Compliance West HT-3000 User manual

HT-3000
Dielectric Withstand Tester
0-2000 Volts AC Output
0-2800 Volts DC Output
Instruction Manual
COMPLIANCE
WESTUSA

Rev. 2.2 May 4, 2005 i
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.
Compliance West USA stands by your instrument with a full one-
year warranty and a loaner instrument policy. If the need arises,
please don't hesitate to call on us.
Thank you for your trust and confidence.

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Table of Contents
An Introduction to Dielectric Withstand Testing with the HT-3000..........................................................1
Safety Precautions........................................................................................................................1
Test Personnel................................................................................................................1
Testing Area...................................................................................................................1
Safety Techniques..........................................................................................................2
Using the HT-3000 Dielectric Withstand Tester..........................................................................2
Ground Check................................................................................................................2
Ground Check Failures....................................................................................2
Defeating the Ground Check...........................................................................3
Leakage Test..................................................................................................................3
Sporadic Leakage Current Failures .................................................................3
Chronic Leakage Current Failures...................................................................3
High Voltage Dielectric Withstand Test........................................................................4
High Voltage Dielectric Withstand Test Failures............................................4
High Voltage Discharge..................................................................................4
Testing Equipment with non-Standard Plugs or Pigtail Operation................................4
Introduction and Specifications..................................................................................................................5
Introduction..................................................................................................................................5
Specifications...............................................................................................................................5
Operation....................................................................................................................................................7
Setting up your Tester..................................................................................................................7
AC Line Voltage Requirements...................................................................................................7
Fuse Replacement ........................................................................................................................7
Front and Rear Panel Features .....................................................................................................7
Initial Checkout Procedure...........................................................................................................12
Setting up the HT-3000 for Production Line Testing ..................................................................13
Factory Settings .............................................................................................................13
Adjustment of the Leakage Current Level.....................................................................13
Adjustment of the High Voltage Ramp Time................................................................14
Adjustment of the High Voltage Level..........................................................................14
Adjustment of the High Voltage Test Duration.............................................................15
Setting the Ground Check Switch..................................................................................15
Operating Techniques..................................................................................................................16
Daily Operation Test......................................................................................................16
Testing ...........................................................................................................................16
Test Verification procedure when using the HTT-1 function checker:...........16
Test Verification procedure when NOT using the HTT-1 function
checker: ...........................................................................................................17
Test results.....................................................................................................................17
Hipot Pass........................................................................................................17
Red LED/Buzzer .............................................................................................17
Technical Assistance..................................................................................................................................19

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Maintenance and Calibration......................................................................................................................20
Service Information......................................................................................................................20
General Maintenance ...................................................................................................................20
Interior Access...............................................................................................................20
Calibration Access...........................................................................................20
Cleaning.........................................................................................................................21
Performance Test .........................................................................................................................21
Operation/Function Test................................................................................................21
Calibration Procedure ..................................................................................................................22
Meter Calibration Adjustment .......................................................................................22
Continuity Calibration Adjustment................................................................................23

iv

1
Section 1
An Introduction to Dielectric Withstand Testing with the HT-3000
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.
Safety Precautions
The dielectric withstand test generates voltages of up to 2000 volts ac at potentially lethal current
levels. Currents of as little as 5 mA at 120 volts can cause death, and the HT-3000 is capable of generating
20 mA AC at up to 2000 volts, and 5 mA DC at up to 2800 volts. The HT-3000 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.
It is imperative that a good ground be provided to the HT-3000. Before connecting the HT-3000,
ensure that a low-resistance ground is provided by the building wiring. If the HT-3000 is used on a high-
resistance grounding circuit, dangerous high voltages may be present to the operator. In addition, the

2
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-3000 can be shut off at any time by pressing the RESET
button.
The HT-3000 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 ready.
The HT-3000 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-3000 may not recognize the failure. The test will
continue for its normal length of time, and the HT-3000 may show a "PASS".
The HT-3000 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-3000 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-3000 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-3000 until the front panel meter reads zero volts.
Using the HT-3000 Dielectric Withstand Tester
The dielectric withstand test involves high voltage and caution should be exercised when using
the Tester. The Tester's return lead 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. In the sections below, the three tests are discussed.
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.
If the green Ground OK LED lights and the test continues, the connection between the grounding
pin and the exposed dead metal of the equipment being tested has a resistance of below three ohms*.
Ground Check Failures
If the red Ground Open LED lights, the buzzer sounds, and the test is terminated. The
connection between the grounding pin of the attachment plug cap and the exposed dead metal of the
chassis has a resistance of greater than three ohms*. This indicates a problem with the connection of the
HT-3000 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.

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*Special calibrations available by internal adjustment. Must be performed by qualified service personnel. See Sec. 5.
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. Additionally, the HT-3000 may not
recognize the failure. The test will continue for its normal length of time, and the HT-3000 may
show a "PASS".
To allow the HT-3000 to test equipment using a two wire power supply cord, the Ground check
can be defeated by turning the rear panel Ground Check switch Off. To remind the operator that the
Ground check is not being conducted, both the Ground OK and Ground Open LED's are lit continuously
during each test. When testing with the Ground Check switch Off, 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-3000 properly reports all failures.
Leakage Test
The HT-3000 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-3000 to ensure that excessive leakage does not
keep the Tester from developing full voltage required for the high voltage test. The HT-3000 will provide
full voltage at any leakage current level up to 20 mA. The leakage current trip level is adjustable on the
rear panel.
The leakage test is conducted by shorting the power 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 lights and the test continues, the leakage current was below the
amount set by the rear panel adjustment.
Sporadic Leakage Current Failures
If the red Excess Leakage LED lights, the buzzer sounds, and the test is terminated. The leakage
current delivered to the equipment being tested was over the amount 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.
Chronic Leakage Current Failures

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If the the HT-3000 is being used to conduct an AC test and the leakage current adjustment is set to
20 mA and almost all examples of the model being tested fail, 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 20 mA to flow at the desired high voltage level, the
HT-3000 cannot successfully conduct an AC 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. If the problem was due to high leakage current, 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-3000 uses a separate high-frequency transformer circuit to check for and 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 lights, the test cycle has been successfully completed. The
equipment under test is in accordance with the preset test parameters. The HT-3000 is ready to test the
next piece of equipment.
High Voltage Dielectric Withstand Test Failures
If the red Hipot Fail LED lights, a problem has been found with the insulation system between
primary and ground. The equipment under test should be examined, reworked and successfully tested
before being shipped.
High Voltage Discharge
The HT-3000 is designed to discharge the high voltage after completion of the dielectric
withstand test. The equipment being tested should remain connected to the HT-3000 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.
Testing Equipment with non-Standard Plugs or Pigtail Operation
The front panel of the HT-3000 is provided with a high-voltage output connector, as well as 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. If tests of this type are contemplated, call us for information.

Rev. 2.2 May 4, 2005 5
Section 2
Introduction and Specifications
Introduction
This manual contains complete operating,
maintenance and calibration instructions for the
Compliance West USA Model HT-3000
Dielectric Withstand Tester.
The instrument is a bench-type Dielectric
Withstand Tester with AC or DC Output,
designed for production line testing.
The HT-3000 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.
•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.
•A non-defeatable rampdown circuit returns
output voltage to safe levels before test
termination. The Hipot Pass or Hipot Fail
light will not light until voltage has been
ramped down by the HT-3000.
•If a failure is encountered, the high voltage
output is disabled, a buzzer sounds, and any
voltage stored in the equipment being tested
is bled off by an internal rampdown circuit
in the HT-3000. Voltage discharge progress
shown by front panel meter.
•The failure mode is shown by the front
panel LEDs.
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-3000 allows custom setups for
voltage ramp, test time and leakage limit.
•The continuity check can be defeated by a
switch on the rear panel for testing of
products using a two wire power supply
cord.
•Ground continuity pass/fail resistance level
is adjustable during the calibration cycle.
•A 120kohm resistor is supplied on the rear
panel for leakage current checks.
The HT-3000 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.
Specifications
Specifications for the HT-3000 are listed in
Table 1.