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.

ii
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

iii
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.

3
*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

4
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.

6
ELECTRICAL
Output 0-2000 Volts AC or 0-2800 Volts DC .
Pigtail and Receptacle adapters available for most
configurations. Consult factory.
Leakage Current 0-20 mA AC; 0-5 mA DC
Pass/Fail Criteria:
Continuity: 3 ohms ± 5% * (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.
Voltage Ramp-down Time: Factory set 1 sec. approx.
Pass/Fail Repeatability ±3%
Meter accuracy + 20VAC (1% of full-scale reading)
+20 VDC (0.75% of full-scale reading)
Duty cycle 100 %
Test adjustments Rear Panel: Ramp Time
TestTime
Leakage Limit
VoltageAdjust
Tamperproof operation available by removing
adjustment shafts.
ENVIRONMENTAL
Operating Temperature 15-40°C
Relative Humidity Range 0-90% non-condensing
GENERAL
Input power requirements Model HT-3000: 114-127 volts, 50/60 Hz
Model HT-3000L: 98-120 volts, 50/60 Hz
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; 3 ohm pass/fail point*. May be defeated
for testing of products with two wire power supply
cords.
Leakage Test Provided; 5 mA AC/1 mA DC factory set pass/fail
point, user adjustable. 120Kohm calibration resistor
provided on rear panel.
Operation Instructions Provided on rear panel.
Table 1. HT-3000 Specifications
*Continuity Level can be adjusted from .5 to 5 ohms during the calibration procedure.

7
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 short shipment to
Compliance West USA. The container should
include the following:
•The HT-3000 Dielectric Withstand Tester
•A black 18 AWG Test Return Lead
(Alligator Clip/Banana Plug ends)
•A red 18 AWG High Voltage Test Lead
(Alligator Clip/High Voltage jack)
•A Power Cord to provide power to the
HT-3000.
•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 two inches of shock-absorbing material
on all sides of the container.
Remove the Tester from its container and place
it on a test bench.
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.
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-
Fuseholder 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 HT-3000 from the source of
supply.
3. Remove the power cord from the HT-3000.
4. Using a small screwdriver, pry open the
fuseholder door.
5. Replace the fuse with a new one of the
correct rating.
6. Replace the fuseholder 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-3000 are shown in Figure 2
and described in Table 2. The rear panel
features of the HT-3000 are shown in Figure 3
and described in Table 3.

8
Figure 2. Controls, Indicators, Connectors - Model HT-3000 Front Panel

9
ITEM NAME FUNCTION
1 RESET Button / Red Indicator When lit, indicates that the HT-3000 is unarmed. This button must be pushed before the TEST Button is
functional. When the RESET Button is pressed, the red RESET indicator goes out and the yellow TEST
indicator is lit. PRESSING THE RESET BUTTON AT ANY TIME STOPS TEST.
2
TEST Button / Yellow
Indicator When lit, indicates that the HT-3000 is ready to test the connected equipment. The yellow TEST indicator goes
out when the TEST Button is pressed.
3 Ground OK / Ground Open
LED's Indicates result of Ground test between grounding pin of the line cord and exposed metal parts of the
equipment under test. If the ground circuit has more than three ohms resistance, or if the leads are not properly
connected, the red Ground Open LED will light, the internal buzzer will sound, and the test will be
terminated. If the ground circuit resistance is acceptable, the green continuity LED will light and the test will
continue. If the continuity test is defeated by the operator, both LED's will be lit for the duration of the test.
4 Excess Leakage LED Indicates failure of leakage current test. If leakage current between the primary circuit and ground is higher
than the preset value, the red LED will light, the internal buzzer will sound, and the test will be terminated.
5 Full Voltage LED If full voltage is successfully reached, the Full Voltage LED will light and the high voltage duration timer
starts.
6 Hipot Fail LED Indicates failure of high voltage test. If arcing or a flashover of the insulation system between primary parts
and ground is encountered, the red breakdown LED will light, the internal buzzer will sound, and the test will
be terminated.
7 Hipot Pass LED At the end of the preset high voltage duration time, if no insulation breakdowns are encountered, the green light
will light and the test will terminate.
8 Voltage Meter Provides visual indication to the operator of the actual output voltage of the Tester. Used to set the automatic
voltage level during the setup procedure.
9 Ramp Bar Graph LED’s Individual LED’s light in sequence from left to right as the test voltage ramps from zero to full voltage. LED’s
turn off (ramp back down) at end of test.
10 Return Lead Receptacle Grounded banana plug receptacle. The 18 AWG Test Return Lead provided is connected here.
11 High Voltage Device
Receptacle NEMA 5-15R receptacle. For connection of the equipment under test.
12 High Voltage Test Jack Red High Voltage jack. For connection of high voltage test lead for testing insulating materials, etc.
13 AC/DC Switch Selects AC or DC output. Changing switch setting does not change output until the next time the Reset button
is pushed.
Table 2. Controls, Indicators, Connectors - Model HT-3000 Front Panel

10
Figure 3-2. Controls, Indicators, Connectors - Model HT-3000 Rear Panel

11
ITEM NO. NAME FUNCTION
1 Ground Check Switch Turn ON for use with three-wire (grounded) power supply cords.
Turn OFF for use with two-wire power supply cords.
(When ON, conducts Continuity Test between the chassis and the grounding pin of the line cord of the
equipment being tested. When OFF, Continuity Test is bypassed for testing of double-insulated
equipment and other types of equipment without a grounding pin in the line cord.)
2
Directions Provides directions for Tester operation to test personnel.
3 Ramp Time Adjustment Used to adjust the amount of time used to increase the high voltage from zero volts to the required level.
See "Adjustment of the High Voltage Ramp Time" for this procedure.
4 Test Time Adjustment Used to adjust high voltage test duration. See "Adjustment of the High Voltage Test Duration" section
for this procedure.
5 Leakage Limit Adjustment Used to adjust the trip level for the excessive leakage current test. See "Adjustment of the Leakage
Current Level" section for this procedure.
6 Voltage Adjust Used to adjust the High Voltage output. See "Adjustment of the High Voltage Level" section for this
procedure.
7 Calibration Resistor Used in the Leakage Limit Adjustment procedure. See "Adjustment of the Leakage Current Level"
section for more information
8 Appliance Inlet / Fuseholder /
Power Switch Use supplied cordset to connect Tester to appropriate source of supply. Replace line fuse. Turn Tester ON/OFF.
9 Fuse replacement warning /
Rating of supply
Specifies replacement fuse and supply voltage used.
Table 3 Control, Indicators, Connectors - Model HT-3000 Rear Panel

12
Initial Checkout Procedure
The following procedure will verify that the
Tester is working correctly. We recommend that
this procedure be conducted periodically to
ensure proper operation of the Tester.
The following items are needed to conduct this
procedure:
A test lead with a banana plug on one end.
The other end will be clipped to the
alligator clip end of the black test lead
supplied with the HT-3000.
CAUTION
High voltage (up to 2000 Volts
AC or 2800 Volts DC)
generated by the HT-3000 is
exposed during this test. A
risk of shock exists. Exercise
care when using the HT-3000.
1. Connect the Tester to a proper source of
supply using the included 18 AWG power
supply cord. Turn the HT-3000 on.
2. Turn the Ground Check switch on the
rear panel to Off.
3. Disconnect all leads.
4. Push the red RESET button. Verify the
yellow TEST indicator is lit.
5. Push the yellow TEST button.
6. The Tester should conduct a test sequence.
At the end of the test, the Ground OK,
Ground Open, Full Voltage, Hipot Pass,
and red RESET lamps should be lit.
7. Turn the Ground Check switch on the
rear test panel On.
8. Verify that all test leads are disconnected
from the HT-3000.
9. Push the red RESET button, then the
yellow TEST button.
10. The Tester should sound the buzzer. The
Ground Open and red RESET LED’s
should be lit.
11. Plug the supplied Test Lead into the
RETURN receptacle on the front panel.
12. Connect the banana plug end of the extra
test lead into the grounding jack of the
orange DEVICE receptacle. The
grounding jack is circular in shape and is
located at the bottom of the DEVICE
receptacle.
13. Connect the other end of the extra test lead
to the black lead plugged into the
RETURN receptacle.
14. Push the red RESET button and then the
yellow TEST button.
15. The Tester should conduct a test sequence.
At test termination, the Ground OK, Full
Voltage, Hipot Pass, and Red RESET
LED’s should be lit.
16. Turn the Ground Check switch on the
rear panel "Off".
17. Disconnect the extra test lead from the
DEVICE receptacle. The black lead
should remain plugged into the RETURN
jack on the front panel.
18. Connect the red high voltage test lead to
the High Voltage Test jack on the lower
right corner of the front panel. Connect
the other end of the red high voltage test
lead to the black lead that is plugged into
the RETURN jack.
Keep clear of the wire while the test is
in progress.
19. Push the red RESET button and then push
the yellow TEST button.
20. The tester should conduct a test sequence,
terminated with a buzzer. At test
termination, the Ground OK, Ground
Open, Excess Leakage, and red RESET
LED’s should be lit.
Note: The Hipot Fail LED may also light
during this test.
Note: The following procedure
tests the "Hipot Breakdown"
circuit of the HT-3000 and
involves high voltage. The only
exposed parts during this test are
at ground potential. However,
the voltage inside the High
Voltage Device socket may be as
much as 2800 volts. Proceed
with caution.
22. Make sure the black lead is still plugged
into the RETURN jack on the front panel,
and the red high voltage test lead is
plugged into the High Voltage Test jack.
23. Make sure the Ground Check switch on
the rear panel is Off.
24. Carefully hold the black lead by its
insulated alligator clip boot.
25. Push the red RESET button, then the
yellow TEST button. After the Full
Voltage LED lights, and before the Hipot
Pass LED has lit, touch the ends of the red
and black leads together.

13
26. The test should immediately terminate
with a buzzer. The Ground OK, Ground
Open, Full Voltage, Hipot Fail and red
RESET lamps should be lit.
Note: Depending on how the connection
between the two test leads is made, the
Excess Leakage LED may light, and in
some instances, the Ground OK LED
may extinguish.
Passage of these tests indicates that the
HT-3000 is functioning properly and that it is
safe to use.
If the results of the performance test are
not in accordance with the above, service is
required. Remove the HT-3000 from service
and contact the manufacturer for servicing
information.
Setting up the HT-3000 for
Production Line Testing
This section describes procedures for setting the
pass/fail leakage current level, high voltage ramp
time, high voltage level, and high voltage test
time. The HT-3000 is calibrated as shown
below at the factory to be usable without
adjustment in the majority of applications. If the
factory settings are acceptable, you may skip this
section.
Factory Settings
The HT-3000 is configured as shown when
shipped from Compliance West USA:
Voltage Type: AC
Leakage Current Level: 5 mA
High Voltage Ramp Time: 1 second
High Voltage Level: 1200 volts
High Voltage Test Time: 2 seconds
Adjustment of the various settings are shown
below.
CAUTION
High voltage is generated by
the HT-3000. Although the
chassis of the equipment under
test is grounded by the HT-
3000, a risk of shock exists.
Exercise care when using the
HT-3000.
NOTE
These adjustment procedures set
the use parameters of the HT-
3000. They do not take the place
of the annual calibration required
by the safety agencies.
Adjustment of the Leakage
Current Level
AC Leakage Current can be set to levels
of up to 20 mA. DC Leakage Current can be set
to levels of up to 5 mA.
Calibration is checked using the
120 kohm resistor and the Leakage Limit
adjustment on the rear panel. This procedure
requires the high voltage adjustment to be set to
a level determined by Ohm's law. After this
procedure, the high voltage level is to be reset
using the procedure Adjustment of the High
Voltage Level, and the test time is to be reset
using the procedure Adjustment of the High
Voltage Test Time.
NOTE
High voltages are present on the
calibration resistor during this
test. We recommend that you
remove it from the back panel of
the HT-3000 and lay it on a non-
conductive surface well away
from the rear panel adjustments
while conducting this test.
1. Determine the proper voltage meter setting
for the desired leakage current level, using
the formula:
Voltage=(Leakage Current in mA)X(120).
Example: A 5 mA current level is desired.
The voltage needed is:
(5mA)X(120)=600 volts.
1a. Note: For leakage current levels higher
than 16 mA, calculated voltages exceed
the capabilities of the resistor supplied
with the HT-3000. An external resistor
having a lower value must be used in
place of the 120 kohm resistor. Substitute
the formula:
V=(Leakage Current in mA)X(Kohm)
where Kohm is the resistance, in kohm, of
the resistor used. Select a resistor which
results in a voltage of 1500 volts ±20%.
Example: An 18 mA leakage current
threshold is desired. The desired voltage

14
is 1500 volts. The approximate resistor
value is determined:
1500=(18mA)(Kohm).
Solving for the resistor value:
(Kohm)=1500/18mA=83Kohm
Select a convenient resistor value and
solve for the voltage:
(76Kohm)(18mA)=1368 Volts
2. Turn the Ground Check switch on the
rear panel Off.
3. Connect the HT-3000 to a correctly rated
source of supply and turn the power
switch to the I or ON position. Push the
RESET button. The yellow TEST
indictor should light, indicating that the
Tester is ready to test.
4. Adjust the Test Time control on the rear
panel to approximately the middle of its
travel.
5. Make sure there are no test leads
connected to the HT-3000. Push the
TEST button.
6. The voltage will ramp and hold after
approximately one second. Using the
front panel meter, set the Voltage Ajust
control to the value determined in 1.
above. After the voltage value has been
set, the test can be stopped by pressing the
RESET button.
7. Turn the Leakage Limit control on the
rear panel to its maximum clockwise
position.
8. Connect the black test lead to the
RETURN receptacle and the red high
voltage test lead to the High Voltage
output jack, both on the front panel of the
HT-3000. Connect the two leads across
the 120kohm resistor on the rear panel. (If
a special resistor value is being used,
connect the leads to it instead.) Make sure
neither clip touches the chassis of the HT-
3000.
9. Push the red RESET Button and then the
yellow TEST Button. First, make a coarse
adjustment by waiting until the Full
Voltage LED lights. Turn down the
Leakage Limit control on the rear panel
until the buzzer sounds and the Excess
Leakage LED lights. Repeat step 9 until
the exact setting is reached. The exact
setting is the minimum possible setting of
the Leakage Limit control which still
allows the Tester to reach full voltage and
light the Full Voltage LED. If the red
Excess Leakage LED lights, the
adjustment is set too low. Turn the
Leakage Limit control up slightly and
repeat Step 9 until the correct setting is
achieved.
10. If tamperproof settings are desired, the
Leakage Limit control shaft may be
pulled away with a slight tug. (It may be
reinserted for future adjustments.)
11. Remove the test leads from the front
panel. Check the position of the Ground
Check switch. After this procedure, the
high voltage level is to be reset using the
procedure Adjustment of the High
Voltage Level, and the test time is to be
reset using the procedure Adjustment of
the High Voltage Test Time.
Adjustment of the High Voltage
Ramp Time
This procedure controls the amount of time used
to ramp the high voltage to the required level.
The factory setting of one second is adequate for
most situations. Use this procedure if
adjustment to a different ramp time within the
range of 1-5 seconds is required.
1. Defeat the Ground Check by turning the
rear panel switch Off.
2. Connect the HT-3000 to a correctly rated
source of supply and turn the power
switch to the I or ON position. Push the
RESET button. The yellow TEST light
should light, indicating that the HT-3000
is ready to test.
3. Make sure there are no test leads
connected to the HT-3000. Push the
TEST button.
4. When the TEST button is pressed, the
voltage will ramp and hold. Adjust the
Ramp Time control on the rear panel until
the desired ramp time is reached. The test
can be terminated at any time by pressing
the RESET button.
5. If tamperproof settings are desired, the
Ramp Time control shaft may be pulled
away with a slight tug. (It may be
reinserted for future adjustments.)
6. Check the position of the Ground Check
switch before testing.
Adjustment of the High Voltage
Level

15
This procedure controls the high voltage level
used in the dielectric withstand test. It is
specified by safety agency personnel. Most
safety agencies allow a shorter duration test
(usually 1 sec. vs. 1 min.) if the voltage is
increased by 20%. The HT-3000 is factory set
for 1200 volts AC, a voltage level used for the
one second duration test for many types of
equipment. Consult the safety agencies for the
required voltage level for the type of equipment
being tested. If a different voltage level is
required, use this procedure to set it.
1. Defeat the Ground Check by turning the
rear panel switch Off.
2. Adjust the Test Duration control to
approximately the middle of its travel.
3. Connect the HT-3000 to a correctly rated
source of supply and turn the power
switch to the I or ON position. Push the
RESET button. The yellow TEST light
should light, indicating that the HT-3000
is ready to test.
4. Make sure there are no test leads
connected to the Tester. Push the TEST
button.
5. After the TEST button is pressed, the
voltage will ramp and hold. Set the
Voltage Adjust control on the rear panel
to the desired voltage.
6. If tamperproof operation is desired, we
suggest placing a calibration-style label
over the voltage adjust hole.
7. Check the position of the Ground Check
switch, and reset the test time using the
procedure Adjustment of the High
Voltage Test Time.
Adjustment of the High Voltage
Test Duration
This procedure sets the amount of time the
Tester will conduct the high voltage test. The
test time is specified by the safety agencies and
is tied to the test voltage. Most safety agencies
allow a much shorter test (usually 1 second vs. 1
minute) if the voltage is increased by 20%. The
HT-3000 is factory set for 2 seconds. Consult
the safety agencies for the test time for the type
of equipment being tested. If a different test
time is required, use this procedure to set it.
1. Defeat the Ground Check by turning the
rear panel switch Off.
2. Connect the HT-3000 to a correctly rated
source of supply and turn the power
switch to the I or ON position. Push the
RESET button. The yellow TEST
indicator should light, indicating that the
HT-3000 is ready to test.
3. Make sure there are no test leads
connected to the Tester. Push the TEST
button.
4. After the voltage has ramped, the Full
Voltage LED will light. The test time is
measured from when the Full Voltage
LED lights to when the voltage begins to
ramp down. Time the test.
5. After the test is complete, adjust the Test
Time control on the rear panel. If the time
desired is shorter, turn the Control
counterclockwise, and vice versa.
6. Push the RESET Button, then the TEST
Button and time the new test. Adjust the
Test Time control until correct.
7. Check the position of the Ground Check
switch before conducting testing.
Setting the Ground Check Switch
This switch controls whether the
Ground Test is conducted between the chassis
and the power supply cord grounding pin of the
unit being tested. The safety agencies require
that this test be conducted on all equipment
using a three-wire power supply cord. For other
types of equipment, such as some portable lamps
and all double-insulated equipment, there are
only two wires in the power supply cord and the
ground continuity check is waived by the safety
agencies.
If the power supply cord of the
equipment being tested has only two pins, the
Ground Check switch should be set to the Off
position. When the Ground Check switch is
turned Off, both the Ground OK and Ground
Open LED's on the front panel are lit as a
reminder to the operator that the ground
continuity test is not being conducted.
If the power supply cord of the
equipment being tested has three pins, the
Ground Check switch should be set to the On
position.
When testing with the Ground Check
switch Off, the operator must ensure that the
Return lead is properly connected to exposed