USER'S GUIDE

MODEL: HDA5

PART NOM: CSll-1031

appli£d high voltage technology fOr indil~s!ryut lUes

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HIP 0 TRON Ie S. IN C. ~~BREWSTER' NEW YORK 10509 (914) 279-8091 I TWX 710-574-2420

USER'S GUIDE

MODEL: HDA5

PART NO.: CSll-1031

DANGER HIGH VOLTAGE fWAR N I N G : T his pub lie a t ion des c rib e sap rod uc t e.ngin e ere d

and designed to supply HIGH VOLTAGE Accordingly, maximum

safeguards have been built into the equipment and the best

safety techniques possible are set forth in the unit's

operating instructions. These instructions contain cautions,

warning the user to exercise great care in the use of certain

controls and at appropriate points in the operating procedures.

Despite thes,e written warnings the operator of this equipment

is nevertheless strongly advised to maintain a safety

consciousness at all times. The following rules are particularly

relevent and must be followed at all times.

BEFORE CONNECTING INPUT POWER, GROUND CASE.BEFORE UNGROUNDING CASE, DISCONNECT POWER.

·SECTION

ADDENDUM

SCOPE

GENERAL DESCRIPTION

FEATURES AND SPECIFICATIONS

CONTROLS M~D INDICATORS

KilovoltmeterLeakage DetectorArcing LampRaise VoltageAC Power ControlsHV OUtGround

INSTALLATION INSTRUCTIONS

OPERATION INSTRUCTIONS

SPECIAL OPERATIONS

TROUBLE-SHOOTING GUIDE

RETURNED MATERIAL

WARRANTY

TABL];;".TOFCONm~TS

2

3

3

4

4444444

5

5

6

7

8·

9-10

(

®LEA~(AGE

ADJUST

ADDENDUM,The LEAKAGE ADJUST~lliNT and KILOVOLTMETERpotentiometers are located on the printedcircuit board inside the unit facing rear.

The LEAKAGE ADJUST~lliNTpotentiometer islocated on the LEFT. The KILOVOLTMETERpotentiometer on the RIGHT.

@VMCAL

This publication describes the HIPOTRONICS' HD Series of Hipot Testers.intended to provide a simplified reference for users of this equipment,allow them to make use of its features quickly, safely and efficiently.

It isand to

Information in the body of this publication applies to all models in the HD Series.Information pertinent to the specific model purchased is provided in the pocket ofthe publication. This includes an electrical schematic and a parts list.

The publication contains four major sections: General Description, InstallationInstructions, Operation Instructions and Special Operations.

The General Description section contains a description of the functions of themodels in the HD Series and also contains a description of the functions performedby each of the controls and indicators on the control panel.

The Installation Instructions section provides step-by-step instructions forinstallation or setup of the unit.

The Operation Instructions section provides step-by-step instructions for utilizingthe HD Series of Hipot Testers.

The Special Operations section describes the procedures involved in the Kilovolt-meter Recalibration and Trouble-shooting.

2

GENERAL PESCRIPTION

This section is intended to acquaint the user with the major features of the modelsin the HD Series. The functions and uses of the controls and indicators aredescribed below.

FEATURES AND §EECIFICATIONS

The HD Series of Hipot Testers is designed for simple and reliable production linetesting. Each model has continuously variable output voltage and output connectedKV Meter providing optimum test accuracy. Non-destructive testing is ensured witha sensitive leakage and arc detection system.

Features include:

- an AC POWER ON switch, and internal fuse and a pilot light- continuously adjustable output voltage control- corona network arc detector and indicator- a shielded output lead with an alligator clip termination

3

CONTROLS AND JNDICATQR§

The functions and uses of the various controls and indicators are described below.

KILOVOLTMETER

This output connected kilovoltmeter measures the amount of output voltage beingdelivered to the test sample. The maximum output voltage of each unit in the HDSeries is indicated by the digit after the series indicator. Example: and HD-A3is a 3 kV ac unit. (A for AC, B for DC)

LEAKAGE DETEC'l'OR

The leakage adjustment potentiometer locatdon the printed circuit board inside theunit, sets the trip point of the leakage detector. This setting may be adjusted toa value between 500 ~A and 5 mA. An appropriate resistor must be used to giverequired leakage current ata selected voltage. The unit will trip when the testsample draws more current than the leakage detector is set for.

ARCING LAl-1P

The arcing lamp will light up when any compontent leakage or arcing is detected.

RAISE VOL'.rAGE

The output voltage is regulated by means of the RAISE VOLTAGE control. The markingsaround the control indicate the percentage by which the voltage may be increased.

AC POWER CONTROLS

The AC POWER section on the control panel contains an ON/OFF toggle switch and anindicator light that glows when the unit is on.

HV OUT

The high voltage re-entrant jack must be interconnected to the high side of the testsample with the factory provided test lead.

GROUND

The GROUND stud should be connected to the low side of the test sample.

4

INSTALLATION INSTRUCTIONS

This section provides step-by-step instructions for the installation and setup ofthe A and B Series of Hipot Testers.

1. Select a location for the unit that will place the meters at eye level to allowmaximum accuracy in readings.

2. Set the RAISE VOLTAGE control to zero and check to ensure that the AC POWERswitch is in the OFF (down) position.

3. Ground the case before connecting the input power. The GROUND stud on thecontrol pimel may beused for this purpose-:----

4. Plug the line cord into the 115 V ac, 50/60 Hz outlet. If a two-prong adaptoris used, be sure to gro~~the third wire.

5. Turn the AC POWER switch ON (up). The unit is now ready for operation.

OPERATION INSTRUCTI~

This section provides step-by-step instructions for performing hipot testing.

1. Ensure that the unit is properly grounded and that the RAISE VOLTAGE controlis set at zero.

2. Determine the appropriate resistor to meet test voltage requirements.

Example: The desired leakage at 5 kV is 1 IDA.

V 5 x 103R1 = I = ~;-10~A = 5 megohms

P = I2R = (1 x 10-3)2 (5 megohms) 5 watts

Select a 5 megohm, 5 watt resistor

3. Turn the ~C POWER ON.

4. Increase the voltage to the desired level with the RAISE VOLTAGE control. Turnthe leakage adjust potentiometer until the leakage light glows. The leakagecurrent limit is now set.

5. Return the RAISE VOLTAGE control to zero.

6. Connect the high voltage lead to the high side of the test sample. The groundshould be connected to the low side.

7. Raise the output control to the desired value. Arcing in the sample will beindicated on the arcing lamp. If the sample draws more current than theleakage detector is set for, the leakage light will glow.

5

SPECIAL OPERATIO~

This section describes the step-by-step procedures required to perform any specialoperations incidental to the major functions described in the preceding sections.These special operations are kilovoltmeter recalibration and trouble-shooting.

1. Ensure that the RAISE VOLTAGE control is set at zero and the high voltage isOFF. The meter needle should be adjusted to the zero position.

2. Select a location for the unit that will place the kilovoltmeter at a levelallowing maximum accuracy in calibration.

_..3. Remove the rear panel of the unit for access to the calibration potentiometer(R3) •

4. Hookup the high voltage end of a standard meter to the high voltage output ofthe unit.

5. The low end of the standard meter should be connected to the ground on the unit.

6. Turn the AC POWER ON.

7. Increase the output voltage with the RAISE VOLTAGE control to about 3/4 of thefull standard meter.

8. Use and insulated screwdriver to adjust the unit meter with the calibrationpotentiometer.

9. Reduce the RAISE VOLTAGE powerstat to zero. The unit is now calibrated.

6

)UBLE-SHOOTING GUIDE

TROUBLE REMEDY,POSSIBLE CAUSE

NO HIGH VOLTAGEOUTPUT

a. Damage to T2 Transformerb. Damage to Tl VAriac

(RAISE VOLTAGE control)

a&b Check output of component withexternal voltmeter; replace ifnecessary

LOW VOLTHETERREADINGS

ERRATIC HIGH VOLTAGEOUTPUT

a. Voltmeter out of adjustmentb. Damage to Cl capacitorc. Low line voltage

a. Recalibrate voltmeterb. Replace Cl capacitorc. Obtain reading at power source

and inform responsibleauthority.

a. Variac (RAISE VOLTAGE control)bur shes dirty or worn

b. Fluctuating line voltage

AC OUTPUT OKAY;NO IX: OUTPUT

~RRATIC OUTPUT CURRENT

a. Clean or replace Variacbrushes

b. Obtain reading at power sourceand inform responsibleauthority.

a. Faulty CRl diode a. Replace CRl diode

a. Arcing from Rl Resistorb. Internal arcing in T2

Transformer

a. Replace Rl Resistorb. Check output current from T2

Transformer replace if notconstant.

RAISING VOLTAGEBLOWS FUSE(NO LOAD)

a. Damage to Tl Variacb. Faulty component in HIGH

VOLTAGE section

7

a. Check Variac and brushes forburn marks; replace if damaged

b. Disconnect input to Clcapacitor and raise voltage.If fuse does not blow, checkand replace faulty Clcapacitor or CRl diode.

RETURNED Ml\TEHIII,L

If, for any reason, it should become necessary to return theequiplIent described in this publication to the factory, the Warral}tyService Department of Hipotronics must be contacted, at which time:thefollowing data must be given in order that we may identify the unit. anddetermine the necessity for return. (Tel. (914) 279-8091) MODEL, SERIALNO. and TYPE (Part No) is indicated on the black and silver ·tag affixed tothe unit.

MODEL:SERIAL NUl,1BER:'fYPE (Part No) :REASON FOR HE'fUHN:DEFEC'f:ALLEGED CAUSE OF DEFECT:

If Ilipotronics deems return of the unit appropriate, an"Authorization for Return" tag will be issued. 'l'hiswill instruct 'you asto the method of return. The pink copy is for your records, the hard copyto be affixed to the unit being returned. tf return is not deemedadvisable, other inspection arrang~nents will be made.

No'rE: Material received at. this point without the properauthorization shall be held as "customer's property," with noservice perfonned until such time as the proper steps havebeen taken.

Your coopera·tion is requested in order to ensure prompt seJ~vice.Thank yo.u.

PAR'l'SORDERING

To order replacement parts of this unit, please refer to the PartsList contained in the pocket of this publication. '1'henumber of thespecific component is required, along with the TYPE (Part No) of the unit.The 'l'YPE(Part No) is indicated on your Parts List, and on the black andsilver tag affixed to the unit.

-8-

Exhibit ASOPII652

WARRANTY

Hipotronics, Inc. warrants to the orginal purchaser of any new merchandisethat the merchandise is free from defects in material and workmanshipunder normal use and service for a period of one year from the date ofshipnent. l'he obligation of Hipotronics, Inc. under this Warranty islimited, in its exclusive option, to repair, replace or issue credit forparts or ma-terials which prove-to be defective, and is subject toPurchaser's compliance with the Ilipo tronics, Inc. Warranty Claim Procedureas set forth below. The happening of anyone or more of the followingevents will serve to void this Warranty and any defect or damage resultingtherefrom is specifically eXCluded for Warranty coverage: (a) defects dueto accident, negligence, alteration, modification, faulty installation byPurchaser or Purchaser's agents or employee, abuse or misuse; (b)attempted or actual dismantling, disassembling, service or repair by anyperson, firm or corporation not specifically authorized in writing byHipotronics, Inc. (c) defects caused by or due to handling by carrier, orincurred d~ring shipnent, transshipnent or other move.

This Warranty covers only those parts and/or materials deemed byHipotronics, Inc. to be defective within the meaning of this Warranty.The liability of Hipotronics, Inc. shall be limited to the repair,replacement or issuance of credit for parts deemed defective within themeaning of this \~arran ty. Costs incurred by purchaser for labor or otherexpenses incidental to the inspection, repair, replacement or issuance ofcredit for such parts and/or material shall be the sole responsibility ofpurchaser. This Warranty shall not apply to any accessories, parts, ormaterials not manufactured or supplied by Hipotronics, Inc. and if, in thesole discretion of Ilipotronics, Inc., Purchaser's claim relates to anymaterials or workmanship manufactured or performed by the supplier of acomponent part, or of the manufacturer of a device of which the defectivepart is a component, Hipotronics, Inc. reserves the right to disclaimliability WIder this Warranty and to direct that the Purchaser dealdirectly with such supplier or manufacturer. Hipotronics, Inc. agrees toassist the Purchaser in processing or settling any such claim withoutprejudicing its position as to liability.

\~ARRANTY CLAIM PROCEDURE

Compliance with the following Warranty claim Procedure is a conditionpreceden t to the obliga tion of Iiipo tronics, Inc. under this Harran ty:

a. Purchaser must- notify Hipotronics, Inc. in writing by certified, orregistered mail, of the defect claimed within twelve months after dateof original shiJxnent.* Said notice shall describe in detail thed~fect, the defective part, and the alleged cause of defect.

-9-

b. At the exclusive option of Hipo tronics, Inc., Purchaser shalldismantle or disassemble at Purchaser's cost and expense and shallship the defective part or ma terial prepaid to Hipotronics, Inc.,Brewster, New York 10509, for inspection, or permit an authorizedservice representative of Hipotronics, Inc. to inspect the defectivepart or material at'Purchaser's premises. If Hipotronics, Inc. shallinspect _the part or ma terial at the Purchaser's premises, Purchasershall provide facilities for, and at Purchaser's cost and expense,dismantle, disassemble, or otherwise make accessible the subject partor ma -terial whether or not same is a component of or installed in adevice other than that manufactured or supplied by lIipotron~.cs, Inc.If disclosure shows that the defect is not one for which Hipotronics,Inc. is liable, the Purchaser a9rees to reimburse lIipotronics, Inc.for all expense incurred.

c. Upon receipt of the defective part or material, or after acces~ tosame, Hipo tronics, Inc. shall inspec t __~he part or ma terial todetermine the validity of Purchaser's claim.

The validity of any Warranty Claim, Purchaser's compliance withHipotronics, Inc. Warran-ty Claim Procedure, the obligation -toeitherrepair, replace, or issue credit, or direct the purchaser to deal directlywith a manufacturer or supplier are to be determined solely andexclusively by Hipotronics, Inc. and aily determination so made shall befinal and binding.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESSED ORIMPLIEq ON THE PAR;r OF IlIPOTRONICS, INC., INCLUDING THE WARRANTIES OFMECIIANTABILITY 1\ND'FITNESS FOR USE, AND CONSEQUENTIAL DAMAGES ARISING FROMANY BREACH THEREOF AND HIPOTRONICS, INC. NEITHER ASSUMES Nc;:>RAUTHORIZESANY OTHER PERSON, FIRM OR CORPORATION TO ASSUME ANY LIABILITY OROBLIGATION IN CONNECTION WITH THIS SALE ON ITS BEliALF AND PURCHASERACKNOWLEDGES THA'X NO REPRESENTA'rIONS EXCEPT THOSE MADE HEREIN HAVE BEENMADE TO PURcHASER.

-10-

1~is unit has been modifi~d to operate from a 220/240Va c, 50 /60 Hz.

INSTALLSTION:

Connect the input termination to a 220/240V ac, 3 ampservice. Connect the ground termination to stationground.

PARTS ADDUNDUM:

A step down transformer has been added at the input ofthe unit. The input transformer is SV4115.

PARTS LISTPage 1

MODEL NO:PART NO:

HDA5CS 11-1 031

REF. DESCIUP'rION MFG. piN HIPO piN

I II

I I IA1 Subassembly, Audible Failure PCB, Hipotronics I BS60-667A2 Subassembly, voltmeter PCB, Hipotronics I AS60-193-1

BU1 I Buzzer, P&B I BU-40

I C1 I Capacitor, 500 pF @ 20 kV, Sprague I 20DK-T5

F1XF1

Fuse, 3 amp, BussFuse Holder, Littelfuse

3AG-3A357001

M1 Meoter, wjO-5 kV ac scale 118

PL1-3 pilit Light, Leecraft 3600

R1R2

Resistor, 250 k ohm, 50 W, Tab TerminalResistor, 30 M ohm, 3 watt

S1 Switch, Toggle, DPDT, C&H 7565-K5

T1T2

Transformer, Variable, StacoTransformer, Hipotronics

221DV1025

output Bushing Assembly, HipotronicsOutput Cable Asse~bly, HipotronicsGround Lead Assembly, Hipotronics

BA29-13BA29-380BA29-384

I I@JotroEJ HIPOTRONICS, INC. Brewster, NY 10509

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NOTES:

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REVISIONS

DESCRIPTION

R3501<

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I HI~fTRO+ICSBR.:E::rVV"S'I'ER., N. 'Y:

. .~..- .MODEL NO

NOTEDDRAWN DATE DWG NO. REV.

~~~~K~~AIiA 8-86 AS 60 ~193 - IFRACTIONS DECIMALS

± 1/64 ± .005SCALE

FULL SHT I OF