Compliance West HT-3000P-1A-AC User manual

HT-3000P-1A-AC
Dielectric Withstand Tester
0-3000 Volts AC 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 micro-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 contact us.
Thank you for your trust and confidence.
Rev. 1.0, February, 2012

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Table of Contents
Safety Precautions........................................................................................................................2
Test Personnel................................................................................................................2
Testing Area...................................................................................................................2
Safety Techniques ........................................................................................................................3
Using the HT-3000P-1A-AC Dielectric Withstand Tester...........................................................3
Leakage Test..................................................................................................................3
Sporadic Leakage Current Failures..................................................................4
Chronic Leakage Current Failures...................................................................4
High Voltage Discharge...................................................................................4
Introduction and Specifications..................................................................................................................5
Specifications...............................................................................................................................6
Operation....................................................................................................................................................7
Setting up your Tester ..................................................................................................................7
AC Line Voltage Requirements....................................................................................................7
Fuse Replacement.........................................................................................................................7
Front Panel Features.....................................................................................................................7
Initial Checkout Procedure...........................................................................................................10
Performance Test .........................................................................................................................10
Setting up the HT-3000P-1A-AC.................................................................................................10
Factory Settings..............................................................................................................11
Display of Leakage Limit and Duration settings............................................................11
Adjustment of the Leakage Current Level .....................................................................11
Adjustment of the High Voltage Level ..........................................................................11
Adjustment of the High Voltage Test Time...................................................................12
Operating Techniques ..................................................................................................................12
Daily Operation Test......................................................................................................12
Test results.....................................................................................................................12
Red LED/Buzzer..............................................................................................12
Technical Assistance ..................................................................................................................................13
Maintenance and Calibration......................................................................................................................14
Introduction..................................................................................................................................14
Service Information......................................................................................................................14
General Maintenance....................................................................................................................14
Cleaning.........................................................................................................................14
Calibration Procedure...................................................................................................................15
Calibration and Software Version Information..............................................................16
Voltage Calibration Adjustment.....................................................................................16
Current Calibration Adjustment.....................................................................................17

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Section 1
Safety Precautions
The dielectric withstand test generates voltages of up to 3000 volts ac at potentially
lethal current levels. Currents of as little as 5 mA at 120 volts can cause death, and the HT-
3000P-1A-AC is capable of generating 1 A at up to 3000 volts. The HT-3000P-1A-AC 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-3000P-1A-AC. Before
connecting the HT-3000P-1A-AC, ensure that a low-resistance ground is provided by the
building wiring. If the HT-3000P-1A-AC 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.

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Safety Techniques
The high voltage circuit of the HT-3000P-1A-AC can be shut off at any time by pressing
the RESET button. The HT-3000P-1A-AC 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-3000P-1A-AC 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-3000P-1A-AC 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-3000P-1A-AC 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-
3000P-1A-AC until the front panel meter reads zero volts.
Using the HT-3000P-1A-AC 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.
Leakage Test
The HT-3000P-1A-AC 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-3000P-1A-AC to ensure that excessive
leakage does not keep the tester from developing full voltage required for the high voltage test.
The HT-3000P-1A-AC will provide full voltage at any leakage current level up to 1000 mA. The
leakage current trip level is adjustable on the front panel.
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 leakage adjust knob.

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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 leakage
adjust knob. If other equipment of the same type routinely passes this test, there may be a
problem, the unit should be checked and reworked if necessary.
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-3000P-1A-AC is set to 1 A and almost all the
samples 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 produce a leakage current of more than 1 A to flow at the desired test
voltage, the HT-3000P-1A-AC 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 cause leakage through the primary circuit capacitors. A DC voltage dielectric
withstand tester, may allow successful test of models chronically failing the HT-3000P-1A-AC
leakage current test.
High Voltage Discharge
The HT-3000P-1A-AC is designed to discharge the high voltage after completion of the
dielectric withstand test. The equipment being tested should remain connected to the HT-3000P-
1A-AC 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.