other corner of the
630ES while flipping up the release latch.
At this point the 630ES lid will normally be
able to be raised, and placed in an open lid
state.
If the 630ES doesn’t open after flipping up
the release latches, a change in atmospheric
pressure since the unit was last closed may
be the culprit. Turn the Air Pressure
Equalization or “Purge Valve” counter-
clockwise. Once air-pressure is equalized,
the 630ES can be opened. If the Purge
Valve was opened, return the valve to the
closed state (tighten = clockwise) once the
630ES lid is open. +
The 630ES has a way to remove it’s lid
completely, for example when used in an
indoor laboratory environment. With the
630ES open, remove the units two hinge
pins (hex type) by twisting them. The lid
should come free at the hinge. Once the lid is
removed replace the hinge pins in the hole they
were pulled out of.
A-4. AC/DC Battery Charger - Power
Requirements
The AMPTEC 630ES is powered by an
internal rechargeable heavy-duty nickel-
cadmium battery pack (4 ea D cell - 5.7 AHr).
The battery charge is maintained by an
external AC/DC converter that plugs into a
standard 115VAC receptacle. The AC adapter
provides 9VDC @ 1.1A. The AC Adapter
Battery Charger is configured with a keyed
connector that plugs into the “mating” keyed
connector on the 630ES front panel.
For safety reasons, the battery charger’s keyed
connector blocks access to the test lead
connections that are also part of the
the AC adapter must be connected for 4 hours in
order to fully restore the charge. If you need a
replacement AC/DC Battery Charger for the 630A,
contact the AMPTEC customer service department
and request an option “630DC” Battery Charger.
A-5. Setup and Use
Once the AMPTEC 630ES has had it’s batteries
charged for 12 to 24 hours it is ready for use. The
630ES consumes little power and generates virtually
no heat. Consequently, it may be used in any area
where the environment does not exceed the
specifications of Table B-2.
Avoid exposing the 630ES Explosive Safety Igniter
Tester to extremes of temperature which will affect
accuracy and shorten battery life-span.
630ES Explosive Safety Igniter Tester keyed
connector. In this way the user may not ever be able
to connect any test leads while the unit is charging.
The 630ES is designed so it is virtually impossible to
be powered (in operating - measurement mode)
directly from the AC line adapter. As an additional
note, the 630ES main power switch must also be in
the “Off/Charging” mode in order for the connected
battery charger to recharge the 630ES’s batteries.
For customers using 220VAC 50 HZ AC line power
for running the battery charger, please inform
AMPTEC’s sales department at the time of your
order and the appropriate adaptor will be included
with the 630ES Failsafe Ohmmeter shipment for an
additional fee.
A fully charged battery pack may power the 630ES
for approximately 8 to 10 hours before requiring a
recharge. Amptec installs a quality set of 4 each
Heavy Duty (5700 mAHr) Ni-Cad batteries. The
620A will also operate on a 4000 mAhr D cell Ni-
Cads with a shortened operating time between
charges.
The “Power” switch has two separate modes. The
“ON” position supplies internal battery isolated
power to operate the 630ES when they are charged.
If you turn on the 630ES, and the display does not
come on, it may indicate the batteries need charging.
The “OFF/CHARGING” power switch position is for
use when the batteries need charging or the 630ES is
not in use. As mentioned earlier of course the AC/DC
Battery Charger must be plugged into the 630ES’s
keyed connector to facilitate charging the batteries.
Although the batteries are fully charged prior to
shipment, it may be desirable to refresh the charge
for 24 hours before use. As a rule of thumb, the
630ES requires twice as much time to fully recharge
as the amount of discharge time. For example, if the
instrument was used continuously for 2 hours,
SECTION B - 630ES EXPLOSIVE SAFETY
IGNITER TESTER - SPECIFICATIONS
______________________________________________________________
Table B-2. Specifications
Accuracy: (for 1 year @25°C ± 10°C)
2.0 Ohm range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0.02% of reading ±0.05% of range
20 Ohm through 200 Ohm ranges . . . . . . . . . . . . . . . . ±0.02% of reading ±0.02% of range
200 KOhm range . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0.05% of reading ±0.05% of range
Temperature Range
Operating 0°C to 50°C
Storage -10°C to 70°C
Temperature Coefficient
2.0 Ohm through 200 Ohm ranges . . . . . . ±0.002% per °C (from 0°C-15°C and 35°C-50°C)
200 KOhm ranges . . . . . . . . . . . . . ±0.005% per °C (from 0°C-15°C and 35°C-50°C)
. . . . . . . . . . . . . . . . . . . .
Instrument Display . . (20,000 count) 4½ digit Super Bright Light Emitting Diodes (LED)
Over-Range Indication . . . . . . . . . . . . . . . . ( select next higher range) 630ES Display flashes
Measurement Update Rate . . . . . Approximately 300ms (~3 per second)
Voltage Protection - Maximum Input . . . . 250VDC or AC without damage
peak
Open Circuit Current Source Compliance Voltage . . . . . clamped at ~1.6 volts ( ± 2% )
Power . . . . (4 "D" 5.0 AHr Heavy Duty) 1.2V rechargeable nickel-cadmium batteries
Fuse . . . . . . 2 ampere fast blo (3 AG type)
AC/DC Battery Charger (Option 630DC) provides 9VDC at 1.1 Ampere nominal
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5" (34.3cm) W x 12" (30.5cm) D x 6"(15.2cm) H
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 lbs net; 15 lbs shipping
Conversion Rate . Approximately 3 per second
Functional Test Section - The 630ES Functional Test Section provides added measurement integrity using a
milliammeter and test resistors to cross check the overall 630ES operation whenever desired. The test
resistors are for cross checking 630ES basic operation and should not be used for calibration purposes.
Simpsontm DC Milliammeter Range - 0-10 mA fullscale, Accuracy ±3%
FTSR1 01-23572 0.1 Ohm 3.0 % Resistor, Tc-50ppm/°C 1/4W
FTSR2 01-23573 1.0 Ohm 3.0% Resistor, Tc- 50ppm/°C 1/4W
FTSR3 01-23574 10.0 Ohm 3.0% Resistor, Tc- 50ppm/°C 1/4W
FTSR4 01-23576 100.0 Ohm 3.0% Resistor, Tc- 50ppm/°C 1/4W
FTSR5 01-23580 100 KOhm 3.0% Resistor , Tc- 50ppm/°C 1/4W
FTSR6 01-23582 190 KOhm 3.0% Resistor, Tc- 50ppm/°C 1/4W
MILLAMPERES
2
4
6
8
10
1.0 OHM
190K OHM
CHAPTER C - REPLACEABLE ITEMS,
OPTIONS AND ACCESSORIES
C-1. Available Accessories and Options
This manual does not list all possible
accessories that AMPTEC RESEARCH is
willing to provide as a support items for the
630ES Explosive Safety Meter Igniter Tester.
Contact the sales department at AMPTEC if you
have a request for an item that is not described
here. Listed below are the options available for
use with the AMPTEC 630ES Explosive Safety
Meter Igniter Tester.
Option 630-BAT: Replacement Battery Pack
The rechargeable NICAD battery pack
installed in the 630ES Explosive Safety Meter
should provide trouble-free operation.
Replacement, however, may eventually be
necessary. The 630ES Explosive Safety Meter
battery pack uses four "D cell" - 1.2V (5.0 AHr
NICAD recommended) installed in a
rechargeable battery pack.
C-2. 630ES Test Lead and Connector Sets
All AMPTEC Explosive Safety - Igniter Tester /
Failsafe Ohmmeter Test Leads and Probe sets
are a minimum 48" length. One end of the test
lead set is terminated with the mating connector
for 630ES Front panel connection port (user
specified). AMPTEC RESEARCH's website
http://www.amptec.com should also provide the
latest information on accessories available.
Option 630-300 : A 4 Terminal Kelvin Clip
Lead Set (630ES compatible)
The option "630-300" is a shielded 48" lead set
terminating in ½" opening Gold Plated 4
Terminal Kelvin clips that is AMPTEC 630ES
compatible. The option "630-300" can clip
easily to wires, pins, and medium size (up to ½"
diameter) conductors. Option "630-300" is the
recommended Kelvin Clip four wire lead set for
the 630ES Series Igniter Testers. The notched
connector end plugs directly into the 630ES’s J1
main front panel connector labeled for “test
leads”.
(photo shows AMPTEC 630ES battery pack)
The reliability of the 630ES battery pack is
estimated to be ten fold better than individual
batteries simply placed in the battery holder.
AMPTEC RESEARCH does not recommend
using individual NICAD batteries in lieu of the
AMPTEC 630ES battery pack, and as such
would be deemed a violation of product
warranty. To order a replacement
AMPTEC630ES Explosive Safety Meter
NICAD battery pack specify AMPTEC part
number "OP630-BAT".
The option "630-400" can clip easily to wires,
pins, and medium size (up to ½" diameter con-
ductors). The notched connector end plugs
directly into the 630’s J1 main front panel con-
nector labeled for “test leads”.
Option 630-305: Separate/Twin Banana Plug
(Red tipped and Black tipped) Cable Set
Option "630-305" is a 48" long replacement
cable set normally supplied as part of the
AMPTEC 630BN Ohmmeter package. The
Option “640-305 has two single banana plugs
(meter and common) terminated with the
630BN style notched connector. One banana
plug is red (Voltage high and Current High) and
one banana plug lead end is black (Voltage low
and Current low) . The 4-wire configuration is
maintained up to the point of the banana plug,
eliminating most cable resistance effects.
Option 630-Plug: For Custom Test Harnesses
Option "630-Plug" is the 630Test Lead Plug
along with 8 gold pin/sockets for custom wir-
ing/missile test harness applications.
Contact the sales department at AMPTEC
RESEARCH (phone 1-800-350-5105 from
inside the USA) if you have need for a special
probe, adapter, lead set, or custom option..
AMPTEC’S engineers have helped customers
with special igniter tester accessory require-
ments. Check with our website which is
http://www.amptec.com for latest AMPTEC
RESEARCH contact (address and phone #
changes) information.
C-1. Available Accessories and Options
This manual does not list all possible
accessories that AMPTEC RESEARCH is
willing to provide as a support items for the
630BN Igniter Tester. Contact the sales
department at AMPTEC if you have a request
for an item that is not described here. Listed
below are the options available for use with the
AMPTEC 630BN Igniter Tester.
Option 630DC: Battery Charger
Option "630DC" is an AC/DC converter that
converts 115VAC line voltage to 9VDC at 1.1A.
The 630 Battery Charger is fitted with the
mating plug that connects to the unit’s J1
connector. One charger is provided as a standard
accessory with every 630ES Igniter Tester .
Replacement Batteries
The rechargeable NICAD batteries installed in
the 630ES should provide trouble-free
operation. Replacement, however, will
eventually be necessary. The 630ES uses four
1.2V cells (5.7 AHr recommended) installed in a
reusable battery box. The batteries are held in
place by a metal retaining plate. When
ordering replacement batteries, please specify
AMPTEC Stock #05-10117, quantity four (4).
C-2. Test Lead and Connector Sets
Option 630-400: 4 Wire Kelvin Lead Set
Option "630-400" is the recommended Kelvin
four wire lead set for the 630 Series Igniter
Testers ( especially for versions that have a 2
Ohm range). Option 630-300 is a shielded 48"
lead set terminating in ½" opening Kelvin clips.
A
B
C
D
E
F
H
G
A= I High
B= V High
C= V Low
D= I Low
E=
F= Ground (-)
G=Chassis Ground
H= +5 V
The AMPTEC 630ES Igniter Tester test leads are normally 48" long. The 630ES uses the water-resistant
ITT Cannon Tridenttm (Test Lead mate) connector on its front panel. Most all AMPTEC 630 series
ohmmeter 4 Wire Kelvin test leads are compatible.
Option "630-304" Gold 4-Wire Kelvin Banana Jack
Test Lead Set ( twin single banana jack version also available)
Option "630-401" Gold 4-Wire Kelvin
Single Point Probe Lead Set are 4 wire
to the base of each tip
Option "630-304"
Gold 4-Wire Kelvin
Clip Test Lead Set
Option "KCS"
Kelvin Clips accept
banana jacks in back.
works with
Option "630-403" is a 4-wire Kelvin
Handheld Probe Lead set terminated with
two handheld probes (2 sharp pointed gold
plated spring loaded tips per probe).
SECTION C: REPLACEABLE ITEMS & ACCESSORY ITEMS CONTINUED
The AMPTEC 630ES Explosive Safety Igniter Tester is compatible with most all 630 series
accessories and test leads. Including the option "PG-401" 4 Wire Kelvin type
Pistol Grip Kelvin Probes (OP PG-401) shown below.
Option "PG-401" 4 Wire Kelvin
Pistol Grip Probes/Test Leads
Option "630-305" twin single banana jack lead set
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