Compliance West HTT-1S User manual

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Dear Customer:
Congratulations! Compliance West USA is proud to
present you with your HTT-1S. The operating instructions
are included in the Manual, so please retain this
information for future use.
Thank you for your trust and confidence.
Rev. 0, March 2017

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Table of Contents
Operating Instructions ......................................................................................2
Theory of Operation .......................................................................................... 2
Introduction and Specifications.........................................................................4
Introduction ....................................................................................................... 4
Specifications..................................................................................................... 4
Table 1: Specifications of the HTT-1S............................................................ 4
Operation..........................................................................................................6
Setting up the HTT-1S........................................................................................ 6
Figure 2: HTT-1S Front Panel Features.......................................................... 7
Figure 3: HTT-1S OFFSET switch location ...................................................... 7
TTable 2: HTT-1S front panel Controls, Indicators, and Connectors............. 8
Setup Procedure: Hipot Tester .......................................................................... 9
Setup Procedure: Ground Bond Tester .......................................................... 11
Figure 5: Connection to a Ground bond tester............................................ 11
Unanticipated Results...................................................................................... 12
Troubleshooting the HTT-1S............................................................................13
Table 3: HTT-1S Normal operating modes and expected results................ 13
Table 4: HTT-1S Resistance for ground circuit ............................................ 14
Technical Assistance........................................................................................15

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Section 1
Operating Instructions
Theory of Operation
The HTT-1S is designed to be a solution for fast and easy function testing of
the HT-S series of dielectric withstand and continuity testers, including high
current models delivering up to 30 amps. It allows function tests of all three
failure modes to ensure that your tester is functioning properly.
The HTT-1S is designed to verify calibration points at a fixed value.
The HTT-1S, used daily, will prove function of the safety testers before shifts
or before testing of a lot of products. It is provided with three switches which
simulate passing and failing equipment for ground continuity, high leakage
between primary circuits and ground, and dielectric withstand failure between
primary and ground circuits. While all three switches can be simultaneously set
for failing modes, we recommend that the HTT-1S be set with one failure at a
time to ensure that your testers are functioning correctly.
A proper test plan would be constituted of the following tests:
1. Connect HTT-1S to the tester outputs.
2. Set all three switches on the HTT-1S to ‘PASS’.
3. Verify passing result on the Tester.
4. Set the Ground switch on the HTT-1S to ‘FAIL’; set both other switches to
‘PASS’.
5. Verify Ground failure on the Tester.
6. Set the Leakage switch on the HTT-1S to ‘FAIL’; set both other switches to
‘PASS’.
7. Verify Leakage current failure on the Tester.
8. Set the Hipot switch on the HTT-1S to ‘FAIL’; set both other switches to
‘PASS’.
9. Confirm high voltage output by watching for a spark in the Arc Detect window
of the HTT-1S; verify dielectric breakdown failure on the Tester.
The above plan is presented in more detail in the Operation Section of this
Manual; showing proper connection of the HTT-1S to any dielectric tester and
any high current ground continuity tester you may wish to test.
If any of the tests above return unanticipated results, you may have a problem
with your tester. It is recommended that it be removed from service until the

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problem can be resolved. Section 4 of this manual also has troubleshooting
information to help you determine if the HTT-1S is functioning correctly.

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Section 2
Introduction and Specifications
Introduction
This manual contains complete operating, maintenance and calibration
instructions for the Compliance West USA Model HTT-1S Function Tester.
The instrument is a portable function tester used to verify proper
operation of hipot and ground continuity testers. The HTT-1S is intended to be
used as a calibration verification tool.
The HTT-1S is warranted for a period of one year upon shipment to the
original purchaser.
Specifications
Specifications for the HTT-1S are listed in the following table:
Table 1: Specifications of the HTT-1S
Maximum current capability of GROUND test circuit: 30 Amps
Ground Test time should be 3 seconds Max and rest 10 s for currents above 10A
Setting of PASS for Ground Circuit: 0.025 ohm resistor *
Setting of FAIL for Ground Circuit: 0.1 ohm resistor *
Setting of PASS for Leakage Current: open circuit
Setting of FAIL for Leakage Current: short-circuit
Maximum voltage capability of HIPOT test circuit: 3000VAC / 4200VDC
Setting of PASS for Hipot test: open circuit
Setting of FAIL for Hipot test: arc-over at 750 + 400VAC / 1050 + 560VDC
HT-1S model only works with the following S series testers:
-HT-2000S
-HT-2800S
-HT-3000S
*Note: Switch contacts resistance and connectors can add up to 0.03 to the total
resistance. For customized values see product label.

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Figure 1 Electrical Diagram of the HTT-1S

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Section 3
Operation
This section describes how to set up and use the HTT-1S.
Setting up the HTT-1S
As shipped from the factory, the HTT-1S container contains the following
items:
•The HTT-1S Function Tester
•This manual
•Return cable
•Output cable
Remove the HTT-1S from the container and place it on a non-conductive
test bench. Plug the cables; follow instructions on Set up procedure. To begin
testing, follow the directions in Section 1 above.
Note: This setup will work for any hipot / ground bond tester having a standard
wall receptacle and return banana jack connectors.

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Figure 2: HTT-1S Front Panel Features
Figure 3: HTT-1S OFFSET switch location

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Table 2: HTT-1S front panel Controls, Indicators, and Connectors
Item
Name
Function
1
Return Banana
Receptacle
Connected to the Return Lead on the Hipot or Ground Continuity Tester,
which is normally connected to dead metal parts of the equipment undergoing
dielectric test.
2
Output Cable
Connected to the high voltage output of the Hipot Tester being checked.
3
Arc View
When Dielectric Breakdown function is being checked, a spark will be
visually demonstrated the breakdown occurred.
4
Ground Test
Switch
When set to FAIL, an open ground is simulated and the tester should stop
testing and indicate a failure. When set to PASS, a normal passing result is
simulated.
5
Leakage Test
Switch
When set to FAIL, an excess leakage condition is simulated and the tester
should stop testing and indicate a failure. When set to PASS, a normal
passing result is simulated. Used for Dielectric Testers only.
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Hipot Test
Switch
When set to FAIL, a dielectric breakdown will be simulated and a spark can
be seen in the Arc View window. When set to PASS, a normal passing result
is simulated. Used for Dielectric Testers only.
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OFFSET
switch
Switch used to offset the HTT-1S cables for proper ground reading. Before
any testing is done, be sure to Offset the HTT-1S ground on the Hipot tester,
refer to setup procedure for offset instructions.

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Setup Procedure: Hipot Tester
This procedure will describe the connection of the HTT-1S to a hipot
tester or a combination hipot/ground bond tester. Because of the varying types of
tester outputs, cables provided with the HTT-1S may not fit the hipot / ground
bond tester. For custom cables, please contact Compliance West USA.
1)Connect the hipot tester to the HTT-1S.
i) On your hipot tester, identify the high voltage output receptacle. Connect
the Output to the high voltage receptacle.
ii) On your hipot tester, identify the return lead of the high voltage output.
This is connected to the black banana Return jack receptacle of the HTT-1S.
Figure 4: Connection to a hipot tester

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2)Ground OFFSET instructions:
a) With the HTT-1S connected to your Hipot tester (S series only!), press
the OFFSET switch and keep it pressed during all the subsequent actions.
b) Press and hold the Ground Offset switch on the back of the Hipot Tester
for longer than 5 seconds until the display shows a resistance value that
equals to the offset.
c) To verify that it worked, after the offset is done, with the HTT-1S still
connected press the Ground Offset switch on the Hipot Tester for about 2
to 3 seconds and a resistance value for ground will display, check Table 4
on this manual for the correct value for the ground resistance.
3)Conduct a simulated PASSING test by setting all three switches of the HTT-1S
to the PASS (green) setting and initiating a hipot test by starting your hipot tester.
i) Your hipot tester should indicate ‘PASS’.
4)If your tester checks for ground continuity, conduct a simulated GROUND
OPEN test by setting the GROUND switch on the HTT-1S to ‘FAIL’. (All other
switches on the HTT-1S should be set to ‘PASS’.) Begin testing by starting your
hipot tester.
i) Your hipot tester should indicate ‘FAIL’, stop testing, and sound a buzzer
or otherwise warn the operator of a problem.
5)Conduct a simulated EXCESS LEAKAGE test by setting the LEAKAGE
switch on the HTT-1S to ‘FAIL’. (All other switches on the HTT-1S should be
set to ‘PASS’). Begin testing by starting your hipot tester.
i) Your hipot tester should indicate ‘FAIL’, stop testing, and sound a buzzer
or otherwise warn the operator of a problem.
6)Conduct a simulated HIPOT FAILURE test by setting the HIPOT switch on the
HTT-1S to ‘FAIL’. (All other switches on the HTT-1S should be set to ‘PASS’.)
Begin testing by starting your hipot tester.
i) The dielectric breakdown will be visible as an arc in the ARC VIEW
window of the HTT-1S.
ii) Your hipot tester should indicate ‘FAIL’, stop testing and sound a buzzer
or otherwise warn the operator of a problem. (If the current of the spark
is above the leakage limit, the Excess Leakage failure may occur as well)

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Setup Procedure: Ground Bond Tester
This procedure will describe connection of the HTT-1S to a ground bond
tester. Because of the varying types of tester outputs, only return banana to
banana cable is provided with the HTT-1S that can be used on a Ground bond
tester. For custom cables, please contact Compliance West USA.
If the ground bond tester has an output current above 15A, make sure
the test time is not higher than 3 seconds, to repeat another test wait for 10
seconds. Resistors inside may overheat, this can cause permanent damage
and miss readings.
1) Connect the ground bond tester to the HTT-1S.
a) On your ground bond tester, plug the return lead of the high current
output to the black return banana receptacle of the HTT-1S.
b) On your ground continuity tester, plug the HTT-1S into the high current
receptacle.
Figure 5: Connection to a Ground bond tester

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2) Conduct a simulated PASSING test by setting all three switches of the HTT-
1S to the PASS (green) setting and initiating a ground bond test by starting your
ground bond tester.
a) Your ground bond tester should indicate ‘PASS’.
3) Conduct a simulated GROUND OPEN test by setting the GROUND switch on
the HTT-1S to ‘FAIL’. (All other switches on the HTT-1S should be set to
‘PASS’.) Begin testing by starting your ground bond tester.
a) Your ground bond tester should indicate ‘FAIL’, stop testing, and sound a
buzzer or otherwise warn the operator of a problem.
Unanticipated Results
The HTT-1S test may cause your tester to give results not consistent with those
anticipated by the switch setting of the HTT-1S. Until the problem is resolved,
your tester should be removed from service.
If there is an unexpected leakage or ground result, first check the hipot or ground
bond trip limit settings are correct.
If it is not detecting hipot failures, make sure testing voltage is above 750Vac.
If there is a question regarding the proper operation of the HTT-1S,
troubleshooting information in Section 4 can be used to verify proper operation of
the HTT-1S.

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Section 4
Troubleshooting the HTT-1S
The HTT-1S requires an annual calibration. If the HTT-1S does not operate as
described in the Theory of Operation section, and the equipment connected to the
HTT-1S has been verified to be in good working condition, then the HTT-1S
should be returned to Compliance West USA for inspection and/or repair.
Table 3 shows expected results for a known good hipot tester for all
recommended operating modes. Table 4 and 5 shows the expected values to be
measured with a resistance meter. Values of less than 1 ohm should be measured
with a high precision resistance meter.
Switch designation / Switch position
Operating mode
GROUND
LEAKAGE
HIPOT
PASS
PASS
PASS
No failure: the tester connected to the
HTT-1S should indicate test completion
with a passing result.
FAIL
PASS
PASS
Ground Fail: the tester connected to the
HTT-1S should indicate a “ground open”
or “ground fail” condition.
PASS
FAIL
PASS
Leakage Fail: the tester connected to the
HTT-1S should indicate an “excess
leakage” or “excess current” failure.
PASS
PASS
FAIL
Hipot Fail: The tester connected to the
HTT-1S should indicate a “hipot fail” or
“dielectric failure”. The high-voltage arc
that occurs to create the simulated test
failure is visible through the ARC VIEW
window.
Table 3: HTT-1S Normal operating modes and expected results.

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Table 4: HTT-1S Resistance for ground circuit
Ground switch position
Resistance between Chassis and Return with
±0.03tolerances
Pass
0.0250.055
Fail
0.10.13

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Section 5
Technical Assistance
Technical Assistance from Compliance West USA is available:
Phone: [phone]
Hours: 8:00 AM - 4:00 PM Pacific Time.
Also available on our web site at: www.compwest.com
Contact:
Compliance West USA
650 Gateway Center Way, Suite D
San Diego, CA., 92102
United States of America.
Phone: [phone]
FAX: [phone]