Compliance West HT-5000P User 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 microcontroller circuit design and ergonomic
front panel, and represents the latest in high voltage laboratory
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. If the need arises, please don't hesitate to call on
us.
Thank you for your trust and confidence.
Rev 1.0, Sep, 2013.

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Table of Contents
An Introduction to Dielectric Withstand Testing with the HT-5000P ac/dc 200mA..................................2
Leakage Test ................................................................................................................................2
High Voltage Dielectric Withstand Test ......................................................................................2
High Voltage Discharge...............................................................................................................3
Introduction and Specifications..................................................................................................................4
Specifications...............................................................................................................................5
Operation....................................................................................................................................................6
Setting up the HT-5000P ac/dc 200mA........................................................................................6
AC Line Voltage Requirements and Fuse Replacement...............................................................6
Front and Rear Panel Features......................................................................................................6
Initial Checkout Procedure...........................................................................................................9
Setting up the HT-5000P ac/dc 200mA for Laboratory Testing...................................................10
Factory Settings..............................................................................................................10
Voltage Type Selection..................................................................................................10
Display of Leakage Limit and Duration Settings ...........................................................10
Leakage Current Level Adjust .......................................................................................10
Voltage Adjust...............................................................................................................11
High Voltage Test Time Adjust.....................................................................................11
Setting the Test Timer Switch........................................................................................11
Setting the Failure Shutdown Switch.............................................................................12
Operating Techniques ..................................................................................................................12
Testing Products ............................................................................................................12
Test Results....................................................................................................................13
Maintenance and Calibration......................................................................................................................15
Service Information......................................................................................................................15
Cleaning .......................................................................................................................................15
Calibration Procedure...................................................................................................................15
Entering Calibration Mode.............................................................................................16
Calibration and Software Version Information..............................................................16
Voltage Meter Verification............................................................................................17
Voltage Meter Re-Calibration........................................................................................17
Leakage Meter Verification ...........................................................................................18
Leakage Current Re-Calibration ....................................................................................19
Technical Assistance ..................................................................................................................................20

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Section 1
An Introduction to Dielectric Withstand Testing with the HT-5000P ac/dc
200mA
The dielectric withstand test is a test which is recognized by safety agencies worldwide
as a valid criterion of safe assembly of end-use equipment. The HT-5000P ac/dc 200mA is
designed as a research instrument to determine the dielectric properties of component assemblies
of end-use equipment. It applies a high-voltage potential between Output and Return test leads
and monitors Leakage Current, and watches for Dielectric Breakdown during the test. To aid in
testing, the HT-5000P ac/dc 200mA can be configured with or without a test duration timer, and
can be set to deliver high voltage after an arc has been detected to pinpoint an area of arcing.
The dielectric withstand test involves high voltage, and caution should be exercised
when using the HT-5000P ac/dc 200mA. The Return Receptacle on the front panel is connected
to ground potential, and setups should be designed with this in mind, to guard against the
operator contacting high voltage. Always make sure the return lead is firmly connected.
Leakage Test
The HT-5000P ac/dc 200mA leakage test uses a separate low-frequency circuit to detect
excessive current between the Output and Return receptacles on the front panel. 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 sample may indicate an assembly, and or a
component problem in the circuit.
The leakage current is also monitored by the HT-5000P ac/dc 200mA to ensure that
excessive leakage does not keep the tester from developing full voltage required for the high
voltage test. The HT-5000P ac/dc 200mA will provide full voltage at any leakage current level
up to 200mA. Set the acceptable leakage current limit using the Shutdown Limit Potentiometer
on the front panel.
If the green Full Voltage indicator lights and the test continue, the leakage current was
below the acceptable limit. If the red Excess Leakage indicator lights, the buzzer sounds,
and the test is terminated; the leakage current was above the acceptable limit.
High Voltage Dielectric Withstand Test
This test checks for insulation system breakdown’s by applying a high voltage between
the Output and Return receptacles on the front panel. The HT-5000P ac/dc 200mA uses a
separate high-frequency circuit to detect arc breakdowns.
Set the test duration with the Timer Control Potentiometer on the front panel. The test
time is counted from the time the Full Voltage indicator is lit to the completion of the test. The
Timer Control Switch must be set to ON, or the HT-5000P ac/dc 200mA will test only while the
Test Button is pressed. The minimum test time is one second regardless of the setting of the
Timer Control Switch.

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If the green Hipot Pass indicator lights, the test cycle has been successfully completed,
meaning there was no dielectric breakdown. If the red Hipot Fail indicator lights, a
breakdown arc has been detected.
High Voltage Discharge
The HT-5000P ac/dc 200mA has an internal circuit designed to remove the high voltage,
after completion of the dielectric withstand test. The HT-5000P ac/dc 200mA should remain
connected to the circuit until the front panel meter shows that the output voltage has dropped to a
safe level.

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Section 2
Introduction and Specifications
This manual contains complete operating and specifications for the HT-5000P ac/dc
200mA Dielectric Withstand Tester.
The instrument is a bench-type Dielectric Withstand Tester with AC and DC Output,
designed for laboratory testing of components, and insulation systems.
The HT-5000P ac/dc 200mA features automatic two buttons operation, with numerous
safety features designed to protect the operator:
- The test return lead is directly connected to ground potential for operator safety.
- The test can be immediately terminated at any time by pressing the red RESET button.
- Before the test can commence, the Zero Voltage Start safety feature most be disarmed by
turning the voltage knob to the minimum, also the unit must be armed by pressing the red
RESET button. The test will not begin until the blue TEST Button is pushed.
- If a failure is encountered, the high voltage is immediately shut down, a buzzer sounds
and the voltage discharge progress is shown by the front panel meter.
- Failure modes are shown by the front panel LED's.
Convenience and testing features include:
- Test time, and leakage limit are settable.
- Test duration timer is defeatable for specialized testing.
- Testing may be terminated or continued when a dielectric breakdown is detected.
- Test results are determined quickly, without operator intervention.
- The HT-5000P ac/dc 200mA allows custom setups for test time and leakage limit.
Your Tester has a warranty for a period of one year upon shipment of the instrument to the
original purchaser.

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Specifications
ELECTRICAL
Voltage Output AC: 0 - 5000V
DC: 0 - 7000V
Max Leakage Current Output: AC: 5000V = 200mA
DC: 5000V= 200mA, 7000V=140mA
Leakage Current Limit Adjustment: AC: 5 –200 mA
DC: 5 –200 mA
Pass/Fail Criteria:
Leakage Current: Pass/Fail point user adjustable.
Dielectric Breakdown: Separate high frequency detection circuit for
breakdown spike detection
Test Time: User adjustable 1 to 90 sec. 1 sec steps, defeatable
Voltage Meter Accuracy AC: ±1.0% FSC from 0.50KV to 5.00KV volts
DC: ±1.0% FSC from 0.50KV to 7.00KV volts
Leakage Meter Accuracy ± 1mA
Duty cycle 100 %
Test adjustments Front Panel:
Test Time
Leakage Limit
Voltage Adjustment
Timer ON/DEFEAT
Hipot ON/DEFEAT
ENVIRONMENTAL
Operating Temperature 15-40 C
Relative Humidity Range 0-90% non-condensing
GENERAL
Input power requirements 208VAC, 3φ, 50/60Hz, 6A/phase.
Weight 90 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 can be automatically terminated on failure
Leakage Test Provided; 5 mA AC factory set pass/fail point, user
adjustable.
Zero Voltage Start It will NOT let to start the test until the voltage
adjustment knob is at the minimum position.
Table 2-1. HT-5000P ac/dc 200mA Specifications

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Section 3
Operation
This section describes how to set up and make measurements with the HT-5000P ac/dc
200mA unit. We recommend that you read the entire section carefully so that you can use all of
its features.
Setting up the HT-5000P ac/dc 200mA
The HT-5000P ac/dc 200mA is shipped in a special protective container that should
prevent damage during shipping. The container will include the following:
The HT-5000P ac/dc 200mA 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 Plug ends)
A Power Cord.
This Instruction Manual
18 AWG Line Power
Cord
GL Return Test Lead
Red 18 AWG High
Voltage Test Lead
Table 3-1. Shipment Cables & Connectors
Use the original shipping container for subsequent shipping. If the original shipping
container is not available, be sure that adequate protection is provided to prevent damage during
shipment.
AC Line Voltage Requirements and Fuse Replacement
Connect the HT-5000P ac 200mA only to the voltage source indicated on the rear panel.
There is a user-replaceable fuse located on the front panel. The fuse rating is printed on
the front panel. For continued protection against risk of fire, replace only with same type and
rating of fuse. The AC Power switch should be turned off while the fuse is being replaced.
Front and Rear Panel Features
Before using the HT-5000P ac/dc 200mA tester, take a few minutes to become familiar
with the use of its controls, indicators, and connectors. The front panel features of the HT-5000P
ac/dc 200mA are shown in Figure 3-1 and described in Table 3-2.

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Figure 3-1. Front Panel Controls, Indicators and Connectors

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ITEM
NO.
NAME
FUNCTION
1
HIPOT
When ON, Dielectric breakdown detect will be activated.
When in DEFEAT position, test will continue regardless of a dielectric breakdown, but it can be stopped by the excess
leakage limit. NOTE: The TIMER switch must also be in the DEFEAT position, otherwise the buzzer will sound. The
test will continue only as long as the TEST button is pressed. Minimum test time is approximately one second.
2
TIMER
When ON, test duration is set by TIMER ADJUST, Item 4.
When in DEFEAT position, testing continues only as long at TEST button is pressed. Minimum test time is one second.
NOTE: TIMER Switch position must be DEFEAT when HIPOT Switch is in the DEFEAT position.
3
LEAKAGE ADJUST
Adjusts the shutdown point for the Leakage Current Test. For details see “Leakage Current Adjust.”
4
TIMER ADJUST
Adjusts the test duration. For details see “Test Time Adjust”.
5
RESET Button
When lit, indicates that the HT-5000P ac/dc 200mA is unarmed. When the RESET button is pressed, the TEST switch is
lit. PRESSING THE RESET BUTTON AT ANY TIME IMMEDIATELY STOPS TESTING.
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TEST Button
When lit, indicates the HT-5000P ac/dc 200mA is ready to test; press to begin testing. NOTE: The Voltage Adjust knob
must be at the minimum position in order to disarm the Zero Voltage Start safety feature, Item 15.
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VOLTAGE METER
Connected to the output. Reads actual output voltage. Adjust meter range with VOLTAGE ADJUST Knob, Item 15.
8
HIPOT PASS LED
Indicates test conclusion with satisfactory results.
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FULL VOLTAGE LED
Lights when output voltage has ramped up. Test time starts when this indicator lights.
10
HIPOT FAIL LED
Lights when arcing or insulation flashover has occurred.
11
EXCESS LEAKAGE LED
Actual leakage current has exceeded the shutdown point set with Shutdown Limit Potentiometer, Item 3.
12
CURRENT METER
Connected to the output. Read the current flowing through the return lead of the HT-5000P ac/dc 200mA during the
test.
13
HIGH VOLTAGE output
jack
Connect high voltage lead here to conduct an AC & DC test.
14
RETURN Receptacle
At chassis ground reference level. Connect black return lead here.
15
VOLTAGE ADJUST Knob
Voltage is continuously adjustable before or during testing with this knob. NOTE: Before the test can commence, the
Zero Voltage Start safety feature most be disarmed by turning the voltage knob to the minimum.
16
AC POWER Switch
Energizes the HT-5000P ac/dc 200mA.
17
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 3-2. Front Panel Control, Indicators and Connectors

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Initial Checkout Procedure
Use this procedure to verify that the HT-5000P ac/dc 200mA tester is working correctly.
Refer to table 3-1, figure 3-1 and table 3-2 for location of items.
CAUTION
High voltage, risk of shock, use with care.
1. Turn the Tester on using the AC Power switch.
2. Set the Test Timer switch, and Failure Shutdown switch to ON position.
3. Disconnect leads from the Output and Return jacks.
4. Set the Test Time to around 30 seconds.
5. Push the RESET button. The TEST button should light.
6. Disarm the Zero Voltage Start safety feature by turning the voltage knob to the minimum.
7. Push the TEST button.
8. After the FULL VOLTAGE indicator lights, use the Voltage Adjust knob to set the desired
output voltage. At the end of the test, the Full Voltage, Hipot Pass, and RESET switch
indicators should be lit.
9. Push the RESET button. The TEST button should light.
10. Disarm the Zero Voltage Start safety feature by turning the voltage knob to the minimum.
11. Connect the red lead to the Output receptacle, and connect the black lead to the Return
receptacle, then, connect the two leads together to simulate a high leakage current condition.
12. Push the TEST button.
13. Use the Voltage Adjust knob to increase the voltage output, but the test should terminate
immediately and the buzzer should sound. The Excess Leakage Indicator and RESET button
indicators should be lit.
14. Disconnect the red lead (banana connector) from the HV output of the HT-5000P ac/dc
200mA, but keep the red alligator clip connected with the black lead which is already
connected to the Return receptacle.
15. Push the RESET button. The TEST button should light.
16. Disarm the Zero Voltage Start safety feature by turning the voltage knob to the minimum.
17. Push the TEST button.
18. After the FULL VOLTAGE indicator lights, use the Voltage Adjust knob to set the output
voltage to approx. 1500 volts.
19. (This test simulates a dielectric breakdown. High voltage could exist on the alligator clips.
Exercise caution to avoid shock.) Pick up the red lead and insert it into the HV Output
during the machine is performing the test. The test will immediately terminate with a buzzer.
The Full Voltage, Hipot Fail, and RESET button indicators should be lit.
20. Push the RESET button. The TEST button should light.
If any of these tests give unexpected results, service may be required. Please check the
test setup and if further information is needed, contact our Service hotline for assistance.

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Setting up the HT-5000P ac/dc 200mA for Laboratory Testing
This section describes procedures for setting the HT-5000P ac/dc 200mA tester.
a. Leakage current level
b. High voltage level
c. High voltage test time
d. Test timer switch
e. Breakdown detect switch.
This will allow you to change settings from the factory settings below. Refer to table 3-1,
figure 3-1 and table 3-2 for location of items.
Factory Settings
The HT-5000P ac/dc 200mA is configured as shown when shipped from Compliance
West USA:
Voltage Display: Vrms
Leakage Current Level: 5mA
High Voltage Level: Minimum
High Voltage Test Time: 1 second
Test Timer switch: ON
Breakdown Detect switch: ON
Voltage Type Selection
Use the AC/DC Voltage Switch. This switch is functional only when the RESET or
TEST button is lit.
Display of Leakage Limit and Duration Settings
To view the Test Duration, and Leakage Limit current settings, hold down the RESET button for 2
seconds. The meter will display “L” with the Leakage Limit value in mA. Hold down the RESET button
again for 2 seconds, and the meter will display “d” with the Test Duration set time in seconds.
Leakage Current Level Adjust
1. Connect the HT-5000P ac/dc 200mA to a correctly rated source of supply and turn ON the
tester.
2. Push the RESET button. The TEST indicator should light, indicating that the HT-5000P
ac/dc 200mA is ready.
3. Turn the Leakage Limit Adjust. As soon as the potentiometer starts turning, the voltage
meter will start blinking and displaying “L” with the new value. Leakage Level can be set in
1 mA increments.

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Voltage Adjust
This procedure controls the high voltage level used in the dielectric withstand test.
Testing can be terminated at any time by pressing the RESET button. Use the procedure below to
set it.
1. Set the Test Timer switch, and Failure Shutdown switch to ON position.
2. Disarm the Zero Voltage Start safety feature by turning the voltage knob to the minimum.
3. Push the RESET button. The TEST button should light.
4. Push the TEST button.
5. After the FULL VOLTAGE indicator lights, use the Voltage Adjust knob to set the desired
output voltage.
6. Push the RESET button to terminate the test.
High Voltage Test Time Adjust
This procedure sets the length of time the HT-5000P ac/dc 200mA 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 will allow a much shorter test (usually 1 second vs. 1 minute) if the voltage is
increased by 20%. The factory set is for 1 second. Consult the safety agencies on the test time for
the type of equipment being tested. If a different test time is required, use this procedure to set it.
1. Connect the tester to a correctly rated source of supply and turn ON the power switch.
2. Push the RESET button. The TEST indicator should light, indicating that the HT-5000P
ac/dc 200mA is ready.
3. Adjust the Test Time potentiometer. As soon as the potentiometer starts turning, the voltage
meter will display “d” with the new value. Test Time can be set in 1 second increments from
1 to 90 seconds.
Setting the Test Timer Switch
The Timer Control switch allows test time to be controlled by the HT-5000P ac/dc
200mA internal timer or to continue until terminated by the operator.
When this switch is in the DEFEAT position, the test will continue only while the TEST
button is held down. The minimum test time is approx. 1 second.
When this switch is in the ON position, the test time will be controlled by the HT-5000P
ac/dc 200mA internal timer. For information on how to set this time, see instructions above.
The Test Timer must be defeated if Breakdown Detect Defeat is desired. See Table 3-3
for details.

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Setting the Failure Shutdown Switch
Use extreme caution when using this feature
The Breakdown Detect switch allows the operator to continue testing after a failure is
encountered. This allows the operator to find the breakdown point, but all arc shutdown
circuitry in the HT-5000P ac/dc 200mA is disabled when the Breakdown Detect switch is in
the DEFEAT position. The excess leakage limit may stop the test. Also the tests may be
terminated at any time by releasing the TEST button.
WARNING: Testing with the Shutdown Limit switch in the DEFEAT position is
extremely hazardous. The HT-5000P ac/dc 200mA can generate lethal levels of voltage and
current. Therefore, care should be taken in examining the equipment being tested, to locate
areas of failure while the HT-5000P ac/dc 200mA is operating.
Operating Techniques
The following paragraphs describe how to operate the HT-5000P ac/dc 200mA
Dielectric Withstand Tester.
CAUTION:
High voltage is generated by the HT-5000P ac/dc 200mA. Although the
chassis of the equipment under test is grounded by the HT-5000P ac/dc 200mA, a risk
of shock exists.
Testing Products
This section describes how to conduct a test. Testing can be terminated at any time by
pressing the RESET button.
1. Set up tester to correct parameters for unit to be tested using the previously described
procedures.
2. Connect the HT-5000P ac/dc 200mA to a correctly rated source of supply and turn it on.
3. Plug the black lead into the Return receptacle. Plug the red lead into the Output receptacle.
4. Connect the alligator clips of the leads across the circuit or part being tested. Keep in mind
that the black lead is connected to earth ground.
5. Press the RESET button. The TEST button should light, indicating that the HT-5000P ac/dc
200mA is ready to test.
6. Set the VOLTAGE ADJUST Knob to minimum in order to disarm the Zero Voltage Start
safety feature.
7. Push the TEST button. The HT-5000P ac 200mA will energize the high voltage output.
8. After the FULL VOLTAGE indicator lights, use the Voltage Adjust knob to set the desired
output.
9. If the Shutdown Limit switch is set to ON, and if the leakage current of the circuit under
test exceeds the alarm value, the Excess Leakage indicator will light and the test will
terminate.

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If the Shutdown Limit switch is set to DEFEAT, and the requirements of Table 4-3 are
met, the HT-5000P ac/dc 200mA will continue to test. Voltage output may sag if the power
required by the circuit is beyond the capabilities of the HT-5000P ac/dc 200mA.
10. If the Timer Control switch is set to ON, the HT-5000P ac/dc 200mA will conduct the high
voltage test for the amount of time set in the Test Duration procedure.
If the Timer Control switch is set to DEFEAT, the high voltage test will continue only
while the TEST button is pressed.
11. If an insulation system breakdown is detected, and
The Shutdown Limit switch is ON, the Hipot Fail indicator will light, the buzzer will
sound, and the voltage will be removed.
The Shutdown Limit switch is set to DEFEAT, and the requirements of Table 4-3 are
met, the Hipot Fail indicator will light, and the test will continue as long as the TEST
button is pressed.
12. If no breakdown is detected, the high voltage will be removed at the end of the test, the
Hipot Pass indicator will light, and the RESET button will light.
13. Do not disconnect the leads from the equipment being tested until test has ended, and the
voltage meter indicates zero volts.
Test Results
Hipot Pass: If the Hipot Pass light is lit, the equipment being tested passed all test parameters.
Red Indicator/Buzzer: Any red indicator/buzzer test result means the equipment being tested
failed a test phase. If unanticipated test failures continue, and you suspect that the equipment
under test is built correctly, check the following items:
1. Shutdown Limit Setting: May be set too low. This would cause normal input capacitor
charging to draw more that the preset leakage current limit, triggering a Leakage Current
Fail light, and terminating the test. Consider raising the acceptable leakage current level;
see Leakage Current Level Adjust. If this limit level is at its highest setting, and failures
continue, a DC hipot tester may be required

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Result
TIMER
HIPOT
ON
ON
Test Timer and the breakdown detect are On. Test will stop automatically if the internal
test time counter is completed, or a leakage failure, or breakdown failure.
DEFEAT
ON
Test Timer is defeated. After full voltage is reached, the test will continue only as long as
the Test button is held in, minimum one second. Test will stop automatically on all leakage
or breakdown failures.
ON
DEFEAT
Buzzer will turn sound, It will not allow to test until the Test Timer switch is in defeat.
DEFEAT
DEFEAT
Test will continue only as long as the TEST button is held in, minimum one second. The
HT-5000P ac/dc 200mA will NOT shut down on a dielectric failure, but the front panel
Hipot Fail light will flash to indicate a dielectric breakdown. The Hipot Pass light will not
light at the completion of a successful test. For safety reasons, excessive leakage current,
as set by the Leakage knob, will cause the HT-5000P ac/dc 200mA to shut down.
Table 3-3: Front Panel Switch Truth Table

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Section 4
Maintenance and Calibration
WARNING
THESE SERVICE INSTRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL
ONLY. TO AVOID ELECTRIC SHOCK, DO NOT PERFORM ANY SERVICING
OTHER THAN THAT CONTAINED IN THE OPERATING INSTRUCTIONS UNLESS
YOU ARE QUALIFIED TO DO SO.
This section contains maintenance information for the HT-5000P ac/dc 200mA
Dielectric Withstand Tester. A 1-year calibration cycle is recommended to maintain the
specifications given in Section 2.
Service Information
The HT-5000P ac/dc 200mA is warranted to the original purchaser for a period of 1 year.
This warranty does not cover problems due to misuse or neglect.
Malfunctions which occur within the limits of the warranty will be corrected at no
charge. Mail the instrument post paid to the manufacturer. Dated proof of purchase is required
for all in-warranty repairs.
The manufacturer is also available for calibration and/or repair of instruments that are
beyond their warranty period. Contact the manufacturer for a cost quotation. Ship the
instrument and your remittance according to the instructions given by the manufacturer.
Cleaning
CAUTION
Do not use aromatic hydrocarbons or chlorinated solvents for cleaning. These
solutions will react with the plastic materials used in the instrument.
Clean the front panel and case with a mild solution of detergent and a damp sponge.
Clean dust from the PWB with clean, dry, low pressure (<20 psi).
Calibration Procedure
The Calibration Procedure should be performed annually and any time your instrument has been
repaired. The calibration procedure consists of the next sections:
1) Entering Calibration Mode.
2) Calibration and Software Version Information.
3) Voltage Meter Verification.
4) Voltage Meter Re-calibration.
5) Leakage Meter Verification.
6) Leakage Current Re-Calibration.