KIT High Voltage Construction

MANUAL

Operating Instructions

High Voltage Construction KIT 4.0

Title KIT High Voltage Construction 4.0 Release date 2018-07-13 Modification: 06 Author M.Ahl/D.Rehm

KIT High Voltage Construction Contents 3

Contents

CONTENTS 3

FOREWORD 6

SAFETY 7

Warnings ....................................................................................................................................... 7 Safety Equipment ......................................................................................................................... 8 Special Information Concerning DC-Voltage ............................................................................ 8

Grounding Of Capacitors for DC-Application .............................................................................. 9 Grounding Instructions ............................................................................................................... 9 Emergency .................................................................................................................................... 9 Five Basic Safety Rules ............................................................................................................. 10 Insulating Oil Shell DIALA D...................................................................................................... 10

GENERAL INFORMATION 11

Product description ................................................................................................................... 11 Introduction ............................................................................................................................... 11 Structure ................................................................................................................................... 12

Components ............................................................................................................................... 16 KIT FC Cabinet: ........................................................................................................................ 16

1 x Power input connection ................................................................................................... 18 1 x Ground connection .......................................................................................................... 19 2 x Connections of the Emergency Stop ............................................................................... 20 1 x Connection of the Interlock ............................................................................................. 22 1 x Power output ................................................................................................................... 23 2 x Measurement of AC-Voltages 0...7 VRMS...................................................................... 24 4 x Measurement of DC voltages 0...7 VDC, ........................................................................ 24 1 x Ground switch connection ............................................................................................... 24 3 x Switch Connection........................................................................................................... 26 4 x Optical connections of the EZK ....................................................................................... 26 4 x Sub-D connections of the AKF/MF "new" ....................................................................... 27 4 x Connections of the AKF/MF "old" .................................................................................... 28 1 x Connection of HTAG Lamp + Horn ................................................................................. 29 1 x Connection of the Lamp + Horn (potential free, for customer use) ................................. 29 1 x LAN connection ............................................................................................................... 30 1 x LWL-LAN connection (optical) ........................................................................................ 30 2 x Customer input/output connections (automatic impulse switch off) ................................ 31

Second components ................................................................................................................. 33 Third Components .................................................................................................................... 35 Control and Measurement ........................................................................................................ 52

Control unit: ........................................................................................................................... 52

Measuring instrument DMI551 ............................................................................................. 52 Measuring instrument Picoscope 3405d /4224 .................................................................... 52 Measuring with the KIT-FC-cabinet ...................................................................................... 52

TECHNICAL DESCRIPTION 53

AC-configuration ....................................................................................................................... 53 DC-configuration ....................................................................................................................... 54

DC 1 stage ............................................................................................................................... 54 DC 2 stages ............................................................................................................................. 56 DC 3 stages ............................................................................................................................. 58

Impulse configuration ............................................................................................................... 59 General .................................................................................................................................... 59 Impulse 1 stage ........................................................................................................................ 61 Impulse 2 and 3 stages ............................................................................................................ 62

Packing material, Transportation, Storage, Unpacking ......................................................... 65

ASSEMBLING, INSTALLATION, FIRST PUTTING INTO OPERATION 66

Installation area ......................................................................................................................... 66 Test room ................................................................................................................................. 67

Safety equipment ................................................................................................................. 67 Screening ............................................................................................................................. 67 Grounding ............................................................................................................................. 67

Assembling ................................................................................................................................ 70 Terminals .................................................................................................................................... 70

PZT Transformer cascade ....................................................................................................... 71 2 stages transformer cascade .............................................................................................. 71 3 stages transformer cascade .............................................................................................. 78

Preparation for first putting into operation ............................................................................. 81 Condition .................................................................................................................................. 81 Procedure ................................................................................................................................ 81

OPERATING INSTRUCTIONS 82

Introduction ................................................................................................................................ 82 Construction of the different KIT-configurations ................................................................... 82

AC-configuration ...................................................................................................................... 83 1 stage .................................................................................................................................. 83 2 stages ................................................................................................................................ 84 3 stages ................................................................................................................................ 85

DC-configuration ...................................................................................................................... 86 1 stage .................................................................................................................................. 86 2 stages ................................................................................................................................ 87 3 stages ................................................................................................................................ 88

Impulse configuration ............................................................................................................... 89 1 stage .................................................................................................................................. 89 2 stages ................................................................................................................................ 90 3 stages ................................................................................................................................ 91

Load ranges of the different KIT-configurations .................................................................... 92 AC-configuration ...................................................................................................................... 92

1 stage .................................................................................................................................. 92 2 stages ................................................................................................................................ 93 3 stages ................................................................................................................................ 95

DC-configuration ...................................................................................................................... 97 1 stage .................................................................................................................................. 97 2 stages ................................................................................................................................ 99 3 stages .............................................................................................................................. 101

Impulse-configuration............................................................................................................. 103

KIT High Voltage Construction Contents 5

1 stage ................................................................................................................................ 103 2 stages .............................................................................................................................. 105 3 stages .............................................................................................................................. 107

Switch on procedure ................................................................................................................ 110 Condition ................................................................................................................................. 110 Procedure ............................................................................................................................... 110

Operation .................................................................................................................................. 110 Normal operation .................................................................................................................... 110 Abnormal occurrence ............................................................................................................. 110

Switch off procedure ............................................................................................................... 111 Procedure ............................................................................................................................... 111

Emergency switch off .............................................................................................................. 111 Switch off ................................................................................................................................ 111 Restart .................................................................................................................................... 111

Options ...................................................................................................................................... 112 Additional equipment KIT 4.0 (overview) ............................................................................... 112

TROUBLE SHOOTING 113

Errors and disturbances .......................................................................................................... 113 Basic trouble shooting ............................................................................................................ 113 Common failures ...................................................................................................................... 113 Minimum data for reporting a fault ......................................................................................... 114

MAINTENANCE 115

Utility services .......................................................................................................................... 115 Support, Maintenance .............................................................................................................. 115 Cleaning .................................................................................................................................... 115 Repairs ...................................................................................................................................... 115 Spare parts ................................................................................................................................ 116

COMPONENTS FROM SUB-SUPPLIERS 117

ONWARD TRANSFERS 118

Resale ........................................................................................................................................ 118 Shut down procedure .............................................................................................................. 118 Disposal .................................................................................................................................... 118 Taking back............................................................................................................................... 118

TRAINING, EDUCATION 119

Training ..................................................................................................................................... 119 Education .................................................................................................................................. 119

DIAGRAMS, DRAWINGS 120

Summary ................................................................................................................................... 120

TECHNICAL DATA 121

Ambient conditions for storage and operation, system data etc. ....................................... 121 System .................................................................................................................................... 121 Components ........................................................................................................................... 121

TEST REPORTS 122

Summary ................................................................................................................................... 122

Foreword

Welcome as a new user of the “High Voltage Construction KIT 4.0”. Thank you for placing your confidence in our product.

With the purchase of this system you have opted for all the advantages that had built a world-wide reputation for Haefely Hipotronics Instrument: Robustness, performance and quality is assured. As a result this system provides a solution which achieves the optimal combination of traditional know-how and leading edge technology.

Any correspondence regarding this system should include the exact type number, sys-tem serial number and firmware version number. With the exception of the firmware version number, this information can be found on the registration plate on the right panel of the system.

The design of this system will be continuously reviewed and improved where possible. Therefore there may be small differences between the operating manual and the actu-al system. Although all efforts are made to avoid mistakes, no responsibility is accept-ed by Haefely Hipotronics for the accuracy of this operating manual.

This operating manual is designed for completeness and easy location of the required information. Customers who already have experience with this kind of equipment will find this document to be of assistance as an extended help. A keyword index at the end of the operating manual greatly eases use.

If you find a mistake or inconsistency in the operating manual then please feel free to inform our Customer Support department with your corrections so that other users may benefit.

Haefely Hipotronics accepts no responsibility for any damage that may be caused dur-ing use of this document. We reserve the right to amend the operation, functionality and design of this system without prior notice. If discrepancies are noticed between the on-line help provided by the system and the operating manual, then the on-line help should be followed.

All rights reserved. Any use of this manual other than for operation of the system re-quires prior written authorization from Haefely Hipotronics. 2018, Haefely Hipotronics, Switzerland

KIT High Voltage Construction Safety 7

Safety

Warnings

High voltage can be lethal! Only trained persons are allowed to work with this equipment! The customer is responsible that the employees, which work with this equipment, are trained. The training has to be repeated in regular inter-vals; the training has to be documented.

The test area has to be equipped with an adequate security circuit (see chap-ter “Safety Equipment”.

When working on high voltage test equipment, at least two persons must al-ways be present, one of them bears responsibility for the test.

Never open a cover or a case in which the line voltage is present before hav-ing disconnected the power supply!

Before entering the test area, after high voltage tests have been performed, it has to be made sure that the power supply is definitely switched of at the KIT control software (see manual KIT control software) and the emergency button is pressed.

After high voltage tests have been performed the first thing which has to be done after entering the test area is making sure that all high voltage parts in the test area have to be grounded!

This concerns especially if test with DC-voltage are performed (DC or Impulse configuration), see chapter “Special Information Concerning DC-Voltage”. Af-ter the grounding procedure the grounding rod has to be placed at the high voltage side of the transformer.

When operators exit the test area before the high voltage is connected, the manual grounding rods must be placed near the entry.

Before the high voltage is connected, the responsible person for the test must verify that:

The test circuit is assembled correctly

The test object is connected correctly

All safety systems are operable

The manual grounding rod has been removed.

Short circuit cables from the capacitors have to be removed.

All persons have left the test area.

It has to be taken into consideration that the earth switch type ES in multi-stage configu-

rations (two or three stages) doesn’t provide a sufficient grounding for all high voltage

parts of the system. Even when the earth switch is activated all high voltage parts of the sys-tem have to be grounded with the grounding rods. If DC-voltage tests are performed (DC or Impulse configuration) special earthing instruction has to be kept in mind (see chapter “Special Information Concerning DC-Voltage”).

The essential safety provisions governing setup and operation in combination with the regu-lating transformer, high voltage transformer and other components of the high voltage test in-stallation are set forth in the following standards:

VDE 0100 (DIN 57100): Setup of power-current systems up to 1000 V (in German language)

VDE 0101 (DIN 57101): Setup of power-current systems over 1000 V (in German language)

VDE 0104 (DIN 57104): Building and operation of electrical examining facilities (in German language)

Safety Equipment

The test area should be enclosed by a metal grid fence of at least 2.2 meters height with a maximum grid spacing of 40 mm.

All doors leading to the test room must be equipped with door contacts, which close when the door is closed. All contacts should be connected in series to the interlock system provided by the KIT FU cabinet. This safety system will automatically turn off the high voltage if the inter-lock is opened while the test system is switched on. Red and green warning lights should be installed at all doors leading to the test room.

Special Information Concerning DC-Voltage

Extra care is essential in direct current experiments, since the high voltage capacitors in many circuits retain their full voltage, for a long time even after disconnection. Even unused capacitors can acquire dangerous charges!

The following earthing regulations have to be strictly observed. Even unused capacitors can acquire dangerous charges. DC-voltage appears in DC- and Impulse configurations.

KIT High Voltage Construction Safety 9

Grounding Of Capacitors for DC-Application

No high voltage capacitors are allowed to be touched which weren’t immediately dis-charged before and aren't short-circuited!

Capacitors, which are not shorted after discharging, could be recharged under no-load condition even when the capacitors are directly discharged before (Recharging effect).

A sufficient discharge will be achieved with two suitable grounding rods between the two poles of the capacitor! For a correct discharging both poles of the capacitor must be connected to earth at the same time sufficiently by means of the two grounding rods.

The capacitor has to be short-circuited after the discharging procedure in a way, that first both poles of the capacitor have to be connected to earth with two grounding rods. It has to be guaranteed that the two grounding rods couldn’t detach from the Poles of the capacitor. As soon as this is ensured, the two connections of this ca-pacitor must be short-circuited by means of an electrically conductive connection.

Capacitors have to be stored in short-circuit condition together with the instruction “Grounding of capacitors for DC-Application”! The short circuiting has to be done af-ter the discharging of the capacitor.

Grounding Instructions

A good test field can enter a separate grounding. This ensures that no disturbances from sur-rounding machines enter the test field and - in case of a failure - the earth potential of the surrounding does not rise, causing damage to electrical equipment. It is necessary for the test field to have a lower grounding resistance than the surrounding building.

Grounding connections have to be made without forming loops.

The ground connection of the measuring and control system, KIT frequency converter, high voltage transformer, floor pedestal and test object should be arranged in star connection, where the central point is grounded. The grounding rods have to be connected to the central earth point, too.

For earthing of components Cu-foil or Cu-braid is recommended.

Emergency

The Emergency-button is connected to the KIT FC (KIT frequency converter) cabinet and a safety PLC.

Five Basic Safety Rules

Always remember the five basic safety rules for working with high voltage:

1) Disconnect mains!

2) Prevent reconnection!

3) Test for absence of harmful voltages!

4) Ground and short circuit!

5) Cover or close off nearby live parts!

Insulating Oil Shell DIALA D

Shell DIALA D oil is the insulating oil of the test transformer KIT PZT100-0.1, some re-sistors, the diodes and the capacitors. For detailed information about the insulating oil please contact the manufacture. Before any operation read the datasheet carefully.

KIT High Voltage Construction General Information 11

General Information

Product description

Introduction

The High Voltage Construction KIT is a system of components for applications in high voltage technology. All components have the same length and mechanical intercon-nections. They can be combined to form a test configuration and are extremely versa-

tile. Test configurations are available which allow the generation of AC voltages up to

300 kV, DC voltages up to 400 kV (under no load condition i.e. without measuring di-

vider) and impulse voltages up to approx. 365 kV with different power output ratings.

Such test configurations are extremely compact and their flexibility allows the test sys-tem to be matched to the prevailing conditions in the test room (dimensions, height etc.).

The application range for the high voltage KIT covers not only the use in high voltage laboratories of technical universities, but also as an industrial test system for routine and type tests on electrical equipment up to 300 kV (AC).

A complete test system requires a floor surface of approx. 5 m x 6 m. The influence of parasitic effects will be lower.

The configuration is built up, as it name suggests, by simply inserting the various ele-ments to form a self-supporting structure. No tools are required.

In spite of its striking simplicity, the KIT is equipped with all the components of compa-rable large industrial test systems.

Numerous accessories are available for the basic KIT elements. The high voltage KIT has got compact dimensions and a wide range of application. It is portable and truly represents a complete high voltage test system.

12 General Information KIT High Voltage Construction

Structure

Figure 1 shows the general block diagram of the KIT.

Fig. 1: Block diagram of high voltage construction KIT

For each configuration (AC, DC and Impulse) there is a single stage or multistage (up to maximum three stages) configuration. For DC and Impulse setup only one test transformer is necessary (even in multistage configuration). But for a two stages AC configuration two test transformers are required and for a three stages AC configuration three test transformers.

A configuration is built up by inserting different KIT components (e.g. resistors, capacitors, etc.) into connection cups resp. floor pedestal to form a self-supporting arrangement. No ad-ditional tools are required.

Due to this design the user can make changes in the circuit quickly and efficiently. Every connection cup has six possible combinations. Two vertical and four horizontal (see figure 2).


Fig. 2: Connection cup for connecting the KIT components

Fig. 3: Floor pedestal with one KIT component and spacer bars

Every floor pedestal has two threads on opposite sides for ground connection. This way the grounding can be made at the end of the assembly simply by screwing the copper foil/ braid to the floor pedestals without need to rearrange them.

Figure 4 shows the structure of an AC circuit 100 kV (rms) (without control unit).

Ground

connection


Fig. 4: Construction of an AC one stage configuration

The configuration is built up by inserting elements to form a self-supporting arrangement. No additional tools are required.

Configurations with more than just one stage can be built as in the following examples (figure 5 and 6).

Fig. 5: Setup of two transformers

For lifting the KIT PZT 100, a crane and a two lifting hooks has to be used. Therefore two M 12 threads are for the lifting hocks. To avoid slipping the KIT PZT 100 transformer is equipped with four bulges. The bottom of the next PZT stage fits inside there.


Fig. 6: Construction of different KIT elements


Components

The KIT 4.0 system comprises the following elements. Depending on the configuration not all parts are necessary (see chapter “Third Components”).The KIT 4.0 system can be divided in-to three sections. The first section is the source (KIT-FC-cabinet), the second component is the high voltage transformer (KIT PZT 100-0.1) and the last components are the add-ons.

KIT FC Cabinet:

Fig. 7: KIT-FC-cabinet

Electrical specification (Input):

Voltage: 3x 380…415 V

Power: 10 kVA

Frequency: 47…63 Hz

Electrical specification (Output):

Voltage: 1 pH – max. 440V

Current: 22.7 A

Frequency: 50 Hz to 200 Hz (10 Hz to 49 Hz derated up to 20 %)

Mechanical specification:

Height 1125 mm

Wide 1000 mm

Depth 800 mm

Weight approx. 200 kg


The KIT-FC-cabinet is a KIT frequency converter frontend, with included PLC-control.

Fig.8: Side view KIT-FC-cabinet.

The KIT-FC-cabinet can provide following connections:


1 x Power input connection

-1X2 is a cable termination for the power input (customer responsibility).

There is: 1 / PE / 2 / 3 / PE / N

The three phases have to be connected to 1, 2, 3; the PE is for the ground of the input cable.

If the input cable provides a "neutral ground" then this can be connected to N, but it is not needed. For input protection, there are varistors between the three phases and the PE.

Fig. 9: Schematic

The ground of the test bay must always be connected See ground connection


1 x Ground connection

The KIT-FC-Cabinet has a copper foil/ braid connection for connect the cabinet with low in-ductance to your test area ground.

Fig. 10: Ground connection

Take always care that the KIT-FC-cabinet is grounded with the power ground from the input. The connection should have a low inductance.

Ground

connection


2 x Connections of the Emergency Stop

-800X5, -800X6

-800X5_or_X6

HAN 6B Gehäuse M25 gew.Harting

4

3

2

1

PE

5

5m

-1W1farb. abg.

4x 0.75

02 01

02 01

-1S1

Emergency Button with Key

6

Fig. 11: Schematic

For the emergency stop button the Haefely product can be used. No.: 3714479

Else you can use the delivered harting plug with six pins to connect your own emergency stop button. Take care that two normally closed contacts are used together. The E-stop works with a dual channel operation, it will monitor the discrepancy time between the two contacts and it has a cross short detection to prevent connecting the two circuits to-gether in a fault case.


-800X5_or_X6


4

3

2

1

PE

5

02 01

02 01

Emergency Button with Key6

Fig.12: Schematic

Pressing the emergency button opens the two output contactors and the input contactor of the KIT-FC-cabinet, so there is no voltage at the power output from the KIT-FC-cabinet.

Shielded cables must be used for emergency connections.

If the second emergency stop is not used, the plug has to be bridged.

At least one emergency stop has to be connected!


1 x Connection of the Interlock

-805X3

For the Interlock the delivered cable can be used No.: 3714480

This is a screened cable connected to the plug with open ends.

-805X3'

HAN 3A Gehäuse M20 gew.Harting

4

3

2

1

PE

02 01

02 01

+Door

02 01

02 01

+Ground-Rod

Fig. 13: Schematic

In this example above the interlock is used to monitor the door to the HV-part of the system, and to monitor if the ground rod is taken out from the high voltage. It can also be a door in a safety fence, mounted around the HV-part.

You can use the delivered harting plug with six pins to connect the interlock.

Take care that two normally closed contacts are used together. The Interlock works with a dual channel operation, so it will monitor the discrepancy time be-tween the two contacts and it has a cross short detection to prevent connecting the two cir-cuits together in a fault case.

Shielded cables must be used for interlock connections.

The cable shield must continue through the connectors.

The end of the safety circuit is a termination or a bridge.

It is recommended to use a safety fence or something equal!


1 x Power output

-850X1

'-850X1


2

1

2

1

BU

BN

PE

3x 2.5mm² PUR1000v flex+ orange

3P 2.5MM2

a

b

U

W

PE

+PZT

Fig. 14: Schematic

The power output get connected with the High voltage-Transformer "PZT"


2 x Measurement of AC-Voltages 0...7 VRMS

Both measurement inputs are spitted up into a Peak/sqrt(2) measurement and a RMS meas-urement

BNC connector VM1 Measurement 1 and 2 in the control software

BNC connector VM2 Measurement 3 and 4 in the control software

4 x Measurement of DC voltages 0...7 VDC,

These measurements are used for DC voltages 0...7 VDC (and can also be used for 0...7 VAC 40...200 Hz, but with less accuracy than the AC inputs)

BNC-connector VM3 Measurement 5 in the control software




1 x Ground switch connection

-812X1 Harting plug with 10 pins

'-812X1HAN 10E pin insert 10 P + PEHarting

GND

Switch is in Grounded Position

1

2

3

4

5

6

7

8

9

10

PE

Switch is in Ungrounded Position

24 VDC Switched

24 VDC

0201

0403

Ea

rth

ing

Co

il

A1

A2

+GND Switch

24 VDC

Fig. 15: Schematic


The Ground Switch is switched to grounded position, when software status is HV OFF or Power OFF. It is always ungrounded when software status is HV Ready or HV On

Always double check after switching off the high voltage parts of the system are grounded correctly!

Beware: If the ground switch is in grounded position, even life parts can be under voltage!


3 x Switch Connection

(Same as ground switch, can be used as ground switch or as a normal switch)

-812X2, -812X3, -812X4 Harting plug with 10 Pins

'-812X2 or X3 or X4HAN 10E pin insert 10 P + PEHarting

GND

Switch is in Grounded Position

1

2

3

4

5

6

7

8

9

10

PE

Switch is in Ungrounded Position

24 VDC Switched

24 VDC

0201

0403

Ea

rth

ing

Co

il

A1

A2

+Switch

24 VDC

Fig. 16: Schematic

These switches can be switched in any state of the software, in power off, HV off, HV ready and HV On.

Always double check after switching off the high voltage parts of the system are grounded correctly!

Beware: If the ground switch is in grounded position, even life parts can be under voltage!

The additional switches can be operated in any state of the system!

4 x Optical connections of the EZK

-811X1, -811X2, -811X3, -811X4

'-811X1 or X2 or X3 or X4

HAN 3A hoodHarting

1

2

-811W510m

optical connection

1

2

+EZK

Trigger

Fig. 17: Schematic


4 x Sub-D connections of the AKF/MF "new"

-832X1, -832X2, -832X3, -832X4

+MF/AKF "new"

-Net plug

L, N, PE

'-832X1, X2, X3, X4

Fig. 18: Schematic


4 x Connections of the AKF/MF "old"

These connections get used together with the Adaption Box No.: 4771502

-816X1, -816X2, -816X3, -816X4

Adaption Box 4771502

-1W1

+AKF/MF "old"

'-816X 1...4

-1W2

-Net plug

L, N, PE

+KIT-Cabinet

Fig. 19: Schematic

The Adaption Box is connected with the KIT FC -Cabinet with the Plug -816X1, -816X2, -816X3, -816X4, The AKF or the MF "old" has to be connected with the adaption box. The net plug depends on the country and the voltage that is used for the AKF or MF.


1 x Connection of HTAG Lamp + Horn

-821X1

'-821X11

5 m

Fig. 20: Schematic

HTAG Warning-Lamp + Horn Set: No.: 3714478

1 x Connection of the Lamp + Horn (potential free, for customer use)

-821X2

'-821X2

1

2

3

4

5

6

7

8

9

10

PE

04 03

04 03

04 03

Horn

NL

GreenX2 X1

RedX2 X1

+SourceImax: 6A

Vmax: 250VAC

Fig. 21: Schematic

Pin 7 is the common of the potential free contacts.

Pin 8 is the switched potential free contact for the red Lamp

Pin 9 is the switched potential free contact for the green Lamp

Pin 10 is the switched potential free contact for the Horn


1 x LAN connection

-831X3

Is used to connect the control laptop to the KIT-FC-cabinet

1 x LWL-LAN connection (optical)

-831X1

Can be used to connect the control laptop to the KIT-FC-cabinet

(You will need an optical cable and a converter for the laptop)


2 x Customer input/output connections (automatic impulse switch off)

-814X1, -815X1

24

VD

C

DI C

usto

me

r sp

are

3

DI C

usto

me

r sp

are

4

DI C

usto

me

r sp

are

1

DO Customer spare 1

11

14

12

DO Customer spare 2

11

14

12

DO Customer spare 3

11

14

12

DO Customer spare 4

11

14

12

AI C

usto

me

r sp

are

2

AI C

usto

me

r sp

are

1

AI

1 G

ND

AI

2 G

ND

PE

'-814X1coding pin

HAN 24B hoodHarting

DI C

usto

me

r sp

are

2

1 2 3 4

13

14

15

16 6

18 7

19 8

20 9

21

11

23

12

24

PE

Ai C

usto

me

r 1

Ai C

usto

me

r 2

Customer dry contacts, Imax 6A Vmax 24 DC

24

VD

C

DI C

usto

me

r sp

are

7

DI C

usto

me

r sp

are

8

DI C

usto

me

r sp

are

5

DO Customer spare 5

11

14

12

DO Customer spare 8

11

14

12

DO Customer spare 6

11

14

12

DO Customer spare 7

11

14

12

AI C

usto

me

r sp

are

4

AI C

usto

me

r sp

are

3

AI

3 G

ND

AI

4 G

ND

PE

'-815X1coding pin

HAN 24B hoodHarting

DI C

usto

me

r sp

are

6

1 2 3 4

13

14

15

16 6

18 7

19 8

20 9

21

11

23

12

24

PE

Ai C

usto

me

r 3

Ai C

usto

me

r 4

Customer dry contacts, Imax 6A Vmax 24 DC

Fig. 22: Schematic

There are 8 digital Inputs, 8 potential free contacts and 4 analogue Inputs for customer use in the two customer plugs -814X1 and 815X1

Example digital Input:

24 VDC

1

DI Customer spare 5 13 0403

'-814X1

Fig. 23: Schematic

Always use 24 VDC from the cabinet, when using the digital inputs. Use potential free, dry contacts for switching the digital Input.


Example analogue input:

'-814X1

AI 3 GND

11AI Customer spare 3

23

Device

0...10 VDC

Fig. 24: Schematic

Maximum input Voltage for external Devices, for example a measuring Signal, is 0...10 VDC

Example digital output:

'-814X1

6

18

DO Customer spare 1

11

14

12

Voltage Source

24V external

Load

Fig. 25: Schematic

Maximum rating of the dry contacts 24 V AC or DC and 6 A


Second components

KIT PZT 100-0.1: single phase AC voltage test transformer

Fig. 1: KIT PZT 100-0.1

Fig. 2: KIT PZT 100-0.1 schematic

Test transformer which can be used for AC-voltage generation and as high voltage supply for DC- and impulse voltage configuration. The output power can be extended by cascading the transformers.

Rated voltage: 2 x 220 V; 440 V / 100 kV / 220 V

Rated power: 9 kVA, continuous 1 day on, one day off

10 kVA, 1 h ON, 1 h OFF, 4 x per days


KDL: Compensating reactor

Fig. 3: Compensating reactor, AC two stage configuration

Compensating reactor type KDL is used between transformers (KIT PZT 100-0.1) in cascade circuits to reduce input power and provide uniform voltage distribution across cascade wind-ing. Compensating reactors are recommended for AC configurations of more than 1 stage.

Top EL: Top electrode

Fig. 4: Top electrode

For AC two and three stages a top electrode on the test transformer is recommended to avoid corona effects.

Compensa-

ting reactor

Top electrode


Third Components

HSEV 200: High voltage connection 200 kV

Fig. 5: HSEV 200/300

HSEV: Connection with suitable contacts to connect AC source (transformer cascade) con-figuration to the test object or divider.

GS: HV diode

Fig. 6: Diode

Diode which can be used for the impulse and DC voltage configuration. The diode consists of a protecting resistor and a high voltage diode.

Protective resistor: 100 kΩ (oil-filled)


Inverse peak voltage: 140 kV

Rated current: 20 mA

CZ/CB: Load capacitor

Fig. 7: CB

Capacitors, which can be used as HV unit for the impulse divider and as load capacitance.

Capacitance: 500pF (CZ)/ 1200 pF (CB) (oil-filled)

Max. DC and IMP voltage: 140 kV

CS: Smoothing and energy storage capacitor

Fig. 8: CS

Capacitors, which can be used as energy storage capacitor for generation of impulse voltag-es or as smoothing capacitor for DC generation.


Capacitance: 25 nF (oil-filled)


CM: Measuring capacitor

Fig. 9: CM

Capacitor, which can be used as HV unit for the AC voltage divider.

Capacitance: 100 pF (oil-filled)

Max. AC voltage: 100 kV

RL: Charging resistor

Fig. 10: RL (here 10 MΩ version)


Resistor, which can be used as charging resistor for multistage impulse configurations, as current limiting resistor in DC configurations and as damping resistor in connection with the grounding switch.

Resistance: 2.5 MΩ or 10 MΩ (oil-filled)


R: Resistor

Fig. 11: R

Resistor, which can be used for impulse voltage configurations, determining the rise time. Low inductance resistors are used for wave tail resistor. High inductance resistors are used for wave front resistors. The 2.4 kΩ resistor is also used for discharching purpose.

Resistance: different values (low inductance: 95 Ω, 140 Ω, 220 Ω, 355 Ω; high inductance: 2.4 kΩ, 55 kΩ, 110 kΩ)



RM: Measuring resistor

Fig. 12: RM

Resistor, which can be used as HV unit for the DC voltage divider.

Resistance: 280 MΩ (oil-filled)

Rated current (continuous): 0.5 mA

Max. DC voltage: 140 kV

ES: grounding switch

Fig. 13: ES

Remote controlled switch, which can be used to ground the high voltage construction KIT.


Max AC voltage 100 kV


Control voltage: 24 V

EST: Discharge and Ground rod

Fig. 20: EST

Ground rod, for manual discharge of HV KIT components.

Length: approx. 2.5 m


EB: Copper Braiding (Grounding)

Copper braiding, which can be used to make ground connections between the individual high voltage apparatus.

Standard length: 10 m

EL: Electrode

Fig. 22: EL

Electrode, used together with grounding switch ES and to reduce corona discharges on high voltage parts of the different configurations.

Diameter: 300 mm


IS: Insulating support

Fig. 23: IS

Support insulator, which can be used as insulating component.



KF: Sphere gap

Fig. 24: KF

Sphere gap, for impulse voltage generation.

Max. IMP voltage: 140 kV

Sphere diameter: 100 mm

Max. gap setting: 80 mm


AKF: Drive for sphere gap

Fig. 26: AKF

Remote controlled drive for sphere gap KF. Drive shaft ASA (short) for 1st stage and ASB (long) for 2nd and 3rd stage needed. The AKF is clamped onto a spacer bar D.

Power supplier: 230 V AC

Frequency: 50/60 Hz

Data cable: optical RS232 V:

Connecting rod

Fig. 27: Connector V

Conductive connection element (aluminium rod).


K: Connecting cup

Fig. 28: Connecting cup K

Conductive connection element, four components can be connected horizontally and two components vertically.

F: Floor pedestal

Fig. 29: Floor pedestal F

Conductive element, for mounting up to four spacer bars horizontally and supporting one component vertically.


D: Spacer bar

Fig. 30: Spacer bar D

Spacer bar, which can be used for mechanical and electrical connection at ground level in-serted into a floor pedestal F.

KIT SEK: Secondary part

Fig. 31: KIT SEK

Secondary unit for AC, DC, impulse and DC ripple divider. Connected between the HF-socket of the measuring capacitor/ resistor and the DMI551 or Picoscope by means of a co-axial cable (BNC). Below an overview of the different secondary units.


Oscilloscope

DMI 551 KIT FU 25

BNC inputs

AC measure-

ment

(used with KIT

CM 100 pF)

Rated capaci-

tance

2 µF 70 nF See oscillo-

scope second-

ary unit

(only up to 200

Hz possible)

Numbers of ca-

pacitors

20 7

Rated frequency 10…400 Hz 10…400 Hz

Divider ratio 20001 701

Maximum output

voltage at 100 kV

(RMS) with KIT

CM 100 pF

5.0 V (RMS) 142.7 V (RMS)

DC measure-

ment

(used with KIT

RM 280 MΩ)

Rated resistance 14 kΩ See oscillo-

scope second-

ary unit

See oscillo-

scope second-

ary unit

Numbers of resis-

tors

4

Divider ratio 20001

Maximum output

voltage at 140 kV

DC with KIT RM

280 MΩ

7.0 V (Peak)

DC ripple

measurement

(used with KIT

RM 280 MΩ

and KIT CB

1200 pF)

Rated resistance/

rated capacitance

14 kΩ/ 24 µF See oscillo-

scope second-

ary unit

See oscillo-

scope second-

ary unit

Numbers of resis-

tors/ capacitors

4/ 16

Divider ratio 20001

Maximum output

voltage at 140 kV

DC with KIT RM

280 MΩ and KIT

CB 1200 pF

7.0 V (Peak)

Impulse Rated capaci-

tance

10.2 µF 418 nF Impulse meas-

urement not


measurement

(used with KIT

CB 1200 pF)

Numbers of ca-

pacitors

14 19 possible

Rated frequency (for impulse

referring to IEC)

Only impulse

peak meas-

urement

Divider ratio 7934 349.3

Maximum output

voltage at 140 kV

(Peak) with KIT

CM 1200 pF

17.65 V (Peak) 400.8 V (Peak)

Internal matching

impedance for

BNC cable

50 Ω -

All values are related to 20 °C


EZK: Electronic trigger sphere (new Type)

Fig. 35: EZK

Trigger sphere, which is used to generate triggered impulses in impulse voltage configura-tions together with sphere gap supplied with fiber-optic cable.

Diameter: 100 mm

Standard length of cable: 10 m

DKU: Vessel for vacuum and pressure

Fig. 37: DKU 4.0

Vessel, which can be used to determine flashover voltage of electrode arrangements as a function of vacuum and over pressure.

Used for: Pressure, vacuum tests


Rated AC voltage: 100 kV (RMS)

Rated DC voltage: 140 kV (Peak)

Max rated pressure: 5 bar rel. (pressure relief valve triggering at 5.5…6 bar rel.)

Operating temperature range: 10°C…30°C

Cylinder volume (empty): 7.8 L (20.6054 gal lqd)

Maximum duration current: 100 mA

For more information about the DKU please note the corresponding manual and the data sheet.

KIT DKU SET 1: Additional set of electrodes

Fig. 38: KIT DKU SET 1

Additional electrodes for use with the DKU.

Sphere electrodes: 20 mm, 50 mm

Needle electrodes

Flat electrodes


KR: Corona cage

Fig. 39: Corona cage KR

Corona cage, which can be used to determine glow intensity as a function of wire diameter. The corona cage is inserted into the vacuum and overpressure vessel (DKU). Measurements can be made at vacuum and over pressure.


Max. DC voltage: 140 kV

OP: Oil testing cup

Fig. 40: OP

Oil testing cup, which can be used to measure flashover voltage of insulating oil. Fitted into the vacuum and pressure vessel (DKU). Electrodes have spherical electrodes acc. to VDE 370, par. 13.


Gap setting: 2.5 mm

MF 100: Measuring sphere gap

Fig. 41: MF100

Sphere gap to measure flashover voltage.



Sphere electrodes: 100 mm

With motor-drive 230V, 50/60Hz

Data cable: optical RS232

KIT MF SET 1

Additional electrodes available for the MF 100.

Sphere electrodes: 20 mm, 50 mm, 100 mm

Needle electrodes

Flat electrodes


Control and Measurement

The high voltage KIT is supplied with two separate instruments:

The KIT control software and the AC, DC and impulse measurement system Picoscope or DMI.

Control unit:

The KIT FC is a software controlled unit. The basis of the software is LabVIEW. For more in-formation about the software please note the KIT control software manual.

Measuring instrument DMI551

The DMI 551 is equipped with three independent measuring channels (AC, DC, IMP) For more information about please note the corresponding manual.

Measuring instrument Picoscope 3405d /4224

Instead of using the DMI a Picoscope can be used as well. The Picoscope is also supported by LabVIEW. For more information please note the corresponding manual.

Measuring with the KIT-FC-cabinet

Also Measuring (AC, DC) with the KIT-FC-cabinet is possible. See chapter “Components, KIT-FC-cabinet”.

KIT High Voltage Construction Technical description 53

Technical description

For each setup (AC, DC or Impulse) configurations (one, two and three stages), which allows different maximum output voltages are possible.

AC-configuration

High alternating voltage AC are required for experiments and AC tests as well as a supply for most of the circuits to generate high direct (DC) or impulse voltage. Test transformers gener-ally used for this purpose have considerably lower power rating and frequently much larger transformation ratios than power transformers. The primary winding is usually supplied by regulating transformers fed from the main supply.

Most tests and experiments with high AC voltage require precise knowledge of the value of the voltage. This demand can normally only be fulfilled by measurement of the voltage on the high voltage side.

The circuit for the AC-configuration 1stage consists of a high voltage transformer with a max-imum output voltage of 100 kV and a capacitive voltage divider (maximum AC voltage: 100 kV) for the measurement of the voltage on the high voltage side.

For the 2 stages configuration two transformers are put together in a cascade configuration to reach a maximum output voltage of 2 x 100 kV. For this reason each transformer is equipped with a tertiary winding. The tertiary winding is used for coupling two transformer modules. For this the tertiary winding of one module is connected to the primary winding of the succeeding module. Also two measuring capacitors are connected in series for the measuring of an AC voltage of 200 kV.

For the 3 stages configuration three transformers are put together in a cascade configuration to reach a maximum output voltage of 3x 100 kV and three measuring capacitors are con-nected in series for the measuring of an AC voltage of 300 kV.

For configurations with more than one stage, compensating reactors type KDL is recom-mended to extend the load range of the cascade configuration.

54 Technical description KIT High Voltage Construction

DC-configuration

The DC test voltage is defined as the arithmetic mean value

T

DC dttuT

U0

)(1

(1)

Ripple is the periodic deviation from the arithmetic mean value of the voltage. The amplitude

U of the ripple is defined as half the difference between the maximum and minimum value:

MinMax UUU 2

1 (2)

The ripple factor is the ratio of the ripple amplitude U to the arithmetic mean value UDC. *)

DC 1 stage

This configuration is realized with a half-wave rectifier circuit (see figure 43).

GS

CS R UU2

Fig. 44: Half-wave rectifier

The smoothing capacitor CS is charged via the diode GS to the direct voltage U

rmsUU 22 (3)

The inverse voltage of the diode must be

rmsinv UU 222 (4)

Under no load conditions (i.e. no test object and no ohmic divider for the voltage measure-ment) an ideal DC-voltage without ripple will be generated.


Under load conditions (divider is part of the load) the ripple of the DC-voltage will increase. During the blocking period t of the diode GS the smoothing capacitor is discharged via the

load R. Only during the short period the capacitor CS will be recharged from the transform-

er. During the period the diode is conductive and a short forward current pulse ID flows (see figure 45).

Fig. 45: Voltage characteristics

The lower the value R (i.e. the higher the required DC-current) the higher will be the ripple of the DC-voltage, because the capacitor will be more discharged by the load. Also the achiev-able DC-voltage will be decreasing with higher load current.


DC 2 stages

This configuration is realized with a multiplier circuit (called “Greinacher doubler-circuit”) so that the same transformer as for the single stage configuration could be used. The electrical diagram shows figure 46 the voltage characteristic is shown in figure 47.

0

1

2

A

R

GS

GSCS CS

CS

U10

UA0

Fig. 46: Greinacher doubler-Circuit

Fig. 47: Voltage characteristics


The left blocking capacitor CS is charged to the peak value of the transformer voltage U10 and thus increases the potential of the terminal 2 with respect to the transformer voltage by this amount (voltage U20 in figure 47). Via another diode CS the smoothing capacitors will be

charged. Under no load condition ((i.e. no test object and no ohmic divider for the voltage measurement) a DC-voltage with

rmsDC UU ,1022 (5)

will be generated.


rmsinv UU ,1022 (6)

The ripple will be increased and the achievable output voltage will be decreased with increas-ing load.


DC 3 stages

This configuration is realized with the “Greinacher cascade circuit” with three stages (see fig-ure 48). This is an extension of the “Greinacher doubler circuit”.

R

GS

GS

GS

U

CS

CS CS

CS

CS

U2

Fig. 48: Greinacher cascade circuit with three stages

Under no load condition ((i.e. no test object and no ohmic divider for the voltage measure-ment) a DC-voltage with

rmsUnU 222 (7)

will be generated, where n is the quantity of stages.


rmsinv UU 222 (8)


Impulse configuration

General

Impulse voltages are required in high voltage tests to simulate the stresses due to external and internal overvoltage, and also for fundamental investigations of the breakdown mecha-nism. They are usually generated by discharging high voltage capacitors through switching onto a network of resistors and capacitors, whereby multiplier circuits are often used.

In high voltage technology a single, unipolar voltage pulse is termed an impulse voltage. For testing purposes, double exponential impulse voltages have been standardized; without ap-preciable oscillation these rapidly reach a maximum, the peak value UPeak, and finally drop less abruptly to zero. If an intentional or unintentional breakdown occurs in the high voltage circuit during the impulse, leading to a sudden collapse of the voltage, this is then called a chopped impulse voltage. The chopping can occur on the front, at the peak or in the tail sec-tion of the impulse.

For overvoltage following lightning strokes, the time required to reach the peak value is in the

order of 1 s; they are named atmospheric or external overvoltage. Voltages generated in a

laboratory to simulate these are called lightning impulse voltages (LI).

For internal overvoltage, occurring as a consequence of switching operations in high voltage

networks, the time taken to reach the peak value is at least about 100s. Their reproduction

in the laboratory is effected by switching impulse voltages (SI); these are of approximately the same shape as lightning impulse voltages, but last considerably longer.

In case of impulse voltages for testing purposes, the shape of the voltage is determined by certain time parameters for the front and tail, as shown in figure 49 and 50.

Fig. 49. Lightning impulse curve

In the international standard IEC 60060-1 the front time T1 or a lightning impulse is a virtual parameter defined as the 1.67 times the interval T between the instants when the impulse is 30 % and 90 % of the peak value (point A and B in figure 49).

The virtual origin O1 of a lightning impulse is the instant preceding that corresponding to point A by a time 0.3T1. For records with linear time scales, this is the intersection with the time ax-is of a straight line drawn through the reference points A and B on the front.


The time to half-value T2 (or tail time) of a lightning impulse is a virtual parameter defined as the time interval between the virtual origin O1 and the instant when the voltage has decreased to half the peak value.

The curves of lightning impulses often have high-frequency oscillations superimposed, due to the parasitic inductances of the impulse circuit; the amplitude should not exceed 5 % of the test voltage.

Standard lightning impulse:

Front time T1: 1.2s (tolerance: 30 %)

Time to half-value T2: 50s (tolerance: 20 %)

Fig. 50. Switching impulse curve

In the international standard IEC 60060-1 the time to peak Tp of a switching impulse is the time interval between the actual origin and the instant when the voltage has reached its peak value.

The time to half-value T2 for a switching impulse is the time interval between the actual and the instant when the voltage has first decreased to half the peak value.

The time above 90% T1 is the time interval during which the impulse voltage exceeds 90 % of its peak value.

Standard switching impulse:

Time to peak Tp: 250 s (tolerance: 20 %)

Time to half-value T2: 2500 s (tolerance: 60 %)

0.5


Impulse 1 stage

Figure 51 shows the basic circuit for generating impulse voltages.

u(t)

KF

CSU0 RE CB

GS RD

Fig. 51: Circuit for generating impulse voltages

The impulse capacitor CS is charged via a diode GS to the direct voltage U0 and then dis-charged by ignition of the switching gap KF. The desired impulse voltage u(t) appears across the load capacitor CB.

The value of the circuit elements determines the curve shape of the impulse voltage. The im-pulse voltage is given by the difference of two exponentially decaying functions with time

constants 1 and 2.

With the usually satisfied approximation

RECS >> RDCB (9)

the following simple expressions are obtained:

BS

BSD

CC

CCR

1 (10)

BSE CCR 2 (11)

There are existing a correlation between 1 and 2 and the front and tail time of lightning and switching impulses defined in the international standards:

111 KTT p (12)

222 KT (13)


The values of K1 and K2 are:

1

.2/50s

2

50/2500s

K

1

2.96

2.41

K

2

0.73

0.87

The efficiency factor is the ratio between the peak value UPeak of the impulse voltage and

the charging voltage U0 of the impulse capacitor (=UPeak/U0). could be approximately cal-culated with the following formula:

BS

S

CC

C

(14)

Impulse 2 and 3 stages

For given DC charging voltage, to obtain impulse voltage with as high a peak value as possi-ble, the multiplier circuit proposed by E. Marx is commonly used. Several identical impulse capacitors are charged in parallel and then discharged in series, obtaining in this way a mul-tiplied total charging voltage, corresponding to the number of stages.

The following two figures shows the multiplier circuit for the 2 and 3 stages impulse configu-ration.


GS

R'L

KF

KF

u(t)

R'D

R'E

R'DC'S CB

U'0

R'E

C'S

Fig. 52: Multiplier circuit for Impulse 2 stages


KF

CB

GS

KF

KF

u(t)

R'E

R'D

R'E

R'D

R'E

C'S

C'S

C'S

R'L

R'L

0U'

R'D

Fig. 53: Multiplier circuit for Impulse 3 stages

The impulse capacitors of the stages C’S are charged to the stage voltage U’0 via the high charging resistor R’L in parallel.

When all switching gaps SF break down, C’S will be connected in series, so that CB is charged via the series connection of all damping resistors R’D; finally C’S and CB will dis-charge again via the resistors R’E and R’D. It is expedient to choose R’L >> R’E.

The n-stage circuit can be reduced to a single stage equivalent circuit, such as in chapter “Impulse 1 stage”, where the following relationships are valid:

U0=nU’0 (15)

RD=nR’D (16)

CS=1/nC’S (17)

RE=nR’E (18)


Packing material, Transportation, Storage, Un-

packing

The rules, instructions and tips concerning this are component specific. Please read the cor-responding chapters in the manuals of the respective used components.

66 Assembling, Installation,

First putting into operation KIT High Voltage Construction

Assembling, Installation,

First putting into operation

Installation area

The floor of the test location must be prepared in a way that there is no sag under the load of the heaviest component.

There must be sufficient clearances from high voltage parts of the system to components connected to earth.

Recommended Clearance for High Voltage Equipment for AC, DC, SI

0

50

100

150

200

250

300

350

400

450

500

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

Clearance [m]

Pe

ak

Va

lue

of

Vo

lta

ge

[k

V]

Diagram 1: Clearances for AC, DC and SI

The empirical formula 3 kV/cm could be used for determining the recommended clearance. With sharp edges or rough surfaces the clearance could be much higher. For Practical dis-charge measurement the mandatory distance has to be also higher.

KIT High Voltage Construction Assembling, Installation,

First putting into operation 67

Test room

A suitable room is required to accommodate the high voltage construction KIT. Depending on the KIT configuration a floor surface of 5 m x 6 m is recommended and a favorable height is 2.5 m to 4.5 m.

Since voltages in excess of 1000 V are to be generated, it is necessary that the respective safety regulations are carefully followed. The most important criteria of a good test room are the screening and grounding.

Safety equipment

The test area should be enclosed by a metal grid fence of at least 2.2 m height with a maxi-mum grid spacing of 40 mm.

All doors leading to the test room must be equipped with door contacts, which close when the door is closed. All contacts should be connected in series to the interlock system. This safety system will automatically turn off the high voltage if a door is opened while the test system is switched on. Red and green warning lights should be installed at all doors leading to the test room.

Screening

The test transformer of the high voltage construction KIT can be used for partial discharge measurements. In order to ensure that the partial discharge measurement is not disturbed by external interference, it is necessary that the test room is screened like a Faraday cage. Walls, ceiling and the floor of the test area have to be covered with a metallic surface. This surface can either be a copper mesh having a spacing of less than 10 mm or a 0.1 mm to 0.2 mm copper. The edges of each individual strip must be carefully joined to the next one so that the conductivity between the sheets is as high as possible. Using a wire mesh, the wires should be bound and soldered. Copper foils can be joined by folding the edges or by solder-ing. Welding or soldering points are preferable to screw or clamp connections. A steel sheet floor with non-slip surface (waffle sheeting) is recommended. All cables leading into the shielded room should enter the Faraday cage at a central position. Ask your Haefely Hipo-tronics Sales Person for assistance on how to erect shielded enclosures and for power line filters.

Grounding

A good test field has a separated grounding. This ensures that no disturbances from sur-rounding machines enter the test field and - in case of a failure - the earth potential of the surrounding does not rise, causing damage to electrical equipment. It is necessary for the test field to have a lower grounding resistance than the surrounding building.

The following measures are required: Use a deep ground rod, radial ground wires below the ground surface, a lightning conductor or water mains outside the building for grounding.

If possible, the whole test room should be screened. Attention should be paid to ensure a good lasting electrical connection between all parts of the screening. The screening surfaces should be made with wide metal strips (at least 60mm in width), since strips of this width are of lower inductivity than round wires having the same cross-sectional area.

Connections have to be made without forming loops.

The ground connection of the high voltage generator, measuring system and test object should be arranged like a star, where the central point is grounded.



To avoid ground loops between different grounding points, the KIT is grounded at only one position through a grounding rod. The rod should have a ground resistance of less than 2 Ω.

If the resistivity of the soil near the factory is not known, we recommend the following proce-dure: A rod with a diameter of about 20 mm is driven into the soil to a depth of approx. 30 m. The first 3 m of this rod below the soil level have to be insulated in order to avoid picking up surface currents. Then the ground resistance is measured. If the resistance is higher than 2 Ω, a second rod must be driven into the soil approx. 10 m from the first, following the same procedure. The two ground rods are then connected in parallel with a copper foil of 150 mm x 0.3 mm cross section for example. This procedure is repeated until the ground resistance of < 2 Ω is achieved.

The length of the grounding rod is not important but the ground resistance must be < 2 Ω for personnel protection.

A local construction company can give you some more details about the depth of the rod. The grounding rod(s) shall be placed close to the test area. The enclosure’s ground stud will be connected to the ground rod with a strong copper band for example 0.3 mm x 100 mm.



Figure 54 shows the grounding resistance as a function of length of rod and soil resistivity

Fig. 54: Grounding resistance as a function of length of rod and soil resistivity

In figure 54 means:

RA: Ground resistance []

E: Soil resistivity [m]

l: Depth of grounding rod [m]

d: Diameter of grounding rod [m]



Assembling

Before the construction is set in operation can it is absolutely necessary to study the chapter ‘Safety’ detailed.

Terminals

Only trained people are allowed to do erection work. The terminal data are component specif-ic. Please read the corresponding chapters in the respective component manuals. The fol-lowing chapters give basic information’s about the terminals of the regulating transformer and transformer cascade.



PZT Transformer cascade

2 stages transformer cascade

Figure 58a shows a schematic diagram with the connections for a 2 stages transformer cas-cade without compensating reactors. Figure 58b shows the schematic diagram for a 2 stages cascade with compensating reactors.

Fig. 58a: Schematic diagram for cascade connection of two test transformers



Fig. 58b: Schematic 2 stages with compensating reactors

S0 is the beginning of the secondary winding, S is the high voltage end of the secondary winding and T is the end of the tertiary winding.

The low voltage winding of the transformer consists of two winding groups (1Px-1Pu, resp. 2Px-2Pu) which could be connected either in series or in parallel. For cascade operation of the transformer with the KIT FU the two winding groups should be connected in series!



Module 1 has to be connected to earth.

The primary windings of the test transformers should be connected in series with the Banana plugs (see figure 59a), i.e. 2Px has to be connected with 1Pu.

Fig. 59 a: Series connection of primary windings

Fig. 59 b: Parallel connection of primary windings

Terminal S0 of module 1 has to be connected with terminal E of module 1 (these two terminals are realized as Banana plug sockets) (see figure 60).

The input power cables has to be connected to the terminals 1Px and 2Pu of module 1 (these two terminals are realized as bushings) (see figure 60).

1Px 2Px 1Pu 2Pu



Fig. 60: Input terminals module

Connections without compensating reactors:

Terminal T of module 1 has to be connected with terminal 2Pu of module 2 (these two terminals are realized as bushings) (see figure 61a).

Terminal S of module 1 has to be connected with terminal 1Px of module 2 (these two terminals are realized as bushings) (see figure 61a).

Terminal S of module 1 has to be connected with terminal S0 of module 2 (these two terminals are realized as Banana plug sockets) (see figure 61a).

Terminal S0 of module 2 has to be connected with terminal E of module 2 (these two terminals are realized as Banana plug sockets) (see figure 61a).

E S0 2Pu 1Px



Fig. 61a: Connections between the two modules

Module 1

Module 2

S T S

2Pu 1Px E S0



Connections with compensating reactors:

Terminal T of module 1 has to be connected with terminal Ru of the compensating reactor 1. Terminal 2Pu of module 2 has also to be connected to terminal Ru (see figure 61b).

Terminal S (bushing) of module 1 has to be connected with terminal Rx of the com-pensating reactor 1. Terminal 1Px of module 2 has also to be connected to terminal Rx (see figure 61b).

Terminal S (Multi-contact socket) of module 1 has to be connected with terminal S0 of module 2. The connection has to be done over a blind terminal at the compensa-tion reactor 1 (see figure 61b).

Terminal S0 of module 2 has to be connected with terminal E of module 2 (Mutli-contact sockets) (see figure 61b).

Terminal T of module 2 has to be connected to terminal Ru of the compensation re-actor 2 (see figure 61c).

Terminal S of module 2 has to be connected to terminal Rx of the compensating re-actor 2 (see figure 61c).

Fig. 61b: Connections between the two modules and the compensating reactor

S T S

Module 2

2Pu 1Px E S0

Module 1

Compensating reactor 1

Rx Ru



Fig. 61c: Connections between the last module and compensating reactor

The required power range for each compensation reactor has to be selected by a wire bridge. Following positions are available:

10 kVAr

5 kVAr

0 kVAr (disconnected)

Top Electrode

Rx Ru

T S



3 stages transformer cascade

Figure 62a shows a schematic diagram with the connections for a 3 stages transformer cas-cade without compensating reactors. Figure 60b shows the schematic diagram for a 3 stages cascade with compensating reactors.

Fig. 62a: Schematic diagram for cascade connection of three test transformers



Fig. 62a: Schematic 3 stages with compensation reactor

Module 1 has to be connected to earth.

Terminal S0 of module 1 has to be connected with terminal E of module 1 (these two terminals are realized as Mutli-contact sockets) (see figure 61).

The primary windings of all test transformers has to be connected in parallel with the Multi-contact plugs (see figure 59), i.e. 1Px has to be connected with 2Px, and 1Pu has to be connected with 2Pu.

Connections without compensating reactors:



Terminal S of module 1 has to be connected with terminal S0 of module 2 (these two terminals are realized as Mutli-contact sockets) (see figure 61a).

Terminal S0 of module 2 has to be connected with terminal E of module 2 (these two terminal are realized as Mutli-contact sockets) (see figure 61a).



Terminal S of module 2 has to be connected with terminal S0 of module 3 (these two terminals are realized as Mutli-contact sockets) (see figure 61a).



Terminal S0 of module 3 has to be connected with terminal E of module 3 (these two terminals are realized as Mutli-contact sockets) (see figure 61a).

Connections with compensating reactors:

Terminal T of module 1 has to be connected with terminal Ru of the compensating reactor 1. Terminal 2Pu of module 2 has also to be connected to terminal Ru (see figure 61b).

Terminal S (bushing) of module 1 has to be connected with terminal Rx of the com-pensating reactor 1. Terminal 1Px of module 2 has also to be connected to terminal Rx (see figure 61b).



Terminal T of module 2 has to be connected with terminal Ru of the compensating reactor 2. Terminal 2Pu of module 3 has also to be connected to this terminal Ru (see figure 61b).

Terminal S (bushing) of module 2 has to be connected with terminal Rx of the com-pensating reactor 2. Terminal 1Px of module 3 has also to be connected to this ter-minal Rx (see figure 61b).



Terminal T of module 3 has to be connected to terminal Ru of the compensation re-actor 3 (see figure 61c).

Terminal S of module 3 has to be connected to terminal Rx of the compensating re-actor 3 (see figure 61c).



Preparation for first putting into operation

Before the system can be put into operation it is absolutely necessary to study the chapter ‘Safety’ in detail.

A specialist of Haefely Hipotronics should generally make the first commissioning.

It is basically recommended to first operate the low voltage components of the system with-out connection to the high voltage components to make sure of their faultless function.

Condition

Condition for this is that all components of the system are assembled, connected and opera-tive according to the manual.

Procedure

Cut the system OFF the electric mains.

Disconnect the cable connection between the regulating transformer and the test transformer.

Connect a voltmeter to the output of the regulating transformer instead of the cable connection.

For the selection of the voltage meter it is necessary to pay attention to the max. out-

put voltage of the regulating transformer.

Connect the system with the electric mains.

Switch on KIT control software according to the manual.

Unlock emergency button.

Make sure, all interlock contacts are closed; modulation index is at zero position.

Switch the primary breaker and the secondary contactor through the KIT control software on (according to the KIT control software manual).

Increase the output voltage at the regulating transformer by the KIT control software continuously and check the correspondence of the voltage meter and the voltage in-dication on the control unit.

Decrease the output voltage at the regulating transformer continuously to zero by the control unit.

Switch the primary breaker and the secondary contactor through the KIT control software off (according to the KIT control software manual)

Can the steps be done without differences out of the tolerance between voltage meter and the voltage indication on the KIT control software a faultless operation of the low voltage components can be assumed.

Disconnect the system from the electric mains

Reinstall the cable connection between regulating transformer and test transformer

82 Operating Instructions KIT High Voltage Construction

Operating Instructions

Introduction

Basically, the KIT control software does the operation of the system. Detailed infor-mation of the following instructions is primary to be taken from the manual of the KIT control software.

Construction of the different KIT-

configurations

The following pictures show how the KIT-components have to be assembled to realize the different configurations for AC, DC and Impulse according the chapter “Technical description”.

KIT High Voltage Construction Operating Instructions 83

AC-configuration

1 stage

Fig. 63: Construction AC configuration 1 stage


2 stages

Fig. 64: Construction AC configuration 2 stages


3 stages

Fig. 65: Construction AC configuration 3 stages


DC-configuration

1 stage

Fig 66: Construction DC configuration 1 stage


2 stages

Fig. 67: Construction DC configuration 2 stages


3 stages

Fig. 68: Construction DC configuration 3 stages


Impulse configuration

1 stage

Fig. 69: Construction Impulse configuration 1 stage


2 stages

Fig. 70: Construction Impulse configuration 2 stages


3 stages

Fig. 71: Construction Impulse configuration 3 stages


Load ranges of the different KIT-configurations

Technical data is subject to alterations!

AC-configuration

1 stage

continu-ous

1h ON, 1h OFF, 4x per day

Rated voltage [rms] [kV] 100 100

Base load (CM) [pF] 100 100

Frequency [Hz] 50 50

Rated current [mA] 90 100

Output [kVA] 9 10

Impedance voltage (approx.) [%] 4.6 -

Max. capacitive load, Cload [nF] 2.7 3.1



Output [kVA] 9 10

Impedance voltage (approx.) [%] 5.6 -


Table 2: Load range AC 1 stage

Impedance voltage relates to rated power continuous and rated frequency


2 stages

Without compensating reactor:

continuous

Rated voltage [rms] [kV] 200

Base load (2 x CM) [pF] 50

Frequency [Hz] 50

Rated current [mA] 38

Output [kVA] 7.6

Impedance voltage (ap-prox.) [%] 8

Max. capacitive load, Cload [pF] 550

Frequency [Hz] 60


Output [kVA] 7.2

Impedance voltage (ap-prox.) [%] 10

Max. capacitive load, Cload [nF] 0.42

Table 3a: Load range AC 2 stages without compensating reactors


With compensating reactor:

continu-ous



Base load (CM) [pF] 50 50



Output [kVA] 16 20




Output [kVA] 16 20


Table 3b: Load range AC 2 stages with compensating reactors


3 stages

Without compensating reactor:

continuous

Rated voltage [rms] [kV] 300

Base load (3 x CM) [pF] 33

Frequency [Hz] 50


Output [kVA] 3

Impedance voltage (approx.) [%] 9


Frequency [Hz] 60


Output [kVA] 1.5

Impedance voltage (approx.) [%] 9


Table 4a: Load range AC 3 stages without compensating reactors


With compensating reactor:

contin-uous



Base load (CM) [pF] - 33


Rated current [mA] 80 -

Output [kVA] 24 -

Max. capacitive load, Cload [pF] 815 -



Output [kVA] 18 24

Max. capacitive load, Cload [pF] 495 675

Table 4b: Load range AC 3 stages with compensating reactors


DC-configuration

The divider is always part of the load!

1 stage

Load characteristic DC 1stage, Divider is part of the load

115

120

125

130

135

140

0 1 2 3 4 5 6 7 8 9 10 11 12 13

Output current [mA] incl. divider

Ou

tpu

t vo

ltag

e [

kV

]

DC 1stage without divider

Diagram 1: Load range DC 1 stage

With divider an output voltage of approx. 137 kV is possible.


Ripple factor, DC 1Stage

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

0 1 2 3 4 5 6 7 8 9 10 11 12 13


Rip

ple

facto

r [%

]

Diagram 2: Ripple factor DC 1 stage

For a ripple factor of 3 % an output current including divider of approx. 10 mA is possi-ble.


2 stages

230

235

240

245

250

255

260

265

270

275

280

0 1 2 3 4 5 6 7 8 9 10 11 12 13

Output voltage [kV]


Load characteristic DC 2stages, Divider is part of the load

DC 2stages without divider

Diagram 3: Load range DC 2 stages



Ripple factor, DC 2stages

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

0 1 2 3 4 5 6 7 8 9 10 11 12 13


Rip

ple

facto

r [%

]

Diagram 4: Ripple factor DC 2 stages

For a ripple factor of 3 % an output current including divider of approx. 10 mA is possi-ble.


3 stages

Load characteristic DC 3stages, Divider is part of the load

330

340

350

360

370

380

390

400

0 1 2 3 4 5 6 7 8 9 10


Ou

tpu

t vo

ltag

e [

kV

]

DC 3stages without divider

Diagram 5: Load range DC 3 stages



Ripple factor, DC 3stages

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

4.0%

0 1 2 3 4 5 6 7 8 9 10


Rip

ple

facto

r [%

]

Diagram 6: Ripple factor DC 3 stages

For a ripple factor of 3 % an output current including divider of approx. 7.4 mA is pos-sible.


Impulse-configuration

For lightning (LI) and switching (SI) impulse existing four different wave front resis-tors/damping resistors to realize different load configurations.

Resistor LI SI

RD 355 75 k

RD 220 55 k

RD 140 40 k

RD 95 30 k

Table 5: Wave front resistors and their values It has to take into consideration that the divider for impulse measurement is a pure ca-pacitive voltage divider, i.e. due to the not existing ohmic damping oscillations in the waveform could be occur if the impulse is recorded with an oscilloscope. An increase of the stage leads to a reduction of the load by the same factor.

1 stage

Impulse Capacitance

25nF (1x CS25)

Max. total charging voltage [kV] 140

Max. energy at max. charging voltage [J] 250

Max. output voltage LI no load [kV] 125

Max. output voltage LI max. load [kV] 100

Max. capacitive load for LI [pF] 6100

Max. output voltage SI no load [kV] 118

Max. output voltage SI max. load [kV] 99

Max. capacitive load for SI [pF] 5000

Table 6: Impulse single stage

Basic configuration per stage:

LI

Smoothing capacitor, CS [nF] 25

Load capacitor, CB (divider) [nF] 1.2

Wave tail resistor, RE [kΩ] 2.4

Table 7: Basic configuration per stage


LI


Wave front resistor RDA [Ω] 355

Load range with RDA, Cload [pF] 0...400

Output voltage at min. load with RDA [kV] 125

Output voltage at max. load with RDA [kV] 122

Table 8: Load range for wave front resistor RDA

LI


Wave front resistor RDB [Ω] 220

Load range with RDB, Cload [pF] 250...1500

Output voltage at min. load with RDB [kV] 124

Output voltage at max. load with RDB [kV] 117

Table 9: Load range for wave front resistor RDB

LI


Wave front resistor RDC [Ω] 140

Load range with RDC, Cload [pF] 1300...3300

Output voltage at min. load with RDC [kV] 120

Output voltage at max. load with RDC [kV] 110

Table 10: Load range for wave front resistor RDC


LI


Wave front resistor RDD [Ω] 95

Load range with RDD, Cload [pF] 3000...6100

Output voltage at min. load with RDD [kV] 112

Output voltage at max. load with RDD [kV] 100

Table 11: Load range for wave front resistor RDD

2 stages

Impulse Capacitance

25nF (1x CS25)









Table 12: Impulse two stages


LI



Charging resistor, RL [MΩ] 2.5




LI







LI







LI








LI







3 stages

Impulse Capacitance

25nF (1x CS25)









Table 18: Impulse three stages


LI



Charging resistor, RL [MΩ] 2.5




LI (IEC 60060-

1)







LI







LI








LI








Switch on procedure

Condition

Generally only trained and in high voltage educated people are allowed to op-erate the system.

Before the system is put into operation it is absolutely necessary to study the chapter ‘Safety’ detailed.

All components of the chosen configuration have to be assembled correctly, connected.

System has to be connected to the chosen electric mains according to the manual

Procedure

Open KIT control software according to its manual

Make sure, no humans are in the danger zone

Make sure that everything is connected properly

Remove ground rod from the system

Be sure that the test area cannot be entered during operation

Unlock emergency button

Switch on low voltage: close the primary breaker at the KIT frequency convert-er by KIT control software (according to the KIT control software manual)

Set the KIT FC cabinet in the ready: Press Ready button

Switch on the high voltage: Press HV ON button

Operation

Normal operation

After switching on the high voltage, the output voltage of the system can be varied by the KIT control software (see KIT control software manual)

Abnormal occurrence

In case of irregularities during tests and measurements the system will be selectively shut off depending on the KIT control software. When something is abnormal and can-not be solved the system should be shut off and the Haefely Hipotronics support should be contacted.


Switch off procedure

Procedure

Decrease the output voltage at the KIT frequency converter continuously to ze-ro by the KIT control software

Switch off the high voltage: open the secondary switch at the KIT frequency converter by the KIT control software(according to the KIT control software manual)

Press emergency button

Open the interlock (safety circuits) contacts

All high voltage parts have to be grounded with the grounding rod.

Follow the five safety regulations

If test with DC-voltage are performed (DC or Impulse configuration) extra care is

essential when grounding capacitors, see chapter “Special Information Con-

cerning DC-Voltage”.

Switch off low voltage: open the primary breaker at the KIT frequency convert-er by the KIT control software (according to the KIT control software manual)

Switch off KIT frequency converter

(Disconnect system from the electric mains)

Emergency switch off

Switch off

By pressing the emergency button the system will be switched off until the input of the KIT frequency converter in any operating state.

The switch off procedure of the system with an output voltage unequal zero should on-ly be done in case of an emergency, because this procedure means a higher stress for the test object and also for the system.

Restart

After system switch off by the emergency button with an output voltage unequal zero the following procedure has to be done:

Unlock the emergency button

Set the KIT FC cabinet in the ready: Press Ready button

Switch on the high voltage: Press HV ON button


Options

All system options and their use are mentioned in the chapter general Information un-der „Components“.

Additional equipment KIT 4.0 (overview) Additional equipment and their use are mentioned in the chapter general Information under „Components“.

Additional KIT components:

DKU: vessel for vacuum and pressure

KIT DKU SET 1: additional set of electrodes

KR: corona cage

OP: oil testing cup

MF 100: measuring sphere gap

KIT MF SET 1: additional set of electrodes

KIT Auto Impulse Off: automation of impulse one stage

KIT High Voltage Construction Trouble shooting 113

Trouble shooting

Errors and disturbances

How an error or a disturbance is indicated the KIT control software will help indicate it. The corresponding Information can be locked up in manual of the KIT Control software.

Basically occurring errors and disturbances are separated into three different clas-ses, depending on their effects:

Alarms: after automatically decreasing the output voltage to zero, the system switches off itself

Interlock: the system will switch off the high voltage immediately

Trips: the system will be switched off until the input of the regulating transformer in any operating state

Basic trouble shooting

In case of an error or a disturbance, the error indication on the KIT control software should be regarded first. The interpretation of it and the resultant actions have to be taken from the manual of the control unit.

Common failures

Electric mains are not switched ON

Emergency button resp. key switch is switched OFF

Interlock contacts (security circuit) not closed

Alarms, Trips not set back (optional)

Wrong current and voltage limiter set (optional)

Earth bar not removed

Regulating transformer is not in zero position

114 Trouble shooting KIT High Voltage Construction

Minimum data for reporting a fault

If an error or a disturbance can’t be located or solved despite of all in the manuals listed actions, contact the customer support of Haefely Hipotronics.

For an efficient work, the customer support needs the following system specific in-formation:

Project number of system ______.

Customers name.

Description of the last actions, before the error or the disturbance occurred, if possible with layout.

Detailed description of how the error showed itself, if possible with prints out or pictures.

Type of installation.

KIT High Voltage Construction Maintenance 115

Maintenance

Utility services

The concerning information has to be taken from the manuals of the individual compo-nents.

Support, Maintenance

KIT test systems are normally maintenance-free. Component specific maintenances have to be taken from their manuals.

All connections must be checked regularly to good fitting of the crews.

Cleaning

Because the individual components are made by different materials, there can’t be given any general information about detergents and interval.

Before any cleaning, the concerning instructions in the component manual have to be studied.

Repairs

A specialist should generally only do reparations. This means, by a specialist of Hae-fely Hipotronics or by a Haefely Hipotronics authorized person.

The action has to be taken from the respective component manual and/or to be dis-cussed with the customer support of Haefely Hipotronics.

To warrant adequate servicing, no general instructions for repair can be given!

116 Maintenance KIT High Voltage Construction

Spare parts

Basically, only original replacement parts can be used. Original or equivalent replace-ment parts can be obtained by Haefely Hipotronics.

For an efficient work, the customer support needs the following system specific infor-mation:

Project number of system ______

Client’s name.

System name plate information of the main components, which contains the replaceable part.

Detailed description of the component that has to be replaced, if possible with picture.

Type of installation.

KIT High Voltage Construction Components from sub-suppliers 117

Components from sub-

suppliers

To possible existing components from third deliverers, it is referred to in the individual manuals.

118 Onward Transfers KIT High Voltage Construction

Onward Transfers

Resale

Haefely Hipotronics has to be informed if the test equipment will be sold to a third company. In case of a resale the equipment has to be sold complete including all op-erating instructions, test reports etc.

If the equipment is resold without information to Haefely Hipotronics, Haefely Hipo-tronics rejects any warranty, liability and claims.

Shut down procedure

If the KIT system has to be stored the following items have to be checked:

Disconnect power, measuring and control cables.

The floor of the storage place must be suitable concerning the load capacity

The storage temperature has to be in range of -5 ... +40°C

The maximum humidity should be <90 % (non condensing)

The component specific recommendations have to be taken from the concern-ing manuals.

Disposal

The information about disposal is very component specific. It is therefore to be taken from the concerning component manual or datasheet.

Taking back

The question of taking back has to be discussed individually. Please contact the cus-tomer support of Haefely Hipotronics.

KIT High Voltage Construction Training, Education 119

Training, Education

Training

Before a person works with or on a system or its components, it is absolutely neces-sary to instruct him/her by a trained person.

Education

If the system is operated irregularly, periodic training helps to prevent user faults and increases user security visibly. The responsible person and operator should be edu-cated in the operation with high voltage systems.

120 Diagrams, Drawings KIT High Voltage Construction

Diagrams, Drawings

Summary

Because the system can be arranged optional with different components (depending on the customer’s order) the concerning plans and drawings are individually, all put to-gether in a client specific file and can be looked into.

KIT High Voltage Construction Technical Data 121

Technical Data

Ambient conditions for storage and opera-

tion, system data etc.

Because the system can be arranged optional with different components (depending on the customer’s order) and the technical data strongly depends on the used compo-nents in the system they are to be taken from the following documents:

System

System test report

Components

Component test report (if the component is tested separately!)

Component name plate (if existing)

122 Test Reports KIT High Voltage Construction

Test Reports

Summary

Because the system can be arranged optional with different components (depending on the client’s order) the concerning test reports are put individually in a client specific file and can be looked into.

KIT High Voltage Construction

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