Phenix Technologies PAD56 User guide

OPERATIONS AND APPLICATIONS MANUAL
MODEL NUMBER PAD56
5 KV AC / 6 KV DC HIGH POTENTIAL TESTER
WITH MEGOHMMETER
Version 2.1
LO/bjf
September 23, 2004

TABLE OF CONTENTS
Section Number
DANGER
PRODUCT INFORMATION 1
-SAFETY AND CAUTION NOTES
-DESCRIPTION
-SPECIFICATIONS
CONTROLS AND CONNECTION 2
-FRONT PANEL CONTROLS AND METERS
-INPUT/OUTPUT CONNECTIONS
INSTALLATION AND OPERATION INSTRUCTIONS 3
-INSTALLATION
-OPERATION
-TEST LEAD CONNECTIONS
SCHEMATIC 4
PARTS LIST 5
PARTS ORDERING INFORMATION 6
RETURNED MATERIAL 7

GENERAL SAFETY PRECAUTIONS


HIGH VOLTAGE
This equipment is capable of providing POTENTIALLY LETHAL VOLTAGES!
Improper operation or test practices may result in injury or death to the operator
or surrounding personnel.
The operation of High Voltage test equipment should only be performed by personnel
familiar with HIGH VOLTAGE testing and safety procedures. The operator of this
equipment must be aware of all hazards associated with High Voltage testing. The op-
erator is responsible for himself and others in close proximity of the testing area.
Some General Safety Practices for working with High Voltage Test Equipment have
been listed below for your reference.
·Become familiar with your instrument before performing an actual test
·Know your work area, check that all circuits are de-energized and locked out.
·Never work alone; always work with another qualified worker.
·Mark off entire work area with barriers and warning tape.
·Make all personnel aware of your testing activities.
·Be aware of dangerous conditions that may arise from energizing a test speci-
men.
·Never modify test equipment, modifications to equipment could introduce an
unknown hazard or hinder a designed-in safety feature.
·DO NOT operate damaged equipment. Remove power, and do not use the
equipment until safe operation can be verified by service-trained personnel.
Phenix Technologies, Inc. assumes no liability for unsafe or improper use of test
equipment.

1-1
PRODUCT INFORMATION
CAUTION: Contact with the test leads on this equipment can cause harm-
ful or fatal electrical shock. Do not touch test leads while a test is in pro-
cess.
SAFETY AND CAUTION NOTES
1. Contact with the test leads on this equipment can cause harmful or fatal electrical shock. Do
not touch test leads while a test is in process.
2. Insure that the tester is properly grounded before proceeding with a test.
3. Turn the tester off before reaching inside. Damage to the tester and hazardous shock to
personnel will result if this procedure is not followed.
4. Insure that the equipment to be tested is deenergized and properly isolated.
5. Insure that the equipment to be tested has been properly grounded using a hot stick and rub-
ber gloves.
6. Insure that barriers and warning signs are erected in order that personnel in the test area are
protected. Use an assistant operator where appropriate to keep non-essential personnel
away from the test site.
7. When testing cables, the conductors at the distant end should be isolated from each other
and taped.
8. When testing a faulted cable, it is advisable to first make an insulation resistance measure-
ment before proceeding with the high voltage test.
9. Use care to avoid damaging the tester during disassembly and reassembly procedures.
10. This unit should only be operated by someone familiar with high voltage testing and safety
procedures.
DESCRIPTION
The PAD56 tester is capable of producing voltages as high as 6 kV DC (5 kV AC) into a variety
of insulated electrical apparatus. The unit will measure leakage current flow through (or insula-
tion resistance levels of) the ground insulation of the test sample. Leakage current as low as .01
microamperes DC (.1 milliamperes AC) and as high as 5000 microamperes DC (5 milliamperes
AC) can be read directly from the testers front panel meter. Insulation resistance values up to
1,000,000 megohms may also be read directly at test voltages of 2.5 or 5 kV DC (a factor scale
for insulation resistances at other test voltages is also provided).

1-2
PRODUCT INFORMATION
The unit incorporates an overcurrent trip circuit which will instantly de-energize the high voltage
power supply if such a condition is encountered. The level of sensitivity at which trip-out will oc-
cur is controlled by the front panel adjustment labeled “Min-Max”. The trip setting can be as low
as 10% or as high as approximately 110% of full scale reading. Overcurrent trip is indicated by
an audible alarm.
SPECIFICATIONS
Description:
AC/DC High Potential Tester with Megohmmeter
Primary Application:
Dielectric withstand testing and insulation resistance measurement of motors, cables,
and
transformers.
Input:
120 Volts AC, 50/60 Hz, single phase, .3 Amps
or
220 Volts AC, 50/60 Hz, single phase, .15 Amps
Output:
0-6 kV DC (0-5 kV AC), continuously adjustable with manual control
Negative Output, Positive Ground
Voltmeter:
2%, 3.5”, analog meter, 0-3/6 kV
Currentmeter/Megohmmeter:
2%, 3.5”, analog meter,
0-.5/5/50/500/5000 microamperes DC
0-5 milliamperes AC
0-.5-50/500/5000/50,000/500,000 megohms at 2.5 kV DC
1-100/1000/10,000/100,000/1,000,000 megohms at 5 kV DC
Termination:
Input: Standard modular 3-wire cord mating to fused input module
High Voltage: 10’ attached cable with clip and insulator
Return: 10’ separate cable with insulated clip (metered and guard)
Ground: 10’ separate cable with clip
Dimensions:
18” W x 11” D x 11.5” H (457 mm W x 279 mm D x 292 mm H)
Weight:
22 lbs. (10 kg) 120 VAC
23 lbs. (10.5 kg) 220 VAC

2-1
CONTROLS AND CONNECTIONS
FRONT PANEL CONTROLS AND METERS
Raise Voltage:
Clockwise rotation of this control increases the tester’s output voltage. The tester’s out-
put range is 0-6,000 volts DC or 0-5,000 volts AC. This control must be returned to the
“0” (full counter clockwise position) before a test can be initiated if either the “Power” or
“High Voltage” switches have been previously disengaged, or if an overcurrent condition
has been encountered.
Power: When depressed and locked, this illuminated pushbutton switch (green lens) supplies AC
power to all tester components with the exception of the high voltage power supply.
High Voltage:
When depressed and locked, this illuminated pushbutton switch (red lens) supplies AC
power to the tester’s high voltage power supply. In normal operation this switch will illu-
minate when depressed if the “Raise Voltage” control has been set to “0”. Illumination of
this switch indicates that high voltage output is available.
Currentmeter-Megohmmeter:
The currentmeter range is selected by the seven position rotary switch. The switch set-
ting indicates the full scale current of the currentmeter and the megohmmeter multiplier.
AC and DC operation is automatically changed depending on the position of the rotary
switch. If a DC range is selected, the output is switched to DC. If the 5 mA AC range is
selected, the output is automatically switched to AC. The table below shows the full
scale currentmeter range with each switch setting.
Currentmeter Ranges
Switch Setting Currentmeter Ranges
.5 microamps 0-.5 microamps
5 microamps
0
-
5 microamps
50 microamps 0-50 microamps
500 microamps 0-500 microamps
5000 microamps 0-5000 microamps
5 milliamps AC
0
-
5 milliamps AC
The megohm multiplier is selected by the same seven position switch as the current-
meter range. This allows direct megohm readings at 2.5 and 5 kV. In order to read
megohms directly, the kilovolt meter must be set to either 2.5 or 5 kV. The megohms
are then read from the right hand meter, megohms at 5 kV on the top scale and meg-
ohms at 2.5 kV on the middle scale. The table below shows the megohm range for each
switch setting and kilovolt range.
Megohmmeter Ranges
Switch Setting
2.5 kV
5 kV
x10K 5,000 - 500,000 megohms 10,000 - 1,000,000 megohms
x1K 500 - 50,000 megohms 1,000 - 100,000 megohms
x100 50 - 5,000 megohms 100 - 10,000 megohms
x10
5
-
500 megohms
10
-
1,000 megohms
x1 .5 - 50 megohms 1 - 100 megohms

2-2
CONTROLS AND CONNECTIONS
FRONT PANEL CONTROLS AND METERS (continued)
Guard: The guard function is selected by a binding post jumper. When the jumper is connected
to “Return”, leakage current or insulation resistance valuesassociated with the “Ground”
terminal will be measured. When the jumper is connected to “Guard”, leakage current or
insulation resistance associated with the “Ground” terminal will not be measured. (See
connection diagram at end of this section.)
Voltmeter Range:
This two position rotary switch scales the DC kilovolt meter. When the switch is rotated
to “3”, the kilovolt meter range is 0-3 kV and the lower black scale is read in order to de-
termine output voltage. When the switch is rotated to “6”, the kilovolt meter range is 0-6
kV and the upper red scale is read in order to determine output voltage.
Current Trip:
This control, located below the currentmeter range select switch, allows the operator to
set the level of leakage current measured by the instrument before high voltage shut-
down occurs. At its highest level (full clockwise) approximately 110% of full scale cur-
rent will be allowed. At its lowest level (full counterclockwise) approximately 10% of full
scale current will be allowed before shutdown.

2-3
CONTROLS AND CONNECTIONS
INPUT/OUTPUT CONNECTIONS
Return:Leakage current or insulation resistance values associated with this terminal is measured
by the “DC Microammeter”.
Guard: Leakage current or insulation resistance values associated with this terminal is always
bypassed around the “DC Microammeter”.
Ground:
Leakage current or insulation resistance values associated with this binding post terminal
may be either measured by the “DC Microammeter” or bypassed around the “DC Micro-
ammeter” depending on the position of the binding post jumper.
NOTE: The ground binding post jumper must always be connected to Ground and
Guard (Guard Mode) or Ground and Return (Grounded Return Mode). DO NOT operate
without jumper properly installed.
Also, if the low potential side of the test specimen connected to Return cannot or will not
be isolated from ground, the Ground post jumper must be connected to Return. Guard
mode cannot be used under these circumstances or the current meter will not function
properly. (See the connection diagram on the following page.)
AC Line:
This cord supplies input power to the tester.
Output:This test lead with clip and insulation boot supplies the testers output to the apparatus
under test.
Fuse:
If this protective fuse opens, AC power to the tester is interrupted.

3-1
INSTALLATION AND OPERATION INSTRUCTIONS
INSTALLATION
Install the tester as follows:
1. Turn the main “Power” switch off (out position, non-illuminated).
2. Turn the “High Voltage” power switch off (out position, non-illuminated).
3. Connect the “AC Line” cord to a 115 Volt source.
4. Make necessary grounding connections.
5. Set all switches and controls present on your tester as listed below for initial start-up:
“Raise Voltage” 0 (zero)
“Ammeter/Megohm” Range X1/5000 (or 5 for AC test)
“Ground Jumper” Jumped to Return or Guard as required by test
“KV Meter” 6 kV
“Current Trip” Mid-range
6. Connect the test leads to the specimen to be tested. See Test Lead Connections section for
information on how to connect the test leads.
OPERATION
1. Turn the unit on by pressing the “Power” switch. The switch will illuminate and remain re-
cessed.
2. Energize the High Voltage power supply by pressing the “High Voltage” power switch. The
switch will illuminate and remain recessed.
NOTE: If the “Raise Voltage” control has not been set to “zero”, the overcurrent alarm will
sound. To silence this alarm insure that the raise voltage control is in its full counter-
clockwise position.
3. Rotate the “Raise Voltage” control clockwise until the desired test voltage is observed on the
“Kilovolt” meter. Maintain output voltage at the desired level for the required amount of
time. If the test was initiated on the “6” scale and a more accurate voltage reading is re-
quired (3 kV or below), select “3” on the “KV Meter” range switch.
NOTE: If an overcurrent condition is encountered before required test voltage is reached
and it is desirable to achieve a higher test voltage, adjust the “Min-Max” to a more clockwise
position.

3-2
INSTALLATION AND OPERATION INSTRUCTIONS
OPERATION (continued)
4. Observe and record the resultant leakage current or insulation resistance value on the “Mi-
croamperes/Megohms” meter. If no current reading is indicated, select a lower sensitivity
range until an observable reading is obtained at less than full scale on the “DC Micro- am-
peres/Megohms” meter.
NOTE: The megohmmeter is scaled to read megohms directly at two test voltages; 2.5 kV
(lower megohm scale) and 5 kV (upper megohm scale). If any other test voltage is used, the
megohm reading must be taken normally by reading megohm scale corresponding to the
voltmeter range setting, multiplied by the megohm range multiplier and then multiplied by
the factor read on the “Multiply Megohm Reading By” scale of the voltmeter. For example, if
a test voltage of 1 kV is used and the meter is on the 2.5 kV scale, the lower megohm scale
reading and range multiplier result reading must be multiplied by .4. Similarly if a test volt-
age of 1 kV is used on the 5 kV scale, the corresponding upper megohm scale reading and
range multiplier result must be multiplied by .2
NOTE: Be sure that the “Ground” jumper is in the desired position. Certain test conditions
may require that leakage currents associated with the “Ground” post be measured by the
microammeter.
5. When testing is completed, return the “Raise Voltage” control to its zero (0) or fully counter-
clockwise position.
6. Observe that the “Kilovolt” meter indicates zero (0) output.
7. Turn off the high voltage power supply by depressing the “High Voltage” power switch. Ob-
serve that this switch is no longer illuminated and is in its out position.
8. If continued testing is required, return to step 2 above.
NOTE: Further testing cannot be accomplished once either or both of the power switches
have been disengaged unless the “Raise Voltage” control has been reset to its zero or full
counter-clockwise position.
9. Turn the tester off by depressing the “Power” switch. Observe that this switch is no longer
illuminated and that it is in its out position.

3-3
INSTALLATION AND OPERATION INSTRUCTIONS
TEST LEAD CONNECTIONS
An understanding of the function of the three current return terminals (return, ground, guard) on
the tester will allow the operator to properly connect the test leads for a variety of configurations.
The following points should be kept in mind when determining the proper connections for a given
test requirement:
1. Always attach the high voltage test lead to the high side of the test specimen.
2. Any current flowing through the test lead attached to the “Return” terminal on the tester will
always be measured by the “DC Microammeter”.
3. Any current flowing through the test lead attached to the “Guard” terminal on the tester will
never be measured by the “DC Microammeter”.
4. Current flowing through the test lead attached to the “Ground” terminal on the tester will be
measured by the “DC Microammeter” only when the “Ground” jumper is connected to Return.
Ground current associated with the “Ground” terminal will not be measured if the “Ground”
jumper is connected to “Guard”.
5. To use the Guard mode, the specimen must be isolated from Ground. If the low potential
side of the specimen will not or cannot be isolated from ground, only the Return mode can
be used (Ground jumper connected to Return).
NEVER OPERATE UNIT WITHOUT THE GROUND JUMPER CONNECTED TO EITHER
RETURN OR GUARD. See diagram at end of Controls and Connections section.

3-4
INSTALLATION AND OPERATION INSTRUCTIONS
NOTES CONCERNING THE USE GUARD AND GROUND
NORMAL MODE CONFIGURATION
In this configuration the Return and Ground is connected together with an external jumper or a
switch internal to the Test Set, depending on the design. Nothing is connected to the Guard.
Both stray leakage to earth ground and leakage through the Test Specimen is indicated on the
current meter. This configuration should be used if it is not possible to isolate the return side of
the Test Specimen from earth ground.
HIGH VOLTAGE
TRANSFORMER
Amp
GuardGroundReturn
Ground
Test
Specimen
Stray
Leakage
High
Side
Return or Low
Side

3-5
INSTALLATION AND OPERATION INSTRUCTIONS
GUARD MODE CONFIGURATION
In this configuration the Guard and Ground is connected together with an external jumper or a
switch internal to the Test Set, depending on the design. Any current associated with the Return
is indicated on the current meter. Any current associated with the Guard bypasses the current
meter. Leakage current through the test specimen is indicated on the current meter. Stray leak-
age to earth ground is not indicated on the current meter. This configuration cannot be used if it
is not possible to isolate the return side of the Test Specimen from earth ground.
HIGH VOLTAGE
TRANSFORMER
Amp
GuardGroundReturn
Ground
Test
Specimen
Stray
Leakage
High
Side
Return or Low
Side

4-1
SCHEMATIC
Drawing Number Description
9109070
PAD56

5-1
PARTS LIST
PAD56
ITEM DESCRIPTION QTY PART NO.
CONTROLS SECTION
F1A,B FUSE, 2A, GDC 2 1603702
CORCOM INPUT CONN.
1
1152590
INPUT CORD 1 1077170
M1,2
METER, 50UA
2
1501012
SW1,2 SWITCH, 1 POLE 2 1860260
LMP1,2
BULB,
60V EAO
2
1420150
LENS, EAO, GREEN 1 1422151
LABEL, “POWER” 1
LENS, EAO, RED
1
1422150
LABEL, “HV ON” 1
PROTECTIVE GROMMET 1
SW3 SWITCH, ROTARY, 2 POLE 1 1863047
SW4
SWITCH, ROTARY, 4 POLE
1
1863045
KNOB FOR ROTARY SWITCH 2 1355310
R23
POT, 10K, SENSITIVITY ADJ
1
1761092
KNOB, FOR ABOVE POT 1355305
PCB
PAD56 MAIN PCB ASSY PCB
1
31116904
REGULATOR/HV SECTION
BINDING POST RED (RETURN) 1 1351102
BINDING POST, BLK (GROUND)
1
1351100
K4-5 HV RELAY 2 1701330
BINDING POST, WHITE (GUARD)
1
1351104
SHORTING LINK 1 1351110
BLACK BOOT
1
1353001
RED BOOT 2 1353000
ALLIGATOR CLIPS 3 1353002
RUBBER FEET BUMPERS
4
2109500
MOV4-6 (120V) 130V MOVISTORS 3 1606100
MOV4 (220V) 275V MOVISTOR 1 1606110
MOV5,6 (220V)
130V MOVISTORS
2
1606100
¼” SPACER 1 1350101
3 POS TERM STRIP 1 1156050

5-2
PARTS LIST
ITEM DESCRIPTION QTY PART NO.
T2 VARIAC 120V PRI., 0-120V, 1.75A, SEC. .231KVA 1 1890100
T3 TRANSFORMER, 120V PRI., 6000V SEC., 1 1896050
130VA, JEFFERSON ELECTRIC #720
-
33
T4 50VA AUTO XFMR 230V:115V (220V INPUT ONLY) 1 1894425
STANCOR P-8620
CASE
1
2100513
SMALL TEST LEAD WIRE (RED) 10’
SMALL TEST LEAD WIRE (BLK)
10’
RG8U, OUTPUT LEAD 10’
D9
DIODE, 40KV, 25MA
1
1782010
EDAL INDUSTRIES B412-40-25
C7,8
CAP., .05UF, 15KV
2
1092565
R35 RES., 47M, ROX1, 6W, 1% 1 1746940
R36
RES., 10K, 10W, 10%
1
1742190
R37 RES., 45M, 6W, 1% 1 1746850
R38 RES., 50K, 100W 1 1743005

6-1
PARTS ORDERING INFORMATION
Replacement parts are available from Phenix Technologies, Inc.
Changes to Phenix Technologies' products are sometimes made to accommodate improved
components as they become available, and to give you the benefit of the latest technical im-
provements developed in our Engineering Department. It is, therefore, important when ordering
parts to include the serial number of the unit as well as the part number of the replacement part.
When your purchase order is received at our office, a representative of Phenix Technologies will
contact you to confirm the current price of the part being ordered. If a part you order has been
replaced with a new or improved part, an Applications Engineer will contact you concerning any
change in part number.
Your order for replacement parts should be sent to:
Replacement Parts Department
Phenix Technologies, Inc.
75 Speicher Drive
Accident, Maryland 21520