Compliance West HT-2000PR User manual

Dielectric Withstand
Tester
HT-2000PR (AC only with Ground Continuity Check)
HT-2800PR (DC only with Ground Continuity Check)
HT-3000PR (AC/DC with Ground Continuity Check)
0-2000 Volts AC Output
0-2800 Volts DC Output
Instruction Manual

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Dear Customer:
Congratulations! Compliance West USA is proud to present you
with your Dielectric Withstand Tester. Your instrument features
a groundbreaking logic-controlled circuit design and ergonomic
front panel, and represents the latest in high voltage production
line testing.
To fully appreciate all the features of your new meter, we
suggest that you take a few moments to review this manual. If
the need arises, please don't hesitate to call on us.
Thank you for your trust and confidence.
Rev.1.1, September 2011

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Table of Contents
An Introduction to Dielectric Withstand Testing with the HT-PR .............................................................2
Safety Precautions ........................................................................................................................3
Test Personnel................................................................................................................3
Testing Area...................................................................................................................3
Safety Techniques ........................................................................................................................4
Using the HT-PR Dielectric Withstand Tester .............................................................................5
Ground Check ................................................................................................................5
Ground Check Failures ....................................................................................6
Defeating the Ground Check ...........................................................................6
Leakage Test ..................................................................................................................7
Sporadic Leakage Current Failures..................................................................7
Chronic Leakage Current Failures ...................................................................8
High Voltage Dielectric Withstand Test ........................................................................8
High Voltage Dielectric Withstand Test Failures ............................................8
High Voltage Discharge...................................................................................8
Testing Equipment with non-Standard Plugs or Pigtail Operation.................................9
Introduction and Specifications ..................................................................................................................10
Specifications ...............................................................................................................................11
Operation....................................................................................................................................................12
Setting up your Tester ..................................................................................................................12
AC Line Voltage Requirements....................................................................................................12
Fuse Replacement.........................................................................................................................13
Front and Rear Panel Features......................................................................................................13
Initial checkout procedure............................................................................................................18
Test Verification procedure when using the HTT-1 function checker:...........................18
Performance Test Using cables ......................................................................................19
Setting up the HT-PR for Production Line Testing ......................................................................22
Factory Settings..............................................................................................................22
High Voltage Level........................................................................................................23
High Voltage Test Time.................................................................................................24
Leakage Current Level...................................................................................................24
High Voltage Ramp Time ..............................................................................................25
Ground Resistance .........................................................................................................25
Ground resistance offset.................................................................................................26
Setting the Ground Check Switch ..................................................................................26
Operation Techniques ..................................................................................................................27
Daily Operation Test......................................................................................................27
Connections....................................................................................................................27
HT-PR output receptacle Description..............................................................27
Testing Connections ........................................................................................28
Test results .....................................................................................................................29
Hipot Pass........................................................................................................29
Red LED/Buzzer..............................................................................................29
Technical Assistance ..................................................................................................................................30
Maintenance and Calibration......................................................................................................................31
Introduction..................................................................................................................................31
Service Information......................................................................................................................31
General Maintenance....................................................................................................................32
Interior Access ...............................................................................................................32
Cleaning .........................................................................................................................32
Calibration Procedure...................................................................................................................32
Calibration and Software Version Information ..............................................................33

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Voltage Calibration Adjustment.....................................................................................33
Current Calibration Adjustment .....................................................................................34
Ground Resistance adjustment .......................................................................................35

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Section 1
An Introduction to Dielectric Withstand Testing with the HT-PR
The continuity test/dielectric withstand test is a production line test which is recognized by safety
agencies worldwide as a valid criterion of safe assembly of end-use equipment. The test ensures
that the primary circuit power and ground conductors were properly wired and connected for safe
operation. It also applies a high-voltage potential between power and ground conductors to make
sure that no unintentional leakage or arcing paths exist between power and ground. The test
consists of a ground continuity check, a leakage current check and a high voltage check. It is
non-destructive to the equipment under test, and can be accomplished in a short time.
The purpose of dielectric testing: Dielectric testing is a simple, non-destructive method of
verifying the adequacy of electrical insulation to withstand the sort of transients that can occur
during transient (surge) events. In addition, the dielectric test can verify that the insulation in
question has an adequate amount of performance "headroom". This is necessary to ensure that
the insulation does not fail because of degradation of the insulation due to aging, moisture, wear
due to vibration, etc.
The method of dielectric testing: A high voltage (typically 1000 Volts or higher) is applied
between two conductors that are "supposed" to be electrically insulated from each other. If the
two conductors (an insulated "live" wire, and a metal enclosure, for example) are completely
isolated from each other, then the application of a large voltage difference between the two
conductors will not allow current to flow between the conductors. The insulation will
"withstand" the application of a large voltage potential between the two conductors - hence the
term "dielectric withstand test". In general, there are two results of the test that are considered a
failure of the insulation: (1) excessive current flow during the test due to low insulation
resistance of the insulating material which separates the two conductors, and (2) an abrupt
dielectric breakdown due to electrical arcing or discharge, either through the insulation material,
over the surface of the insulation material, or a discharge through air.
The determination of a suitable test voltage: If the test voltage is too low, the insulation material
in question will not be adequately stressed during the test. This could cause inadequate
insulation to pass the test, and be considered acceptable. On the other hand, if the test voltage is
too high, then the test could cause permanent damage to an insulation material that is otherwise
adequate for the application. A general "rule of thumb" that is used for the testing of mains
wiring which operates at voltages of 120-240Vac is 1000V plus two times the operating voltage.
Using this rule, 120V wiring would be tested using a voltage of 1240Vac.
Duration of the test: Generally, the test voltage is applied for one minute, in order to adequately
stress the insulation. Many standards allow the test duration to be reduced to 1 second for
production-line testing in order to accommodate large-volume production testing. In this case,
standards quite often require that the test voltage be increased by 20% in order to ensure that the
shorter test duration of one second will adequately test the insulation in question
The following figure show the most common application of this tester, in this kind of devices the
three different test are perform, the ground connection between the exposed metal or Chassis
with the grounding pin of the power supply, the insulation and leakage current between the
primary power and the ground pin of the device are verified.

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Figure 1. Test points of three-wire device.
In some cases the device under test is not necessary an electronic device, it could be any tool that
can be in contact with a source of electric power, for example an ordinary screwdriver, in this
case the only test that we can perform is the insulation between the handle and the metal of
contact (Defeating the ground connection test) to ensure the proper isolation of the handle.
Safety Precautions
The dielectric withstand test generates voltages of up to 2000 Volts AC (HT-2000PR & HT-
3000PR) or 2800 Volts DC (HT-2800PR & HT-3000PR) at potentially lethal current levels.
Currents of as little as 5 mA at 120V can cause death, and the HT-PR is capable of generating
20mA AC at up to 2000 Volts, and 5mA DC at up to 2800 Volts. The HT-PR has been designed
to minimize exposure to high voltages. However, the potential for serious injury or death exists
and personnel should be aware when they conduct this test.
Test Personnel
Personnel require special training to conduct the dielectric withstand test. They should
understand electrical fundamentals clearly, and be aware that high voltage is adept and creative
at completing a path to ground. Instructions should include a warning against any metal jewelry.
Operators should not allow others in the testing area, especially when tests are being conducted.
Organization is to be stressed. The operator should keep the area free of unused leads and
equipment.
Testing Area
The area used for conducting the dielectric withstand test should be as remote as possible from
normal production line activities. Only personnel actually conducting the test should be allowed
in the area, and it should be taped or roped off to preclude casual entry by other employees. In
addition, the area should be marked "WARNING - HIGH VOLTAGE TESTING" or the
equivalent to warn others of the nature of the testing taking place.
The bench being used should be non-conductive, and any exposed metal parts should be tied
together and grounded. If a conductive surface must be used, it should be grounded.
Because of sparking during a dielectric test failure, it is not safe to conduct dielectric withstand
tests in combustible atmospheres.

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It is imperative that a good ground be provided to the HT-PR. Before connecting the HT-PR,
ensure that a low-resistance ground is provided by the building wiring. If the HT-PR is used on a
high-resistance grounding circuit, dangerous high voltages may be present to the operator. In
addition, the power to the Testing Area should be provided with an easily reached shutoff switch
which can be actuated by personnel outside the Area if needed.
Safety Techniques
The high voltage circuit of the HT-PR can be shut off at any time by pressing the RESET button.
The HT-PR has been provided with a Reset switch to provide an unarmed "Standby" setting
when it is energized, but idle. When the red RESET button is lit the tester will not provide high
voltage until the RESET button and the TEST button have been pressed in order. To prevent
inadvertent operation, the operator should be instructed not to press the RESET button until the
test is finish.
The HT-PR is equipped with a Ground Continuity Check which will not allow high voltage to be
applied if the Test Return Lead is not properly connected. This is an important safety feature and
should not be defeated unless two wire products are being tested. In that event, it is imperative
that the operator make absolutely sure the Test Return Lead is properly connected to the
equipment being tested. If the lead is not properly connected, a dielectric withstand test failure
may energize exposed dead metal of the equipment being tested. Additionally, the HT-PR may
not recognize the failure. The test will continue for its normal length of time, and the HT-PR
may show a "PASS", see connections for more details.
The HT-PR has been designed for one-touch operation with the right hand. If possible, it should
be set up to the left and in front of the equipment under test. The equipment under test should be
connected to the HT-PR and then left alone by the operator. After the operator is clear of the
Tester and the equipment under test, he should press the RESET Button, then the TEST Button,
with his right hand. This will allow the greatest separation between the operator and the test
being conducted.
The HT-PR is designed to bleed the high voltage away after the test has concluded. In order to
ensure that any voltage present in the equipment being tested has been completely bled away, the
operator should not unplug the equipment under test from the HT-PR until the front panel meter
reads zero volts.

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Using the HT-PR Dielectric Withstand Tester
The dielectric withstand test involves high voltage and caution should be exercised when using
the tester. The return lead of the tester is connected to ground potential and when properly
connected to the equipment being tested, it will guard against the operator contacting high
voltage. Always make sure the return lead is firmly connected to exposed dead metal before start
testing. To make sure if the connections between the dielectric withstand tester and the
equipment under test is correct, see the connection section for more detail. In the sections below,
the three tests are explained.
Ground Check
The Ground check ensures that the grounding pin of the power supply cord is properly connected
to the exposed dead metal of the chassis. If this connection is absent, the exposed dead metal of
your product could be at line potential indefinitely after an internal wiring fault, causing risk of
shock to anyone touching it.
To make sure that the measure of the ground resistance is correct, the Offset resistance feature is
available in the HT-PR series, this ensures that the resistance of the cables doesn’t affect the
device ground resistance measurement.
This setting indicates the limit of the ground connection resistance value from 0.01 to 1.50Ω, for
the ground continuity test, the measured resistance must not exceed 2.00Ω(including the
resistance of the cables), otherwise the HT-PR will put an open ground result, in this test three
different values of resistance are involved, the measured resistance (continuously checked by the
HT-PR), the Resistance of the cables (offset resistance) and the resistance setting, the following
figure shows the different resistances involved in this test.
Figure 2. Device connection, resistances involved in a ground test.

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To perform the ground connection check test, follow the next steps.
1. Identify the Ground resistance limit of your device (Refer to your Device standard for
the resistance limit setting).
2. Modify if necessary the Ground resistance setting (see Adjustments).
3. Get your Test leads Resistance (see Ground offset in Adjustments section).
4. Connect the Device under test (see Connections section for examples).
5. Run the Dielectric Withstand Test.
Note: the HT-PR always measures the Total resistance connected to the return and Chassis
connector, the open ground point will be:
R open = R2 + R setting
Where R2 is the total resistance of the test leads, if the Ground connection resistance of the
device under test is equal or greater than the value of the resistance setting the R open point will
be reached.
If the green Ground OK LED light is on, the connection between the grounding pin and the
exposed dead metal of the equipment being tested has a resistance lower than the indicated on
the setting.
Ground Check Failures
If the red Ground Open LED light is on, the buzzer sounds, and the test is terminated. The
connection between the grounding pin and the exposed dead metal of the chassis has a resistance
higher than the indicated in the ground setting. This indicates a problem with the connection of
the HT-PR to the equipment being tested, or that the ground connection in the equipment being
tested is defective. The connection to the tester should be checked by removing the Test Return
Lead clip from the equipment under test and reconnecting it, taking care to make a good
connection. The unit should then be retested. If a failing result is repeated, the connection
between the power supply cord ground pin and the chassis of the equipment being tested should
be checked and reworked until a passing result is obtained.
Defeating the Ground Check
The Ground check can only be conducted on equipment using a three wire grounded power
supply cord. Some equipment, such as most portable lamps and all double insulated tools, have
only a two wire power supply cord, so the Ground test cannot be conducted.
Please note that defeating the Ground check should not be done except when necessary to
test two-wire devices. The Ground check feature provides an extra level of operator safety
because high voltage will not be applied if the Test Return Lead is not properly connected
to the exposed dead metal of the equipment being tested. If the Test Return Lead is not
properly connected, a dielectric withstand failure may energize exposed dead metal.

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Additionally, the HT-PR may not recognize the failure. The test will continue for its
normal length of time, and the HT-PR may show a "PASS".
To allow the HT-PR to test equipment using a two wire power supply cord, the Ground Check
can be defeated by turning the rear panel Ground Check switch to the Off position. To remind
the operator that the Ground Check is not being conducted, both the green Ground OK and red
Ground Open LED's will be lit continuously during the test. When testing with the Ground
Check switch in the Off position, the operator must ensure that the Test Return Lead is properly
connected to exposed dead metal of the equipment being tested for safety and to ensure that the
HT-PR properly reports all failures.
Leakage Test
The HT-PR leakage test uses a separate low-frequency circuit to check for excessive leakage
between primary power components and ground. There is not a specific leakage current level
pass/fail requirement at this time for most equipment, however, higher than normal leakage
current on a particular part may indicate an assembly or component problem in the primary
circuit.
The leakage current is also monitored by the HT-PR to ensure that excessive leakage does not
keep the tester from developing full voltage required for the high voltage test. The HT-PR will
provide full voltage at any leakage current level up to 20 mA AC (HT-2000PR & HT-3000PR) or
5mA DC (HT-2800PR & HT-3000PR). The leakage current trip level is adjustable on the rear
panel.
The leakage test is conducted by shorting the line and neutral conductors of the power supply
cord and applying high voltage between them and the exposed dead metal of the chassis of the
equipment being tested.
Excessive leakage current is not grounds for failure of the dielectric withstand test. Leakage
current is a normal result of capacitance in the primary circuit between neutral or line conductors
and ground. (In dielectric tests of some larger electric motors, leakage currents of as high as 95
mA are considered acceptable by safety agencies.) However, leakage currents higher than
normally anticipated for a particular model should not be ignored. This indicates problems of
low resistance up to a short circuit between line/neutral and ground, and failures should be
investigated. Failure modes are discussed below.
If the green Full Voltage LED light is on and the test continues, the leakage current is below the
limit set by the rear panel adjustment.
Sporadic Leakage Current Failures
If the red Excess Leakage LED light is on, the buzzer sounds, and the test is terminated, the
leakage current delivered to the equipment being tested was over the limit set by the rear panel
adjustment. If other equipment of the same type routinely passes this test, there may be a
problem with the primary circuit of the example being tested. The unit should be checked and
reworked if necessary.

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Chronic Leakage Current Failures
AC Dielectric Withstand testing charges all primary circuit capacitors connected line to ground
or neutral to ground. The current flowing through these capacitors is defined as leakage current.
If almost all examples of a model of equipment are not passing the leakage current test, we
recommend that the leakage current limit be increased by resetting the leakage current level on
the rear panel to a higher level.
If the leakage current adjustment of the HT-PR is set to 20mA AC or 5mA DC and almost all
examples of the model being tested are still failing, the primary circuit capacitance of the
equipment may be too high to allow the AC dielectric withstand test to be used. This is due to
the AC voltage charging all capacitors connected between primary voltage and ground. If the
overall value of these capacitors cause a leakage current of more than 20mA to flow at the
desired test voltage, the HT-PR cannot generate full voltage, and cannot successfully conduct the
dielectric withstand test.
However, a DC dielectric withstand test is acceptable for most categories of equipment and will
not charge the primary circuit capacitors. The DC test can be conducted by switching the front
panel switch to DC (only HT-3000PR). If the problem was due to high leakage current on the
capacitors of the circuit, the test should now be successful.
High Voltage Dielectric Withstand Test
This test checks for insulation system breakdowns between the primary and ground circuits. The
HT-PR uses a separate high-frequency transformer circuit to detect arc breakdowns.
The dielectric withstand test is conducted by shorting the line and neutral conductors of the
power supply cord and applying high voltage between them and the exposed dead metal of the
chassis of the equipment being tested. The duration of the test is controlled by the test time
control on the back panel. The test time is counted from the time the Full Voltage LED is lit to
the completion of the test.
If the green Hipot Pass LED light is on, the test cycle has been successfully completed. The
equipment under test is in accordance with the preset test parameters. The HT-PR is ready to test
the next piece of equipment.
High Voltage Dielectric Withstand Test Failures
If the red Hipot Fail LED light is on, a problem has been found with the insulation between
primary and ground. The equipment under test should be examined, reworked and successfully
tested before being shipped.
High Voltage Discharge
The HT-PR is designed to discharge the high voltage after completion of the dielectric withstand
test. The equipment being tested should remain connected to the HT-PR until the voltage has
discharged to a safe level to protect the operator and also to ensure that there is no energy stored
in the tested equipment.

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Testing Equipment with non-Standard Plugs or Pigtail Operation
The front panel of the HT-PR is provided with a NEMA Type 5-15R receptacle, suitable for
testing cord-equipped single-phase products designed for use on a 15 amp branch circuit in North
America. For other types of products, a different receptacle type or pigtail leads may be
required. Various adapters and pigtail leads are available from Compliance West USA, or you
can make your own, just make sure for the correct configuration see the description of the
outputs in the connections section. If tests of this type are contemplated, call us for information.

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Section 2
Introduction and Specifications
This manual contains complete operating, maintenance and calibration instructions for the
Compliance West USA Model HT-PR Dielectric Withstand Tester.
The instrument is a bench-type Dielectric Withstand Tester with AC and/or DC Output, designed
for production line testing.
The HT-PR features automatic one button operation, with numerous safety features designed to
protect the operator:
-The Return Lead is directly connected to ground potential for operator safety.
-In case of trouble, the test can be immediately terminated at any time by pressing the
RESET button.
-Before the test can commence, the unit must be armed by pressing the RESET Button.
The test will not begin until the TEST Button is pushed.
-If a failure is encountered, the high voltage is immediately shut down, a buzzer sounds,
and any voltage stored in the equipment being tested is bled off by a resistor bank in the
HT-PR. The voltage discharge progress is shown by the front panel meter.
-Failure modes are shown by the front panel LED's for quick troubleshooting.
Convenience and testing features include:
-Test results are determined quickly, without operator intervention.
-Operator instructions are printed on the rear panel for quick reference.
-The HT-PR allows custom setups for voltage ramp, test time, leakage limit and ground
resistance limit.
-The Ground check can be defeated by a switch on the rear panel for testing of products
using a two wire power supply cord.
-DC Voltage is discharged by a resistor bank within the HT-3000PR or HT-2800PR upon
test completion. Discharge progress is shown on the front panel meter.
The HT-PR meets all safety agency criteria for automatic production line Dielectric Withstand
Testers.
Your Tester is warranted for a period of one year upon shipment of the instrument to the original
purchaser.

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Specifications
ELECTRICAL
Output 0 - 2000 Volts AC HT-2000PR, HT-3000PR
0 - 2800 Volts DC HT-2800PR, HT-3000PR
Pigtail and Receptacle adapters available for most
configurations. Contact Compliance West for more
information.
Leakage Current 0-20mA AC HT-2000PR, HT-3000PR
0-5mA DC HT-2800PR, HT-3000PR
Pass/Fail Criteria:
Continuity: Pass/Fail Point user adjustable 0.01-1.50Ω±0.02Ω
(Defeatable).
Leakage Current: Pass/Fail point user adjustable.
Dielectric Breakdown: Separate high frequency detection circuit for
breakdown spike detection
Test Time: User adjustable 1-60 sec.
Voltage Ramp-up Time: User adjustable 1-5 sec.
Pass/Fail Repeatability ±3%
Meter accuracy + 2% from 500V to maximum limit voltage
Duty cycle 100 %
Test adjustments Rear Panel: Ramp Time
Test Time
Leakage Limit
Voltage Adjust
Ground Offset
Tamper proof operation available by removing
adjustment shafts.
ENVIRONMENTAL
Operating Temperature 15-40°C
Relative Humidity Range 0-90% non-condensing
GENERAL
Input power requirements See rear panel for input voltage and fuse ratings
Weight 10½ lbs.
SAFETY AGENCY TOPICS
Transformer Output < 500VA
Visual Indication of Voltage Output Provided by front panel meter, directly connected to
high voltage output
Failure Indication Audible, provided by internal buzzer
Visual, provided by red LEDs on front panel
Test automatically terminated on failure
Continuity Test Provided; pass/fail point adjustable. May be defeated
for testing of products with two wire power supply
cords.
Leakage Test Provided; 5mA AC/2mA DC factory set pass/fail
point, user adjustable.
Operation Instructions Provided on rear panel.
Table 1. HT-PR Specifications

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Section 3
Operation
This section describes how to set up and make measurements with your tester. We recommend
that you read the entire section carefully so that you can use all of the features of your tester.
Setting up your Tester
Your tester is shipped in a special protective container that should prevent damage to the
instrument during shipping. Check the shipping order against the contents of the container and
report any damage or incomplete shipment to Compliance West USA. The container should
include the following:
- The HT-PR Dielectric Withstand Tester
- An 18 AWG Test Lead (Alligator Clip/Banana Plug ends, black)
- An 18 AWG Line Power Cord to provide power to the HT-PR
- This Instruction Manual
If reshipment of the instrument is necessary, please use the original shipping container. If the
original shipping container is not available, be sure that adequate protection is provided to
prevent damage during shipment. We recommend that the instrument be surrounded by at least
three inches of shock-absorbing material on all sides of the container.
Remove the tester from its container and place it on a test bench.
Return Test Lead Power cord
Table 2. Included cables
AC Line Voltage Requirements
AC line voltage requirements for your Tester are noted on the rear panel of the instrument. Do
not connect the instrument to a different voltage source, use the power cord and make sure you
have a ground connection in your building before you start testing.

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Fuse Replacement
There is a user-replaceable fuse (F1) located on the rear panel of the instrument. It is located
behind a door in the Power Inlet-Power Switch-Fuse Holder device. The fuse rating is noted on
the rear panel. Do not attempt to replace it with a fuse of any other rating.
Use the following procedure to replace the fuse F1:
1. Turn the power switch to the O or OFF position.
2. Unplug the instrument from the source of supply.
3. Remove the power inlet cord from the instrument.
4. Using a small screwdriver, pry open the fuse holder door.
5. Replace the fuse with a new one of the correct rating.
6. Replace the fuse holder door and power inlet cord.
Front and Rear Panel Features
Before using your tester, take a few minutes to become familiar with the use of its controls,
indicators, and connectors. The front panel features of the HT-PR are shown in Figure 3 and
described in Table 3. The rear panel features of the HT-PR are shown in Figure 4 and described
in Table 4.

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Figure 3. Controls, Indicators, Connectors - Model HT-3000PR Front Panel