.

USERS MANUAL
MODEL 568
Hi-Pot / Continuity
Tester

Revised:
April 2013

175 Lewis Rd., Unit 23

San Jose, CA 95111
Toll Free: (800) 922-2969, Fax (408) 574-0116
E-Mail: [email protected], Se Habla Español

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 Users Manual

CERTIFICATION

All test stations are certified to comply with the current revision of U.L.
Test Specifications, CSA Test Standards, the National Electrical Code
and OSHA Specifications.

WARRANTY

All instruments manufactured by Sotcher Measurement Inc. are warranted

against defects in material and workmanship for a period of one year. We
will repair or replace products which prove to be defective provided they
are returned to Sotcher Measurement Inc. This warranty is in lieu of all
other warranties expressed or implied and no responsibility is assumed
for consequential damage. In no case shall liability exceed the purchase
price.

WARNING: THE TESTING OF PRODUCTS USING THIS EQUIPMENT CAN

BE EXTREMELY DANGEROUS! READ AND UNDERSTAND ALL SAFETY
PRECAUTIONS BEFORE USING THIS EQUIPMENT.

Model 568 2 Sotcher Measurement Inc.

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 Users Manual

Model 568 Hi-Pot / Continuity Tester

Model 568 3 Sotcher Measurement Inc.

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 SECTION 1 Users Manual

GENERAL INFORMATION

Zero Crossing
INTRODUCTION
Dielectric and continuity test voltages are applied
at the zero crossing point for transient free opera-
Model 568 tion.
A Hi-Pot / Continuity Tester is used to verify the
ground wire continuity and insulation integrity of Complies with UL’s 120K Test
electrical equipment. The model 568 brings state Test standard is available on the front panel for
of the art technology to the testing of electrical easy use.
products.
Fast Response
Standard Features The tester uses a fast response detection circuit
Pressing a single button, tests both the dielectric to detect even short duration arcs or breakdowns
strength and ground wire continuity. that might occur. Once a fault is detected the test
circuit opens within milliseconds.
Full 25A Ground Bond Test
The ground wire test is conducted using a test Ground Continuity
current of 25 amperes, rejecting high resistance When ground wire verification is selected, the
ground connections. The continuity test may be tester prevents the application of the dielectric test
turned off when testing double insulated products. voltage unless the ground wire to the product is
verified. The grounded potential of the product is
Choice of Test Methods verified during the dielectric test as well.
The panel-mounted receptacle is useful for com-
pleted products with standard cord sets, while the Direct Reading Leakage Meter
high voltage probe is useful for testing compo- A 0-10 milliamperes meter monitors the actual fault
nents and products with nonstandard plugs. current, to help you identify marginal products.

Automatic Shut Down Adjustable Limits

Excessive leakage, dielectric flash over or failure The dielectric leakage limit and continuity resis-
of the ground circuit causes automatic shut down tance limits are adjustable on the rear panel. A
of the high voltage. calibration label can be placed over the adjust-
ments if desired.
Visual and Audible Alarms
Both visual and audible alarms alert the operator
of an out of tolerance condition. The reset switch
must be operated to continue.

Automatic Timer
User can select test duration of one second, sixty
seconds, or continuous.

Model 568 4 Sotcher Measurement Inc.

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 SECTION 1 Users Manual

GENERAL INFORMATION

SPECIFICATIONS Options Available

· 40537 0 - 5,000 volts AC output

Input Voltage:
· 40561 High Voltage Probe
120V, 60 Hz. (230V, 50 Hz with option 40563-568).
· 40563-568 230 Volt, 50 hertz, AC input
· 40566 Digital Volt Meter
Output Voltage:
· 40567 Digital mA Meter
Sinusoidal with a peak to RMS ratio of 1.3 to 1.5
· 40568 0 – 2500 volts DC output w/trip
within a frequency range of 40 to 70 Hz.
point of 1.0 mA DC
· 40570 0 - 3,000 volts AC output
Output Voltage Range: 0-2,500 volts AC.
· 40581 PLC Interface
Dielectric Trip Point:
Factory set at 5mA +/- 5% accuracy.

Transformer Rating: 50VA.

Volt Meter Impedance: 3 megohms.

Meter Accuracy: +/- 3% FS.

Ground Bond:
25 amperes AC at 0.2 second pulses applied ev-
ery 1.0 second. Ground Bond Test is conducted
continuously when a one second duration is se-
lected.

Ground Bond Trip Point:

0.1 ohms at 25 Amperes +/- 10% accuracy.

Test Duration:
Selector switch selects one second, sixty sec-
onds or continuous operation.

Dimensions:
12” wide, 5.5 “ high, 11” deep.

Weight: 18 pounds.

Model 568 5 Sotcher Measurement Inc.

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 SECTION 2 Users Manual

SAFETY PRECAUTION

WARNING! THIS TESTER PRODUCES VOLT- Conduct the recommended functional test at least
AGES AND CURRENTS WHICH CAN CAUSE once per shift and have the calibration performed
HARMFUL OR FATAL ELECTRICAL SHOCK at least once per year. Sotcher Measurement Inc.
TO THE USER OR BYSTANDER. maintains a fully staffed calibration service, which
is available to you as required.
For your protection, take note of the following
safety procedures: Should the tester fail to pass the functional test,
all products tested since the prior functional test
The tester has been designed with careful atten- should be retested.
tion to safety. Regardless of these efforts, it is
not possible to eliminate all hazards from electri- Should any condition occur where the test station
cal test equipment. For this reason it is essential might have been damaged, or any indication of
that the user understand the proper and safe use malfunction or unusual operation be noted, dis-
of this test station. Read the instructions and continue its use immediately. Do not reuse the
warnings with care. Be sure that you and any- test station until the problem is corrected and a
one who uses the tester, fully understands them. recalibration is performed.
Pay special attention to the following: The tester and its accessories should not be used
for any purpose except those described in this
Provide a dry test area with tester and operator manual.
shielded from traffic.
If there are any questions, please call us. You will
The product being tested must be treated as a find our technical support people helpful and
shock hazard until proven otherwise. friendly. They may be reached
Before conducting any tests, read this manual by phone at (800) 922-2969
and follow the recommend test procedures. by fax at (408) 574-0116
or by e-mail at [email protected]
When others are using the tester they must be
trained in its proper use and made aware of the
hazards. They should be trained to follow a fixed
operation routine for each setup, and be super-
vised by a person who fully understands the safe
use of the tester.

Model 568 6 Sotcher Measurement Inc.

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 SECTION 3 Users Manual

OPERATION INSTRUCTIONS

11. As the voltage increases, monitor the Milliam-

SET UP PROCEDURES
meter. When the test current reaches 4.8 to
5.2 Milliamps the test voltage should drop to
CAUTION: Hi-pot (High Potential) testing im- zero, the buzzer should sound, and the red
poses a hazard. DIELECTRIC lamp should light.
Such testing should only be conducted in NOTE: This procedure verifies the sensitivity set-
clean, well-lit areas and by personnel trained ting of the hi-pot circuit. If the unit does not per-
in the subject. form as indicated, or a different sensitivity is de-
sired, see the calibration instructions in the back
1. Place the tester in a clean work area and pro- of this manual.
vide an insulated surface for the item to be tested.
12. Reset the tester by pressing the RESET but-
2. Plug the tester into a 120 volt, 15-20 amp, 60 ton.
Hz, grounded receptacle.
13. Press the TEST button again and set the test
3. Set the PRODUCT switch on rear panel to voltage that will be used by turning the VOLT-
the 3 WIRE position. AGE CONTROL knob.
4. Turn on the tester and press the TEST button 14. Press the 120K OHM button.
to start the test.
15. The buzzer should sound, the voltage should
· The buzzer should sound. drop to zero and the red DIELECTRIC lamp
· The red CONTINUITY lamp should light. should light until the RESET button is pressed.
NOTE: This procedure verifies the fuctional test NOTE: This procedure verifies compliance with
of the Ground Continuity circuit. Underwriters Laboratory (120K OHM) test speci-
fications.
5. Press the RESET button to clear the failure.
16. Turn off the tester (Power switch to 0)
6. Set the PRODUCT switch in the 2 WIRE po-
sition and 17. Select the desired test duration of 1 SECOND,
60 SECONDS or CONTINUE, using the
7. Set the DIELECTRIC TEST DURATION DIELECTRIC TEST DURATION settings on
switch to 60 SECONDS position. the rear panel.

8. Turn the VOLTAGE CONTROL fully counter 18. If the products to be tested are double insu-
clockwise, and then turn the tester on. lated and do not contain a ground wire then
select PRODUCT - 2 WIRE, otherwise se-
9. Press the TEST button to turn on the dielec- lect PRODUCT - 3 WIRE, on the rear panel.
tric test.

10. Push and hold the 120K OHM button and raise
the test voltage by slowly turning the VOLT-
AGE CONTROL clockwise. The AC KILO-
VOLTS meter reflects the test voltage in kilo-
volts (one kilovolt is equal to 1000 volts).

Model 568 7 Sotcher Measurement Inc.

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 SECTION 3 Users Manual

OPERATION INSTRUCTIONS

Note that one kilovolt is equal to 1000 volts, for

TESTING PRODUCTS
example, 1250 Volts would be read as 1.250 Kilo-
volts on the meter.
This procedure applies to completed products with
standard 120V, 15/20A Non-Locking plugs. 9. Avoid applying a voltage higher than that speci-
fied for the test. Excessive voltage can cause
1. Set the DIELECTRIC TEST DURATION permanent damage to the product under test.
switch on the rear panel for the proper test
time. 10. Maintain the test voltage for the specified time
duration, adjusting the voltage as required to
2. Set the PRODUCT switch (on the rear panel) maintain the specified voltage level.
to the 2 WIRE or 3 WIRE position.
· The amber DIELECTRIC lamp indicates
3. Place the product to be tested on an well-in- that the product meets the dielectric test
sulated surface. A clean, dry rubber mat is requirement.
recommended.
· The red DIELECTRIC lamp indicates an
4. Lock the product’s switch in the ON position electrical breakdown in the product’s in-
for the full test duration. sulation.
CAUTION: Keep clear of the product during 11. If either red lamp comes on, indicating a de-
the test. Failure to do so can expose you to fective product, the test voltage will drop to
lethal electrical current. zero and the internal buzzer will sound. To
clear this condition press the RESET button.
5. Plug the product to be tested into the recep-
tacle on the front of the tester. DO NOT ACCEPT THE PRODUCT UNTIL THE
PROBLEM HAS BEEN CORRECTED AND
6. Attach the test clip from the GND terminal to THE TEST REPEATED SUCCESSFULLY.
the metal frame of the product. The clip should
be attached to an unpainted, exposed metal 12. This completes the continuity and hi-pot tests.
part. It is important that a good solid connec- Turn off the tester (Power switch to 0).
tion is maintained at all times during the test.
Note: The voltage can be preset to the desire volt-
7. Press and release the TEST switch. age, thus avoiding the need to turn it up and down
for each test. This is an acceptable procedure
· The amber CONTINUITY lamp indicates for small components, heating products, or other
that the product’s ground wire meets the noninductive devices. For products containing
test requirement. large motors, transformers, or voltage sensitive
circuits, the slow application and removal of the
· The red CONTINUITY lamp indicated a test voltage is recommended.
defective electrical ground connection in
the product’s cord or plug.

8. Slowly rotate the VOLTAGE CONTROL until

the desired voltage is read on the AC KILO-
VOLTS meter.

Model 568 8 Sotcher Measurement Inc.

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 SECTION 3 Users Manual

OPERATION INSTRUCTIONS

6. Avoid applying a voltage higher than that speci-

TESTING COMPONENTS
fied for the test. Excessive voltages can cause
permanent damage to the component under
Note: Option 40561 High Voltage Probe re- test.
quired.
7. Touch the tip of the high voltage probe to each
This procedure applies to individual components
of the wires or contacts. This can be done by
or products without standard 120V, 15A Non-Lock-
connecting all the leads together or by testing
ing plugs.
them one at a time. On components such as
an armature or field winding where the wires
INSTALLATION
are connected internally a single test checks
1. Unplug the hold plug from HIGH VOLTAGE
all insulation points.
hold.
8. Adjust the VOLTAGE CONTROL as requires
2. Insert the red anderson connector of high volt-
to maintain the specified voltage. Monitor the
age probe through the hold and connect to the
AC Milliamperes meter for indications of cur-
red anderson connector inside tester.
rent flow or arcing.
3. Install the strain relief around the wire and in-
· The amber DIELECTRIC lamp indicates
sert to the hold.
that the product meets the dielectric test
requirement.
Procedures
1. Place the PRODUCT switch in the 2 WIRE
· The red DIELECTRIC lamp indicates an
position and the DIELECTRIC TEST DURA-
electrical breakdown in the product insu-
TION to the HOLD position.
lation.
2. Place the component to be tested on an well-
DO NOT ACCEPT THE PRODUCT UNTIL THE
insulated surface, a clean, dry rubber mat is
PROBLEM HAS BEEN CORRECTED AND
recommended.
THE TEST REPEATED SUCCESSFULLY.
3. Connect the ground clip to an exposed metal
9. If the red lamp comes on, the voltage will drop
frame or housing of the component.
to zero and the buzzer will sound. Press the
RESET button to clear.
CAUTION: Keep clear of the product during
the test. Failure to do so can expose you to
10. This completes the test.
lethal electrical current. DO NOT TOUCH
THE PRODUCT UNDER TEST!
Note: If the product under test is sensitive to the
high voltage test, you might choose to place the
4. Press the TEST button.
DIELECTRIC TEST DURATION switch in the 1
· The amber DIELECTRIC lamp turns on.
SECOND or 60 SECOND position. Then touch
the probe to each test point before pressing the
5. Rotate the VOLTAGE CONTROL until the
TEST button. This allows the zero crossing switch
desired voltage is read on the AC KILOVOLTS
to reduce the voltage stress during the applica-
meter.
tion. The stress level can be further reduced by
starting with the test voltage at zero and increas-
Note that one kilovolt is equal to 1000 volts, for
ing it to the desired level and then decreasing it at
example 1250 Volts would be read as 1.250 Kilo-
the end of the test period.
volts on the meter.

Model 568 9 Sotcher Measurement Inc.

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 SECTION 4 Users Manual

EQUIPMENT SERVICING

Prior to returning the tester, or setting up to

SELF SERVICE
service it, a quick verification of the follow-
ing is recommended: Sotcher Measurement Inc. stands ready to pro-
vide you with technical information or replacement
1. Is the unit plugged into a grounded, 120 Volt, parts.
60 Hz receptacle?
WARNING: As with all components that oper-
2. Has the fuse blown? ate at 120 volts, caution must be taken when
servicing the tester to avoid potentially lethal
CAUTION - FOR CONTINUED PROTECTION shock hazards.
AGAINST FIRE, REPLACE ONLY WITH FUSE
OF THE SPECIFIED VOLTAGE AND CUR- CALIBRATION
RENT RATING. There are a number of adjustments that control
the sensitivity and accuracy of the tester. Care
3. Have you reviewed “SET UP PROCE- must be taken when altering them to insure that
DURES” in SECTION 3? the tester will continue to properly identify defec-
tive equipment.
FACTORY SERVICE
Should the tester require service at any time it Refer to SECTION 3 for information on verifying
may be sent, postage prepaid, to Sotcher Mea- the operation of the tester.
surement Inc. for prompt factory service. Loan-
ers are often available upon request. Equipment Required

Is sure your name, address, and phone number 1. AC Voltmeter - 0.2% FS. or better, capable of
is on the tester, or on a tag attached to it. reading 0-3000 volts AC Voltage
2. Probe - To use with the AC voltmeter
Enclose a note explaining the trouble. 3. AC milliamperes Meter - 0.2% or better, ca-
pable of reading 0-10 AC milliamperes
Return the unit to: 4. AC Ammeter - 2% or better, capable of read-
ing 0-30 amperes
5. Load resistor - 0.10 ohms, 1%, 300 watts
SOTCHER MEASUREMENT INC.
6. Load resistor - 0.09 ohms, 1 %, 300 watts
175 Lewis Rd., Unit 23
7. Load resistor - 300,000 ohms, 5%, 10 watts
San Jose, CA 95111
(800) 922-2969 Ground Bond
Fax (408) 574-0116
1. Place the DIELECTRIC TEST DURATION
switch in the 1 SECOND position and the
PRODUCT switch in the 3 WIRE position.

2. Turn the VOLTAGE CONTROL to its fully

counter clockwise position.

3. Attach the 0.10 ohm resistor standard in se-

ries with the 0-30 ammeter standard between
the test clip and the ground pin in the test re-
ceptacle.

Model 568 10 Sotcher Measurement Inc.

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 SECTION 4 Users Manual

EQUIPMENT SERVICING

4. Verify that the tester produces 25 amp of test Dielectric Trip Point
current when the test button is pressed and
held. Limit the test duration to five seconds or Using the same test setup, Verify that the tester
less during calibration. trips with a fault current of 5.0 milliamps +/- 5%
(or other selected point). Adjust the DIELECTRIC
5. Verify that the continuity test passes with the LEAKAGE LIMIT on the rear of the tester as re-
0.09 ohm test resistor in place and fails with quired.
the 0.10 ohm resistor in place.
Fault Detector
6. Adjust the CONTINUITY RESISTANCE
LIMIT on the rear of the tester as required. Verify that the detector circuit operates the red
lamps, buzzer and holds the hi-pot voltage off,
Kilovolt Meter until reset.

1. Zero the kilovolt meter using the manual ad- Test Duration
justment screw on the meter face.
Verify both the 1 and 60 SECOND time duration.
2. Attach the 0-3000 volt meter standard and
probe between the high voltage probe and the REPLACEMENT PARTS
test clip.
Any of the following replacement parts can
3. Verify the meter reading at 1, 2 and 2.5 kilo- be ordered from Sotcher Measurement Inc.
volts.
Part # Description
4. Adjust trim pot R5 on the internal circuit board
as required. 10231 PWR.SWITCH, ROCKER,BLK
11048 TEST SWITCH, PUSH, BLK
Milliamp Meter 11049 RESET SWITCH, PUSH, RED
10331 PWR. LAMP, AMBER
1. Zero the milliamp kilovolt meter using the 11315 TEST LAMP, AMBER, DOME
manual adjustment screw on the meter face. 11314 FAIL LAMP, RED, DOME
13224 METER, 2-1/2 INCH, 200UA
2. Attach the 0-10 Milliammeter standard in se- 11298 TRANSFORMER, 120/6V, CONT
ries with the 300,000 ohm resistor between 10548 TRANSFORMER, 2600V, HI-POT
the high voltage output and the test clip. 10489 TRANSFORMER, VARIABLE
10710 FUSE, 5A
3. Slowly increase the test voltage checking the 10448 POWER CORD, 18/3X8FT
milliamp meter at 4 milliamps, if the tester is
adjusted for a 5 milliamp trip point. Check at
8 milliamps if a 10 milliamps trip point is used.

Model 568 11 Sotcher Measurement Inc.

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Users Manual