HZZGF

DC Hipot Tester

Huazheng Electric Manufacturing (Baoding) Co., Ltd

Dear us er:

Thank you for choosing HZ Z GF DC Hipot Test er.

We hope that this inst rument can make your work easier and more

enjoyable, so that you can get the feeling of office aut omat ion in the test

and analysis work.

Bef ore us ing the inst rum ent, please read this manual, and oper ate and

maint ain the inst rum ent ac cording to the manual to pr olong its service lif e.

"Just a light pr ess, the test will be com plet ed aut omat ically" is the

oper at ing charact erist ics of this inst rument .

If you ar e sat isfied with this inst rum ent, please tell your colleagues;

if you ar e not satisf ied with this inst rum ent, please call (0312) 6775656 to

tell you to ser ve you at all times- Baoding Huazheng Elect ric Manufact uring

Co. , Lt d. , our company will def initely make you satisf ied !
 Contents

I. Product Overview ...............................................................................................................1

II. Main Functional Characteristics ....................................................................................... 1

III. Product Models And Technical Parameters ....................................................................2

IV.Circuit Diagram And The Product Model ..........................................................................2

V. Product Components ........................................................................................................ 3

VI. Directions .........................................................................................................................8

VII. Attention ........................................................................................................................10

VIII.Guarantee ..................................................................................................................... 11

IX.Common Fault And Solution ...........................................................................................11

X.Packing List ..................................................................................................................... 13

I. Product Overview
DC hipot tester adopts high frequency pulse width modulation (PWM) technology

to make closed adjustment with high voltage stability, small ripple factor and fast

reliable protection circuit. The wide temperature LCD screen adopts green back light,

which enables clear display either in bright light or in darkness. High-pressure

components use Dupont new filling material, making the product more stable and

reliable. Products are widely used in electricity power supply departments, power

transmission and transformation engineering company and preventive test of large

industrial enterprises and scientific research institutes as regulated dc high voltage

power supply.

II. Main Functional Characteristics

1、DC hipot tester adopts high frequency PWM technology to make closed adjustment

with high voltage stability, small ripple factor and fast reliable protection circuit. The

generator can endure direct discharge by devices of large capacitance. It is of small

size and of light weight, convenient for field use.

2、Full range of linear smoothly adjusted voltage, with voltage regulation accuracy

smaller than 0.1%; voltage measurement accuracy is 0.5%, resolution 0.1kv;

Current measurement accuracy is 0.5%, the minimum resolution: control box 1µA,

shock resistance current 0.1µA.

3、The generator uses AC 220 V power supply (AC220V±10%, 50 hz±1%), the ripple

factor is less than 0.5%, and can be used for all-weather at the site .

4、High voltage multiplier uses Dupont materials for full solid encapsulation, overcoming

the inconvenience brought by the air and oil filled equipment. Broad base and outer

cylinder of light quality makes it stand steadily and more convenient for

maintenance.

5、75% MOA voltage switch button, simple and convenient testing arrester.

6、Over-voltage setting function displays the over-voltage value during regulation

process; perfect protection against discharge of over-voltage, over-current and

short circuit. This is the best companion for cable experiments.

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 7、Perfect break line and non-zero potential start protection function protects the

operator and samples at any time. This product has overall design of shock-proof

control box, concise, clear panel design and voice prompt for operation.

III. Product Models And Technical Parameters

Control Box High-Voltage Unit

Voltage (KV)/mA
Rated Weight Weight
Current (mA) Size (mm) Size (mm)
Voltage kg kg
60/2-5 60KV 310 * 250 * 230 5kg 470 * 260 * 220 6kg

80/2-5 80KV 310 * 250 * 230 6kg 490*260*220 8kg

100/2-5 100KV 310 * 250 * 230 6kg 550*260*220 8kg

120/2-5 120KV 310 * 250 * 230 7kg 600 * 260 * 220 10kg

200/2-5 200KV 310 * 250 * 230 8kg 1000 * 280 * 270 20kg

300/2-5 300KV 310 * 250 * 230 9kg 1300 * 280 * 270 22kg

output polarity Negative polarity, no-voltage start, linear continuous adjustment

working power
50HZ AC220V±10%
supply

voltage error 0.5%±2，minimum solution 0.1KV

current error 0.5%±2，minimum solution 0.1µA

ripple factor better than 0.5%

voltage stability Random flunctuation , grid change is 10% , the flunctuation <=0.5%

working manner Interval working, less than 30 minutes under rated load
working
Temperature: 0-40℃, humidity: less than 90%
condition
storage
Temperature: -10℃～40℃, humidity: less than 90%
condition
altitude Lower than 3000 m

size= grading shield diameter(R)*insulating cylinder(r)*total height(H)

IV.Circuit Diagram And The Product Model

Rectificati Power High voltage
AC50Hz Power
Negative
on filter transform boost
220V±10% filter 2 HV
loop unit measurement
elicitatio
loop
n
 sample

Auxiliary Drive Measure

Auxiliary
Power power protection
Power
circuit

Circuit Diagram of BCM DC High Voltage Generator

120 - 3
rated output current value（mA）

rated output voltage value（kV）

V. Product Components
A. Control Panel

1. Voltmeter: displays the output voltage. Display unit: KV. Maximum display: 999.9KV

2. Ammeter: displays the output current (including sample’s leakage current and leakage

current in the air, etc. )

Maximum display 9999 uA, except special made.

3. Power socket: single phase AC220V±10% 50HZ power input.

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4. MOA 75% signal light: signal light is on when voltage change is more than 75% V1mA.

The voltmeter displays the highest output voltage value, not the actual output voltage.

Once the voltage regulation knob is back to zero, reset, the light is off.

5. Aviation socket: please align positioning pin, and press the plug in, then tighten

clockwise to connect socket. Counterclockwise to back out. Note: please hold tight the

plug metal rings, do not grasp or pull the line. Improper disassembling or connection

will shorten the life span of the connecting line.

6. Ground terminal: connect the ground wire to the grounding screw at the bottom of the

generator.

7. MOA 75% button: during test of zinc oxide lightning arrester, V_1mA is high voltage

value when leakage current is1mA. Press MOA 75% button, voltage drop

automatically to 75% V_1mA, conversion accuracy is better than 0.5%.

8. Voltage rough adjustment knob: Clockwise adjustment is to increase voltage, maximum

to 1.1 Ve. Due to the needs of the internal self-test circuit and non-zero start design,

adjusting 3/4 clockwise circles does not have voltage output after the potentiometer is

back to zero.

9. Voltage fine adjustment knob: When the potentiometer in the middle position

adjustment range for the current value of between 3% and 8%

10. Main power switch: Avoid directly turning off high voltage by this switch. Please use

the HV switch first.

11. HV switch: Dial up the HV switch to increase voltage. Turn off the switch before

shutting off the power after test.

12. Fuse: AC inlet fuse. Please use the matching fuse current value.

13. Build-in knob for overvoltage adjustment: the user can set and adjust overvoltage

value within the scope of rated voltage. Overvoltage value can be set statically without

increasing voltage. The error is 1%.

14. Overvoltage indicator: when the output voltage is higher than the set voltage, over

voltage protection action shuts off high voltage, and overvoltage indicator light is on.

15. Over current indicator: when load current is more than 1.1 times the rated current or

short circuit discharges, the indicator light is on, and the high voltage is shut off.
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16, HV indicator: Dial up the high voltage switch with booster conditions, high voltage

indicator light is green. Setting over voltage value can be operated only when the

green light is out and the high voltage switch is off.

B. HV Unit

The base and top parts are made of aluminum

castings. Voltage-multiplying circuit is of full solid

encapsulation.

1. Aluminum-based fast loading air outlet, for connection to the control box. When

installing a cable, high voltage generator is laid low on the ground first, alignment

positioning pin plug, press and screw tight clockwise. Do not shake from left to right,

forbidden holding the cable by hand to avoid damage to the plug wire.

2. Base grounding screw, collecting point of the system. Connect to the ground after

grounding of control box, discharge leveler, short circuit rod, etc. Note: to prevent

accidents, ground wire must be firm, especially when the sample is capacitive

discharge. Please carefully check and make sure the grounding is in good condition in

order to ensure the safety of personnel and equipment.

3. The ferromagnetic circular slot on top of grading shield is HV generating terminal. High

voltage ammeter can be embedded in the slot.

C. Shock-resistance uA ammeter

Two grades green backlight display, 200.0 uA and 2000uA .

Pay attention to the decimal point when reading this meter to

avoid misreading the data. To save the battery, back

light

can be turned off in bright conditions. When battery is low,

symbol appears. Please replace the battery in time to ensure

accurate meter reading. Special custom-made 20 mA ammeter has two grades, 200.0

uA and 20.00 mA. Please pay attention to the position of the decimal point to avoid

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reading error.

1. Green backlight display window. Range 2mA: Maximum display is 1999 uA. Range

20mA: Maximum display is 19.99 uA.

2. Backlight switch

3. Shock-resistance ammeter power switch.

4. Connecting iron base.

5. High voltage cable port with shielding layer.

6. 9vV battery rear cover.

D. Discharge rod (available when discharge voltage is less than 60kv)

This discharge rod selects three telescopic rods with a total length of 80 cm and

internal current-limiting resistor 2M/25W. Place grounding wire into the corresponding

jack of the discharge rod before use, and tilt the grounding wire backward, to avoid the

sample’s direct discharge to grounding wire. The discharge rod should approach the

sample’s measuring terminal from far to near. First the arc discharge is conducted. when

the arc disappears or reduces, the front metal part of the discharge rod can touch the

discharging object to discharge. When the control box displays 0 or a very small figure,

then grounding wire can be used to complete discharge. Special tips: for safety, the

grounding line of the discharge rod must be solid and reliable during discharge.

1. Grounding socket
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 2. Discharge point

3. Ground lead. Tilt the grounding wire backward as much as possible to avoid

flashover discharge.

4. Hand grip. Make sure the grounding socket is safely connected to the earth before

any personnel can hold the discharge rod by hand.

Picture of cable
structure
Compound insulation silicone rubber soft high voltage cable：

1. Silicone rubber insulation of dc withstand voltage 300 V

2. Copper wire strands of inner core

3. Shielding layer of inner core

4. silicone rubber insulation to withstand voltage DC 60kV

The cable wire inner core is led by red clip, the shielding layer is led by the black clip.

Withstanding voltage to ground is 60 kV DC with the leakage current almost zero.

Under the condition of dc 200 kV, The cable and ground potential keeps 50 cm

clearance, air leakage current is less than 5 uA, using shock-resistant current meter,

leakage current of the generator and current on ground shielding layer can be removed.

To ensure the reliability of test data, please note the following points:

(1) Be sure not to touch the cable during test to prevent electric shock.

(2) Avoid cable dragging, twisting, soaking in water or under high drawing force.

(3) When the DC voltage is greater than 60 kV, composite insulation is adopted to

improve bearing capacity. Method: keep the potential effective air insulation

distance 50 cm or more, which is effective insulation distance with highest dc

200 kV make it convenient for site matching. When test environment humidity

is more than 60%, increase the space between the test line and the ground

and surrounding.

(4) The effect depends on the composite insulating space. If the cable touches the
7
 ground accidentally to cause discharge breakdown, there is no cable return,

refund or guarantee.

Rf plug inner core is connected with red clip, outer ring with black clip, which is

convenient for users for maintenance.

VI. Directions
1.On-line and operation method

(1)Connect all the cables, the control box grounding terminal connected to high

voltage generator grounding screw at the bottom of the aluminum base, then

ground to the earth. In order to ensure your safety and equipment’s safety,

please be sure to check the ground again and again. Switch on the power

switch, turn the rough adjustment knob to the end counterclockwise, then

switch on the high voltage, the green light is on. Preparation is completed.

Turn the rough adjustment knob clockwise to 3/4 circle, for the need of circuit

self-check, there is no high voltage is output.

(2) Turn the knob to zero anticlockwise to switch off the high voltage., or switch off

the high voltage directly. Avoid switching off the power.

(3) The panel has voice prompt, protection action, state voice prompt and protection

action indicator light.

(4)Use of MOA 75%: When MOA predicts V1mA, press MOA75 % button, a voice

prompt appear with corresponding the yellow light, then the voltage drop

automatically to 75% V1mA. When operation return to zero, this state

removes automatically.

(5) Static over-voltage setting: On condition that green light goes out, press the

button MOA75 % more than 3 seconds until there is no voice prompt, HV meter

displays the maximum overvoltage value. Once in voltage-increasing state, hv

green light is on, the circuit automatically shifts to actual hv value display.

(6) Turn the rough adjustment knob back to zero, dial up the high voltage switch. If

the HV light is not on, usually check the fast loading multicore cable line 1, line 2

to see if there is shorted.

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 2. Preventive testing method of capacitive equipment

For capacitive equipment like cables, the equivalent circuit is the RC circuit.

Therefore, damping shock problems exist. Please follow the following steps in operation:

(1) Turn the rough adjustment knob back to zero, the green light is on before increasing

voltage. After normal display of the voltmeter, operation can begin. If over-current

occurs at the staring phase, it could be:

a 、 At the brownish red silicone rubber wire terminal, the red clip should be

connected to the tested cable, the black clip at a high potential should be hung

up. If the black clip is connected to cable sheath, there will be a short circuit,

resulting into over current fault. Because there is no insulation at a high

potential between high voltage cable and black clip, this part should keep far

away from the ground at field, or discharge may appear in the process of

voltage increase.

b、No stop as required at 3/4 circle, or not observing voltage display and increase

the voltage rapidly, causing rapid voltage rise and over-current to appear.

c 、 Turn the knob back to zero and dial up the switch, but voltage-increase

operation begin before the green light is on, causing sudden change in voltage

and over-current to appear.

(2) Due to the capacitive video storage, and the function of negative feedback circuit,

there is a time lag between voltage display and the actual voltage.

(3) Zinc oxide lightning arrester pilot test methods: MOA lightning arrester is nonlinear

device. When it reaches a turning point, small changes in voltage can cause great current

9
change.

Take 10 kV earth-sized as an example. The sign V1mA_25kV in actual experiment,

when the voltage is less than 25 KV, current is a few microamperes, but once the

voltage reaches a turning point, 1 mA, 0.1 kV voltage change can cause hundreds of

microampere in the current change. So in field test, the minimum resolution better than

DC hipot testeris 0.1 kV and an error of 1%±1 is allowed. From extensive experience,

current between 950uA～1050uA can be considered to be 1 mA. This is not very precise

but has very small error in actual measurement, which completely satisfies the standard

requirement in “the zinc oxide lightning arrester test standard” GB11032-89.

If over-current occurs, please check:

（1） Whether the high voltage wire has short-circuit with ground, or being

too close to the ground objects.

（2） Whether voltage increase is too rapid at MOV turning point.

VII. Attention
1. In order to ensure the safety of personnel and equipment, good grounding and

discharge after use is very important.

2. Grounding of control box and high voltage generator must be solid and reliable. The

high voltage generator grounding screw at the bottom should be connected to the

earth. Ground wire connection in series is forbidden.

3. After capacitance video discharge is completed, please hang up ground wire before

anyone approaches. Please make sure of reliable grounding in using discharge rod.

All grounding wires should be connected together to the bottom of the high voltage

generator. Discharge rod can be used only when the voltage is less than 60 kV.
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 4. Power supply for this generator is single-phase AC 220 V±10% /50 Hz. Exceeding the

required voltage may cause equipment damage.

5. Select proper fuse, do not use metal wire instead. Do not start with charged inner

machine. Please turn off the high voltage switch before shutting off the power switch.

6. When the equipment is not in use for a long time, to prevent sere electrolytic capacitor,

operation box should be electrified for no less than four hours every six months.

Instrument transportation should avoid water, severe vibration and fall.

7. The generator should be laid low on the ground when plugging in and out the aviation

plug wire. Alignment positioning pin, press the plug and turn clockwise. Strong pull or

twist is forbidden.

8. To ensure the accuracy of measurements, for companies equipped with the more than

one product from our company, please number the control boxes and the high

voltage generators according to their models to make sure they match each other.

Prohibit disorder use.

9. High voltage grading shield concave port has strong magnetic, approach slowly when

connected with high-end ammeter to avoid collision.

10. For capacitive test, because of RC oscillation phenomenon and polarization

absorption current, charging voltage goes into the steady state after 1 minute.

VIII.Guarantee
1. One year free warranty for normal use, life-long maintenance.

2. 24 hours response to take the standby replacement, on-site service or return to the

factory processing, to ensure the user's normal use.

IX.Common Fault And Solution

fault phenomenon solution

Replace ACRD fuse. If burnout again, check whether

The power indicator light is
1 the power supply is over 380v. If so, remove the
on.
varistor, then the product can be used for emergency.

11
 Check if fast loading multi-core cable line 6 and 7 are
Green light is on but HV does disconnected. If HV increased suddenly after turning
2
not increase. the knob clockwise for a few circles, then the problem
lies in the fast loading multi-core cable.

Adjusting knob is turned to

zero and voltage-increasing Check if fast loading multi-core cable line 1 and 2 are
3
switch is on, but there is no disconnected.
indicator light.

Voltage is increased but there Check if fast loading multi-core cable line 1 and 2 are
4
is no display. disconnected.

Current exists but there is no Check if fast loading multi-core cable line 3, 4 and 5 are
5
value display disconnected.

voltage display is unstable

Check if fast loading multi-core cable line 3, 4 and 5 are
6 after voltage increase
disconnected.
(non-capacitive test)
1. Whether operation begins after green light for
Over current always appears voltage increase is on.
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in large capacitive tests 2. Whether stop for 2 seconds at 3/4 circle.
3. Whether hv cable has short circuit to earth.
1. Whether low battery at high terminal ammeter.
Too much deviation for high 2. Whether caused by corona.
8
and low terminal ammeters 3. Whether caused by insulation characters of flexible
cable.
1. Too close to objects on the ground.
No-load voltage increase,
9 2. Dirty insulating cylinder. Clean the cylinder surface.
large current leakage.
3. Too large corona current.
Unable to increase to rated
10 Turn overvoltage knob clockwise to maximum
voltage.
1. Check whether ground wire is removed.
2. Operation begins after green light for voltage
unable to increase voltage,
11 increase is on.
over-current always occurs
3. Whether shielding wire of high voltage cable is
grounded.
1. Whether the black line of shielding layer and the red
High terminal micro ammeter line of core wire is connected.
12
is always zero. 2. Whether one side of the red clip is disconnected at
the root.
fast loading line is difficult to 1. Check alignment pin
13
connect 2. Press and turn clockwise

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 3. Whether leading line inside socket is bent.
1. Check whether grounding wire is removed.
Over-current occurs before 2. Whether operation begins after green light for
14
reaching rated voltage. voltage increase is on.
3. Insufficient insulation distance causes discharge.
Over-current often occurs
1. Whether caused by too rapid voltage increase at
15 during zinc oxide arrester
turning point. Adjust the knob slowly at turning point.
tests.
1.Whether caused by HV equipment to test 10 kV
Unstable current during cable.
16
capacitive tests. 2. Sudden unstable currents are mostly caused by
break of inner wire in fast loading multi-core cable.
Voltage increases from
Caused by inner shield of line 1 and 2, break of line 4
17 non-zero state after turning
and 5 in fast loading multi-core cable
knob clockwise
Partial damage of LCD, return to factory for
18 Picture missing on LCD
replacement.
19 No current at rated voltage Check whether output core wire is broken
Ammeter data exists in
20 control box, but there is no The clip should be suspended in the air.
current display

X.Packing List
No. Item Qty

1 Control Box 1

2 High Voltage Line 1

3 Power Line 1

4 Control Line 1

5 Ground Lead 1

6 High Voltage Generator 1

7 Discharge Rod 1

8 Anti - Shock Ammeter 1

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