High Voltage PFT Series Guide

Safety,Operation,andProcedureInstructionsforthePFTSeriesof
ACHipots
Danger- Lethal Voltages:
Equipment to be used by trained personnel only
This Operator Manual contains instructions for the operation of a High Voltage power source. The operator of this equipment
must use good judgement and follow all safety precautions noted in this guide to ensure the protection of himself and others in
close proximity to the test area. Failure to follow the instructions could result in injury or
death. Proper grounding of the test set must be done prior to connecting this unit
to a power source.
PFT
SERIES
Please Refer to
Documentation
Before Operation

OperatorManual

Last saved 1/29/2009
T:\PRODUCT\DOCUMENTS\Manuals\PFT\MANpft_2k9Re.doc
TableofContents
About the Operator Manual 1
SECTION 1
General Information 2
Features and Specifications 2-3
Controls and Indicators 4-5
SECTION 2
Setting up the Equipment 6
Operating the Equipment 7-10
Blank Page for Notes 11
SECTION 3
Performing Special Operations 12
Meter Re-calibration 12,13
Miscellaneous 14
Packing the Cables 14
Return Material 15
Warranty 16,17

OPERATOR MANUAL
- 1 -
AbouttheOperatorManual
Important
ThisOperatorManual describesthe featuresand safeoperation ofa High
VoltageTestSet.The instructionsare intended to be clear and simple, but
the operator must betrained and qualified according to established
procedures forthe use of thistype of equipment.
ThisOperator Manual isorganized toprovide information onthe PFT Series ofHipots in steps that familiarize
thenew operator withthe operationof thistestset.
Section1: Specifications andControls.
Section2: Setup andOperation.
Section3: Performing SpecialOperations.
TheFunctions,Features,andSpecifications ofthePFTSeriesof ACHipotsarealsodiscussedinthePFTBrochure
availablefromHighVoltage,Inc.

2
GeneralInformation
Thissection familiarizes theoperator withthe features andspecificationsof the
PFT Series ofPower Frequency AC Test Sets manufacturedby HIGH VOLTAGE, INC.
Features and Specifications
The PFT Series of AC hipot test sets provide continuously adjustable output voltages for the GO/NO-GO
testing of high voltage insulation. Earlier versions of the PFT Series were equipped with operator controlled
capacitive compensation switches to minimize input primary currents. The new simplified controls incorporate
thisfeature transparently.
Standardfeatures ofthe PFT Seriesof include:
•Continuouslyadjustable output voltage
•Fixed overload, factoryset to 120% of variabletransformerrated outputcurrent
•“ZeroStart” and ExternalInterlock provision
•Secondaryconnected dual-range voltmeter
•Shieldedoutput cable (50kV andbelow) precludesunnecessary insulated support ofthe cable
•Onepiece portable design(50 kV andbelow)
•Transitprotected meters preventmeter damagebetween test sites
•Capacitive load compensation incorporated to allow up to 3 KVA output power with less than 15
Amperesinput line current.
•FaultBurn Reactor (Optional)
SECTION
1

3
PFT MODEL SPECIFICATIONS
PFT-103 PFT-303 PFT-503 PFT-1003
SEE SPECIFICATIONS
ON LAST SHEET OF PARTS LIST
Table 1 PFTSeries Specifications.

4
VOLTMETER
LOW HIGH
OUTPUT
GROUND
INPUT
FUSE
MAIN
POWER HIGH VOLTAGEOFF ON
EXT
INTLK
AC TEST SET PFT SERIES
RETURN
MODE
GUARDGROUND
LOAD
RETURN
CURRENT RANGE
X10 X1
X100
PLEASE REFER TO
DOCUMENTATION
BEFORE OPERATION
Figure1 PFT Series front panel controls.
MAIN POWER
TheMAIN POWER pushbutton switch provides the power to the controland powercircuits. Theneon lamp in
the switch will light when the power is on and voltage is available through the input line cord. The INPUT
FUSE located electrically beforetheMAIN POWER switch provides linefault protectionfor theunit.
EXT INTLK (EXTERNAL INTERLOCK)
The Ext Intlk connector is provided to allow for a normally open safety interlock switch to control the
energizingof the highvoltage output.
HIGH VOLTAGE ON/OFF
The HIGH VOLTAGE ON and OFF pushbuttons control the high voltage power circuits. The red and green
LEDs provide life long positive indication of the circuit status. The red LED lights when high voltage is
energizedand the greenLED lights whenthe highvoltage isde-energized.
OUTPUT CONTROL
TheOUTPUT control variable transformer adjusts the output voltage.The0-10 markings onthe knobindicate
the low to high setting. The control must be at ZERO (0) to energize the high voltage circuits. The output
control must always be returned to zero at the completion of testing, prior to de-energizing the output

5
VOLTMETER AND RANGE SWITCH
The KILOVOLT METER and associated range switch allows for more accurate output voltage readings. 1-%
precision resistors minimize the need for re-calibration due to aging shift. See Voltmeter Re-calibration in
Section3 for detailson calibration.
CURRENT METER
The CURRENT METER is for accurate secondary load current readings. The range multiplier switch (X1,
X10,X100) allows readingsto betaken aslow as.1mA (5divisions) andup to 100mA.
LOAD RETURN CONNECTOR
The LOAD RETURN connector is for the low side of the test load. It connects to the shielded return lead for
moreaccurate load currentreadings.
RETURN MODE
The RETURN MODE switch allows for accurate secondary load current readings. In the GUARD position, all
ground currents are shunted around the meter. The load must be isolated from ground to use in the GUARD
position. In the GROUND position, the return point is grounded and all currents (load and ground losses) are
metered.
BURN(OPTIONAL)
The BURN toggle is provided for tests when the load has faulted and the insulation must be further scored to
find the problem. The BURN feature will limit current on the output below the overload value and allow for
thoroughmarking ofthefaultarea.
Listofincludedcomponents
 Blacktest lead withblack bootfor ground connections.(2 leadsfor PFT-1003)
 Ext.Intlk. Jumperplug
 Attached20 ft.X-Ray shielded outputcable (50kV andbelow)
 Alligatorand hook connectionsfor workingend of outputcable (50kVand below)
 20 ft. RG58/U coax returnlead

6
SETTINGUPTHEEQUIPMENT
The setup of this equipment has been minimized by careful consideration of the operator during design. The
PFT Series’ one-piece construction (50kV and below) minimizes misplaced components while allowing for
convenientportability.
1. Select a location for the unit that will allow easy viewing of the meters at a safe distance
fromthe testobject.
2. Be sure that all the controls are off,in their de-energized or fully counterclockwise
position.
3. Secure a ground test lead to the panel. TheGroundpost on the front panel should be
used for that purpose. A black test lead with black boot has been provided for the ground
connection. A second ground lead is provided for two-piece units for the grounding of the high
voltagesection.
4. Insert the EXT INTLK plug into the socket on the panel. The plug may also be
wired to a normally open contact of a safety switch for added protection. Hand-held safety
switchesare available fromHigh Voltageto plug directlyinto theEXT INTLK socket.
5. If applicable, connect the interconnect cable between the control and high
voltage section.
6. Thered booted alligatorclamp onthe output cableis usedto connecttheoutput cableto thetest
object. (50kV and below). Connection of the output toroid on the PFT-1003 high voltage section
to the load is accomplished by using a customer provided test lead or tubing (metallic) between
thetoroid (HVoutput) and testobject.
SECTION
2

7
OperatingtheEquipment
This section provides step-by-step instruction on various test methods. Many facilities have their own
in-house test procedures that should not be superceded by this manual. The purpose of this section
isto explain thecapabilities ofthis test setin real-worldapplications.
AC InsulationTesting
1. Ensure that all the steps listed in Setting up the Equipment have been accomplished. Take
special note to ground the control panel to a solid earth ground using the supplied black test
lead.
2. Select the desired VOLTMETER RANGE forthetest voltagelevel expected.
3. Prior to connecting the output cable (toroid) to the test sample, be sure that the test sample is
de-energized.
4. Connect the output lead to the test sample. Be sure that there is enough clearance to
grounded objects for the expected test voltage. The minimum clearance in air is 10 kV
ac/inch.
5. Return the low side of the test sample to the LOAD RETURN connector using the supplied
shielded return lead. See the GUARD/GROUND explanation (pp. 9,10) for direction on which
modemay beappropriatefor your testingrequirements.
6. Connect the input power cord to a grounded source (See the specification table for unit input
requirements).
7. Depressthe MAIN POWER switchtoenergize thecontrol circuits.

8
***CAUTION***
POTENTIALLY LETHAL VOLTAGES
MAY BE PRESENT
8. With the OUTPUT control at zero (zero start interlock engaged), depress the HV ON
pushbutton.The HV ON lightwill glow.
9. Increase the output by rotating the OUTPUT control slowly clockwise until the desired output
voltageis reached.
Note: The high voltage output cable shield is grounded. This grounded shield appears as a
load even under ‘no load’ conditions. The current on a PFT-503CM is about 18mA at full
output with the RETURN MODE in the GROUND position.
10. Maintainthe outputvoltage for thetest timespecifiedin yourstandard procedures.
11. After the test is complete, rotate the OUTPUT control to zero, prior to depressing the HV OFF
pushbutton.
12. If the test sample fails during the test, the internal overload relay will de-energize the high
voltage. This relay is in the primary circuit and is sensitive to primary current overloads.
The overload is set to 120% of the rated current of the variable transformer. The use of a
gappedtransformer in thehigh voltagetank will nullthe primarycurrents (up to1.5 KVA)and the
overload will allow operation to the full output rating of 3 KVA. When testing purely resistive
loads, the unitwill overload above1500 VAof inputpower to thetank.
13. Prior to removing theoutput cable from theload, observe thatthe outputvoltmeter isat zero.
14. Always ground the output cable (or toroid) and test sample prior to disconnecting the
test object.

9
Using the Guarded Return
The use of the GUARD/GROUND return feature of this test set provides for very accurate leakage current
measurements if certain conditions exist allowing for the GUARD circuit to be employed. The following
explanation will detail different test samples and methods that lend themselves to the use of this circuit. The
samesetup precautions suchas proper groundingstill applyto the testbut the groundswill bemanipulated to
accomplishthe test requirements.
1. Grounded Return- With the output return in the grounded mode, the current meter reads all
currentto ground, internaland externalto the testset. Thiscurrentmight includecorona, surface
tracking, and any shunt resistance. The typical diagram for grounded return operation is shown
inFigure 2 below.
2. Guarded Return- With the output return in the guarded mode, the current meter will only read
currents through the test sample. The test sample must be isolated from ground on the low side
asshown in Figure 3 below.
Figure 2, Grounded Return Diagram
Test
Sample
High
Voltage
From Test
Set
Current flow through
return includes all
current to ground
Meter
GUARD GROUND
RETURN
POST
GROUND
POST

10
Figure 3, Guarded Return Diagram
Test
Sample
High
Voltage
From Test
Set
Current flow through
return includes only current
through the test sample.
Note that the current to
ground is returned after the
meter.
Meter
GROUNDGUARD
RETURN
POST
GROUND
POST

11
THIS PAGE LEFT BLANK FOR APPLICATION NOTES

12
PERFORMINGSPECIALOPERATIONS
The following section contains information on the care and upkeep of your new PFT SERIES Power
Frequency AC Test Set. There are some notes on troubleshooting and service, which will save much time
andmoney over thelife oftheunit.
MeterRe-calibration
The PFT SERIES of hipots use precision metal film resistors for measurement and calibration of the
voltmeter. The use of these resistors in both the high voltage tank and the metering circuits has minimized
circuit drift due to aging and temperature. Adjustment of potentiometer (R4) on the voltmeter and current
meterPCB can beused tocorrect formovementchanges fromthe agingof the meter.
The certification of meters on a yearly basis is recommended to ensure accurate test
results.
Voltmeter Re-calibration
1. Locatethe unit ina positionthat will alloweasy readingof themeters.
2. Remove the panel screws and support the panel vertically to gain access to the calibration pot
onthe back ofthe voltmeter.
3. Zerothe meter movementusing thezero adjustment belowthescale window.
4. Perform the steps in Setting up the Equipment at the start of SECTION 2. Be sure to ground
the front panel to a solid earth ground using the supplied black ground test lead prior to
connectingthe unit toinput power.
5. Setthe VOLTMETER RANGE toLOW position.
6. Connect the output cable to a calibrated reference meter with ability to read to the full output
voltageof theunit. Besure toground thelow sideofthe meter.
SECTION
3

13
7. Raisethe output toone halfscale onthe unitmeter. Adjust R4as required.
8. Check calibration at full scale and on the high range at both half and full scale. If the customer
facility calibration certification requires more points of reference, follow those procedures instead
ofthese.
9. Calibration must then be verified with the panel in the horizontal operating position to check for
anymeter balance affecton thecalibration.
Current Meter Re-calibration
10. Locatethe unit ina positionthat will alloweasy readingof themeters.
11. Remove the current meter panel screws and support the panel vertically to gain access to the
calibration poton the backof thecurrentmeter.
12. Zerothe meter movementusing thezero adjustment belowthescale window.
13. Perform the steps in Setting up the Equipment at the start of SECTION 2. Be sure to ground
the front panel to a solid earth ground using the supplied black ground test lead prior to
connectingthe unit toinput power.
14. Setthe CURRENT RANGE toX1 position.
15. Connect the output cable to a calibrated reference meter with ability to read 1mA ac. Use a
series resistance or capacitance to allow for precise resolution when calibrating. Be sure to
connect the low side of the reference current meter to LOAD RETURN and place the RETURN
MODE switchin GUARD position.
16. Raisethe output toone halfscale onthe unitmeter. Adjust R4 asrequired.
17. Check calibration at full scale. If the customer facility calibration certification requires more points
ofreference, follow thoseprocedures insteadof these.
18. Calibration must then be verified with the panel in the horizontal operating position to check for
anymeter balance affecton thecalibration.
19. Check other ranges to verify accuracy. 1% range resistors should not require any adjustment on
higher ranges. The output current can only be run to full output current with a capacitive load.
Resistiveloads are limitedto about 1/2rated current.

14
Miscellaneous
Oil Insulated High Voltage Tanks
The oil-filled tanks in all the PFT SERIES of hipots are field serviceable. The only requirement is that the tank
must be oil filled under vacuum at re-assembly if left out of the oil for longer than 3 hours. The parts to service
the tank are available from HIGH VOLTAGE, INC. at the address noted on the inside front cover of this
manual.
Theoil level inthe tankshould be.5 inchesfrom the lid when the oiltemperature is20°C.
Packing the Cables
The output cable will easily fit into the cable storage area next to the control panel. Care should be used to
avoid damaging the output cable jacket when coiling into the compartment. As the final step, the ground and
returnleads will coilneatly insidethe outputcable coil.

15
RETURNED MATERIAL
If for any reason it becomes necessary to return any equipment or materials to High Voltage,
Inc., the Service Department of High Voltage, Inc. must be notified, and authorization received,
prior to the shipment of the equipment. When notified, the following information must be
provided:
MODEL:
SERIAL NO:
PART NO:
REASON FOR RETURN:
SUSPECTED DEFECT:
CAUSE OF DEFECT:
With the above information provided, High Voltage, Inc. will determine if the return of the
equipment is appropriate. If deemed appropriate, a Return Authorization Number will be
issued. At that time, the Purchaser will be instructed how to mark and return the equipment.
The above procedure must be adhered to in order to ensure prompt service. No equipment
should be returned without the prior knowledge and authorization of High Voltage, Inc.
REPLACEMENT PARTS ORDERING
To order replacement parts, first refer to the Parts List for the product in question. Every part is
issued a part number. It is necessary for this part number and the product model and serial
number to be provided. When calling High Voltage, Inc. request the Service Department.

16
* * * * * * * * * * * * * * * * * * * * *
LIMITED WARRANTY; LIMITED RESPONSIBILITY FOR DAMAGES
High Voltage, Inc. (“High Voltage”) warrants to the original purchaser of any new product, purchased
from High Voltage, that the product is free from defects in material and workmanship under normal use
and service for a period of one year from the date of shipment to the original purchaser by High
Voltage.
This warranty is valid only for normal use of the product. Any use outside High Voltage’s written
operation instructions will void this warranty. In addition, any one of the following events will void this
warranty: (a) any defects due to negligence, alteration, modification, accidental or intended physical
abuse, faulty installation, and/or misuse: (b) attempted or actual dismantling, service or repair by any
person or firm not authorized in writing by High Voltage: (c) defects caused due to handling or transit,
either by carrier or purchaser.
This warranty only covers those parts deemed defective by High Voltage The liability of High Voltage
is limited to only the repair, replacement with new or reconditioned parts, or issuance of credit for those
parts deemed defective within the scope of this warranty. Any additional costs incurred by the
purchaser for labor and/or materials incidental to the inspection, repair, replacement or issuance of
credit for product or materials under warranty is the sole responsibility of the purchaser. This warranty
applies solely to products manufactured by High Voltage. It does not apply to parts, accessories, or
materials not manufactured by High Voltage, or to consumables. If purchaser’s claim relates to
materials manufactured by a supplier to High Voltage, High Voltage reserves the right to disclaim
responsibility and liability and may require the purchaser to deal directly with the other manufacturer of
the defective part. High Voltage may elect to assist the purchaser in settling such claim against such
other manufacturer without prejudicing High Voltage’s position as to its own liability.
WARRANTY CLAIM PROCEDURE
Compliance with the following Warranty Claim Procedure is a condition precedent to the obligation of
High Voltage under this warranty:
a) Purchaser must notify High Voltage as soon as is reasonably possible of any alleged defect in
material, workmanship, or operation of any product covered under this warranty, provided that
any notification must be received by High Voltage within twelve months after the shipment date
of the product in question. Such notice must describe in detail the defect, any and all defective
parts, and the alleged cause of the defect.

17
b) At the exclusive option of High Voltage, purchaser may be directed to dismantle the product at
the purchaser’s cost and expense and ship the product prepaid to High Voltage Refer to the
Returned Material section for instructions regarding the return of any material to High Voltage
If High Voltage elects to inspect the product at the purchaser’s site, and possibly repair,
replace, or ship the defective product to High Voltage’s factory, purchaser, at its own cost and
expense, shall provide suitable facilities for such work as needed to inspect and evaluate and
possibly repair/replace subject product. If inspection discloses that the defect is not one for
which High Voltage is liable, that is, is outside the stated terms of this warranty provided by
High Voltage, then the purchaser agrees to reimburse High Voltage for all expenses incurred.
c) Upon receipt of the defective material or product, or following access to the same, High
Voltage shall inspect and evaluate the material or product and determine the validity of the
purchaser’s claim.
The validity of any warranty claim, the purchaser’s compliance with this warranty and Warranty Claim
Procedure, and the obligation to replace, repair, or issue credit for any product, shall be solely and
exclusively determined by High Voltage and any determination shall be final and binding.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR
IMPLIED ON THE PART OF HIGH VOLTAGE, INCLUDING THE WARRANTIES OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR USE, AND NON-INFRINGEMENT ARISING
FROM ANY BREACH THEREOF AND HIGH VOLTAGE NEITHER ASSUMES NOR AUTHORIZES
ANY OTHER PERSON, FIRM , OR CORPORATION TO ASSUME ANY LIABILITY OR OBLIGATION
IN CONNECTION WITH THIS WARRANTYON ITS BEHALF AND PURCHASER ACKNOWLEDGES
THAT NO REPRESENTATIONS EXCEPT THOSE MADE HEREIN HAVE BEEN MADE TO
PURCHASER. THIS WARRANTY SHALL BE GOVERNED AND CONSTRUED ACCORDING TO
THE INTERNAL LAWS OF THE STATE OF NEW YORK.
LIMITATION OF LIABILITY. TO THE MAXIMUM EXTENT PERMITTED UNDER APPLICABLE LAW,
AND NOTWITHSTANDING ANYTHING ELSE IN THIS DOCUMENT OR OTHERWISE, INCLUDING
THAT HIGH VOLTAGE WAS WARNED THAT DAMAGES WOULD OCCUR OR WERE LIKELY TO
OCCUR, HIGH VOLTAGE SHALL NOT BE LIABLE UNDER ANY CONTRACT, NEGLIGENCE,
STRICT LIABILITY OR OTHER LEGAL OR EQUITABLE THEORY FOR (A) ANY AMOUNTS IN
EXCESS IN THE AMOUNT PAID TO HIGH VOLTAGE FOR THE PARTICULAR PRODUCT OR
PART THEREOF WHICH GAVE RISE TO THE APPLICABLE CAUSE OF ACTION, OR CLAIM, OR
(B) ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, LOST PROFITS OR LOST DATA, OR (C)
COST OF PROCUREMENT OF SUBSTITUTE GOODS, TECHNOLOGY OR SERVICES. HIGH
VOLTAGE SHALL HAVE NO LIABILITY FOR ANY FAILURE OR DELAY DUE TO MATTERS
BEYOND ITS REASONABLE CONTROL.