OPERATION AND MAINTENANCE MANUAL FOR

H.V.BREAKDOWN TESTER 0-75KV 75mA D.C

CUSTOMER: - BHARAT HEAVY ELECTRICALS LTD. BHOPAL

CUSTOMER P.O. NO.: - 1105469

DATED: 07.12.2010

Designed and Manufactured by:

TESLA ELECTRICAL INDUSTRIES

Ancillary to Bharat Heavy Electrical Ltd. Bhopal, 41-B, BHEL Ancillary Industries Estate, Habibganj, Bhopal (M.P) INDIA Phone No. +91-755-2588617 (O)

H.V. BREAKDOWN TESTER

75KV 75mA D.C
THE BREAKDOWN TESTER IS FOR TESTING THE INSULATION STRENGTH OF LARGE ELECTRICAL MACHINES, COMPONENETS, CABLES etc.

TECHNICAL DETAILS:
IT CONSISTS OF TWO MAIN UNITS: 1. THE CONTROL AND METERING PANEL (CMP). 2. THE TRANSFORMER RECTIFIER UNIT (TRU). Operating voltage: 230V, 50Hz, A.C. Output voltage: 0 to 37.5KV and 0 to 75KV D.C Continuously Variable. The set is HIGH RESOLUTION TYPE hence can be used independently for two ranges of 37.5KV & 75KV. This is made possible by two windings, which changes the complete range of HV Transformer. CAPACITY : 75mA max. On H.V Side. 2.812KW in 0 to 37.5KV 5.625KW in 0 to 75KV Range. DUTY CYCLE: 50%

1.

Control & Metering Panel

This consists of main input Fuses, MCB, Contactor fuses, indicating lamps, push buttons, timer, tripping circuits, meters etc. All these equipments are housed in a robust cabinet with adequate ventilation. Bi-directional wheels are provided for mobility of control panel. The cabinet is of min 1.6 mm sheet, sand blasted applied with 2 coats of red oxide and painted in Opline green glossy synthetic enamel. All the wiring is carried out using reputed make cables of appropriate cross-sectional area. All the control wiring is carried out using 1mm sq. multistrand copper wire of reputed make.

3 The ends of cables are terminated with crimped lugs and ferrule makers as per the drawing numbers. The cables are terminated on suitable terminal blocks. Gland plates are provided at the bottom or rear side for the cable entry.

2.

High Voltage Transformer

This is a Step-Up Transformer specifically designed for H.V. Breakdown applications with HIGHELY GRADED INSULATION on secondary side of the windings. The primary winding is in two sections so as to provide high-resolution system. All the Windings are of electrolytic grade copper conductor or appropriate cross sectional area so as to keep the temperature rise within limits. Since the equipment is subjected to frequent short circuits, hence the design is such that it gives trouble free service. The Multi-Stepped Core used is of high grade CRGO steel of M4, M3 or M2 H grade material only. The transformer is Oil-Cooled Type.

3.

Rectifier: It is rated for the required D.C. voltage with several diodes in series. Each diode will have surge protection. The rectifier will be single-phase full wave bridge. It will be oil-cooled type housed in the tank with H.V. Transformer.
4. H.T. Terminal Cable Stand: A Stand is provided for H.V. Terminal end of the High Voltage Cable. On the top side it is insulated from earth for a distance of approx 450mm. H.T. Cable with spherical termination should be kept near the Job under Test, and the sphere side can be connected to the Job with Fuse wire. The earth to the Job should be connected by Earth Clip provided with the H.T. Cable. For transportation purpose the cable stand is folding type. 4.1 Assembly: 1. The Base The H.T. Cable Stand consist of the following: 2. M.S. Pipe 3. Insulated (Epoxy glass) Cable support.

1. The Base is a tripod with a bush at the centre to accommodate bottom side of MS Pipe. 2. The MS. Pipe has two positions for M6 size bolt, one at the centre, and other at 125mm from the Top side. The other side is bottom side, and is to be inserted on the bush of the base stand. 3. Insulated Cable support:- This is a Epoxy glass pipe with slots at right angles at the top for holding the H.T. Cable at Spherical Terminal End.

4 The base, pipe and insulated cable support are mounted separately on H.V. Transformer Tank.

Refer Drg. No. TEI/HVDC/75-75 Page 3 of 3 1. For assembling, keep the base on ground. 2. Insert bottom of MS Pipe on the bush of the base. 3. Take out Insulated Cable Support from MS Pipe. 4. Take out M6 bolt from position2 and insert in position 1 on MS Pipe. 5. Insert the Pipe of Insulated Cable Support to the MS Pipe. The Stand is ready for Use. Now place the stand near to the Job under test and connect ball side terminal to H.T. Side of Job with fuse wire, and earth side with clip.

5.

SPECIAL FEATURS
a. HIGH RESOLUTION DESIGN: This enables to use the set independently as 0 to 37.5KV or 0 to 75KV, hence readability is very fine. b. LEAKAGE CURRENT SETTING: The leakage current can be from 20% to 100% of the maximum value, through a potentiometer provided on the front of the panel. Hence no disconnecting link is required. The tripping Ckt is a watchdog type protection and HV set can be put to operation only when this circuit is healthy. c. VERY SAFE IN OPERATION: as current setting is possible through solidly grounded resistor and no link changing is required on H.T. side of transformer rectifier unit. d. THE HIGH VOLTAGE TRANSFORMER: is a single unit and hence is highly efficient with minimum impedance, better power factor and minimum partial discharge. e. HIGH ACCURACY: with specially designed highly graded winding so as to reduce the capacitance effect and eliminate the use of voltage divider for normal test on insulating materials.

f. All the switchgear items are of reputed make such as L&T, Siemens, BCH, Kaycee, English Electric, Elmex, Technoplast make only. The meters are of MECO or AE make only. THE SET CAN
BE MAINTAINED LOCALLY. EASILY BY PROCURING THE ITEMS

5 g. STAINLESS STEEL EARTHING terminals are provided on both the sides of the control panel and HV Transformer rectifier units. h. Kilovolt meter reads the proportionate voltage from Potential Divider, resulting in high accuracy.

INSTALLATION:
CHECK FOR ANY PHYSICAL DAMAGE TO THE CONTROL PANEL AND TRANSFORMER RECTIFIER UNIT (TRU). CHECK FOR ANY OIL LEAKAGE AND ENSURE THAT OIL LEVEL IS MINIMUM TO THE HALF MARK. EARTH THE CONTROL PANEL AND TRU INDEPENDENTLY AND THEN INTERCONNECT EACH OTHER WITH MINIMUM 6sq.mm FLEXIBLE COPPER CONDUCTOR. CONNECT THE INPUT TERMINALS TO 1PH 230V SUPPLY WITH MIN. 1.5 sq.mm COPPER WIRE. CONNECT WIRE 15 AND 16 TO H4 AND H1 RESPECTIVELY. CONNECT THE WIRE 17 AND 18 TO THE RESPECTIVELY TERMINALS T17 AND T18 AND WIRE D1 AND D2 TO THE TERMINALS D1 AND D2.

OPERATION:
SWITCH ON THE MCB. o MAINS ON INDICATION WILL BE AVAILABLE AND VARIAC WILL MOVE TO ZERO AUTOMATICALLY AND VARIAC ZERO INDICATION WILL BE AVAILABLE. PRESS THE TEST ON PUSH BUTTON. o TEST ON INDICATION WILL BE AVAILABLE AND DANGER LIGHT WILL FLASH. INCREASE THE VOLTAGE WITH TOGGLE SWITCH TS2. DO NOT INCREASE THE VOLTAGE FURTHER IF ANY OF THE NEON LAMP ON THE PANEL GLOWS. (SWITCH OFF THE SET AND CONTACT MANUFACTURER) WHEN REQUIRED TEST VOLTAGE IS ACHIEVED, SWITCH ON THE TIMER.

6 o AFTER THE PRESET TIME, THE BUZZER WILL SOUND. DECREASE THE VOLTAGE TO ZERO WITH THE TOGGLE SWITCH. o IN CASE THE SPECIMEN UNDER TEST FAILS THE SET WILL TRIP AND THE VARIAC WILL COME TO ZERO POSITION AUTOMATICALLY. REPEAT THE ABOVE SEQUENCE FOR SECOND TEST.

MAINTENANCE:
1. CHECK THE OIL LEVEL IN THE TRANSFORMER TANK REGULARLY; FILTER THE OIL IF THE BREAKDOWN VALUE IS LESS THAN 75KV. 2. CHANGE SILICAGEL IN THE BREATHER IF THE COLOR IS CHANGED TO PINK. 3. ALWAYS USE HRC FUSE CATRIDGES. 4. KEEP THE TESTER CLEAN AND IN DRY PLACE. 5. CHECK FOR PROPER EARTHING REGULARLY. 6. IF ANY OF THE NEON LAMP ON THE TANK GLOW, DO NOT USE THE TESTER AND CONTACT TO MANUFACTURER IMMEDIATELY.

CAUTION:
DO NOT INCREASE THE VOLTAGE FURTHER IF ANY OF THE NEON LAMP ON THE TRU GLOWS. (SWITCH OFF THE SET AND CONTACT MANUFACTURER) WHEN REQUIRED TEST VOLTAGE IS ACHIEVED, SWITCH ON THE TIMER. o AFTER THE PRESET TIME, THE BUZZER WILL SOUND. o DECREASE THE VOLTAGE TO ZERO WITH THE TOGGLE SWITCH. o IN CASE THE SPECIMEN UNDER TEST FAILS THE SET WILL TRIP AND THE VARIAC WILL COME TO ZERO POSITION AUTOMATICALLY.

DANGER HIGH VOLTAGE DO NOT OPERATE WITHOUT PROPER EARTHING DO NOT OPERATE THE SET IF ANY OF THE NEON LAMP GLOWS.

7 PLEASE READ THE INSTRUCTION CAREFULLY BEFORE USE ONLY TRAINED PERSONALS TO OPERATE THE SET

PRECAUTIONS:
EARTH THE CONTROL PANEL AND THE H.V. TRANSFORMER UNIT INDEPENDENTLY AND THEN INTERCONNECT EACH OTHER. ALWAYS USE MULTI-STRAND FLEXIBLE COPPER CONDUCTOR (OF CROSS-SECTIONAL AREA 1.5 TIMES OF MAINS INPUT CABLE) FOR EARTHING. USE CRIMPING LUGS WITH SOLDERING AT BOTH THE ENDS. OIL LEVEL SHOULD ALWAYS BE MAINTAINED UP TO THE MINIMUM IN OIL LEVEL INDICATOR BEFORE STARTING THE TESTING. KEEP THE H.V. TRANSFORMER IN DRY PLACE AWAY FROM MOISTURE. CHECK BDV OF H.V. TRANSFORMER OIL IF THE EQUIPMENT IS KEPT STORED (UNUSED) FOR MORE THAN 12 WEEKS. (THE BDV OF OIL SHOULD BE MIN. 60KV).