SECTION 1
General
Elektrotechnik GmbH
SECTION 2
Technical description
User Manual
SECTION 3
KPG 38kV VLF
Preparing the unit for
operation
SECTION 4
Edition:
July 2009
Neumann Elektrotechnik GmbH
Annaberger Straße 73
09111 Chemnitz
Tel:
Fax:
eMail:
website:
+49 (0)371 / 53 032 - 0
+49 (0)371 / 53 032 - 11
info@neumann-chemnitz.de
www.neumann-chemnitz.de
Operating instructions
SECTION 5
Maintenance, care and
service
SECTION 6
Troubleshooting
II
Neumann Elektrotechnik GmbH
KPG 38kV VLF
KPG 38kV VLF
07-2009
III
PREFACE
This user manual provides information on the operation of the unit and is
designed to assist you in quickly resolving any questions or problems
occurring in connection with its use. In case of problems, please refer to
this manual first.
Look up the appropriate section in the table of contents and read it
carefully. In addition, check all terminals and connections of the equipment.
If this will still not solve the problem, please turn to the following address:
Neumann Elektrotechnik GmbH
Annaberger Straße 73
D-09111 Chemnitz
Tel: +49 (0)371 / 53032 - 0
Fax: +49 (0)371 / 53032 - 11
eMail: info@neumann-chemnitz.de
© Neumann Elektrotechnik GmbH
All rights reserved. This manual may neither wholly nor in part be
photocopied or reproduced in any other form without the prior written
permission of Neumann Elektrotechnik GmbH. The content of this manual
is subject to change without notice. Neumann Elektrotechnik GmbH
accepts no liability whatsoever for any technical or printing errors or
deficiencies possibly contained in this manual. Similarly, Neumann
Elektrotechnik GmbH cannot be held liable for damages caused directly or
indirectly by the supply, application or use of this material.
IV
Neumann Elektrotechnik GmbH
Table of contents:
1
1.1
1.1.1
1.1.2
2
2.1
2.1.1
2.1.2
2.1.3
2.2
2.3
2.4
3
3.1
3.2
3.3
4
4.1
4.1.1
4.1.2
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
GENERAL...................................................................................................1
SAFETY INSTRUCTIONS ................................................................................1
General safety regulations.......................................................... 3
Identification used in the description .......................................... 5
TECHNICAL DESCRIPTION..................................................................7
DESCRIPTION OF DEVICE..............................................................................7
Designation of device ................................................................. 7
Scope of supply .......................................................................... 7
Fields of application – Test methodes ........................................ 7
CONSTRUCTION OF DEVICE ........................................................................10
FUNCTION..................................................................................................11
SPECIFICATIONS ........................................................................................12
PREPARING FOR USE...........................................................................15
OPERATING REQUIREMENTS ......................................................................15
CONNECTING THE TEST DEVICE .................................................................16
AVOIDING RADIO INTERFERENCE ..............................................................18
OPERATING INSTRUCTIONS .............................................................19
CONTROL AND INDICATING ELEMENTS ......................................................19
Overview and designation of elements..................................... 19
Description of functions ............................................................ 20
MENU CONTROL VIA ALPHANUMERICAL DISPLAY .....................................21
SEQUENCE OF OPERATIONS........................................................................22
Testing with alternating voltage (VLF) ...................................... 23
Testing with direct voltage (DC) ............................................... 27
Terminating the test .................................................................. 30
Safety measures....................................................................... 31
Operating hour counter............................................................. 32
Data Recording (Option)........................................................... 32
KPG 38kV VLF
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5
5.1
5.2
5.2.1
5.2.2
5.3
CARE, MAINTENANCE AND SERVICE............................................ 37
CARE ........................................................................................................ 37
MAINTENANCE AND SERVICE.................................................................... 37
Maintenance by user.................................................................37
Manufacturer’s service..............................................................38
IMPORTANT TRANSPORT DIRECTIONS........................................................ 38
6
TROUBLESHOOTING .......................................................................... 39
7
SUPPLEMENT
- EG-Declaration of Conformity CE-Mark
- EMC-Certificate
- Certificate of Quality Management System ISO 9001: 2000
VI
Neumann Elektrotechnik GmbH
1 General
The cable test set (KPG) is a device used to generate high voltages.
It may be used for voltage proof testing of the insulation of cables, electrical
installations and items of equipment. By measuring the current and voltage
by means of integrated measuring devices, the insulation resistance of the
equipment under test can be determined.
The KPG is comprised of an operating unit and a high-voltage unit. Thanks
to its small dimensions and a relatively low weight, it is portable and can be
used directly at the equipment to be tested. Clearly arranged control
elements and indicators as well as a simple menu-prompted operation
ensure comfortable handling.
A special ground safety circuit provides for a high degree of safety.
1.1
Safety instructions
Any person intending to install, operate, maintain or repair this unit must
have carefully read this manual and understand the information given
therein.
At the time of delivery, the device and its accessory equipment represent
the state of the art in the area of safety technology. However, due to the
specific nature of operations, there may exist points and parts on the unit
and its associated peripheral equipment, which cannot be fully protected
without unreasonably affecting its function and operation. Consequently,
appropriate personal safety practices are indispensable for preventing
harm to personnel and the unit itself.
The following safety hints must be duly observed!
GENERAL INSTRUCTIONS
Only duly qualified trained and / or instructed personnel shall be allowed to
perform work on this unit and its peripheral equipment. Access to the unit
and equipment by other persons must be prevented.
This manual must be kept available to supervising, operating and
maintenance personnel for ready reference.
KPG 38kV VLF
07-2009
1
Using the device in a way which is not in conformity with the intended
purpose may be dangerous to health and life, to the unit and associated
equipment, and may also affect its appropriate use (UVV – German
Accident Prevention Regulations). The unit may exclusively be used for the
purpose for which it has been designed by the manufacturer.
Always use only appropriate tools which are in a good condition for
performing work on the unit.
Carry out checks on a regular basis to make sure that safety regulations
are complied with during operation and maintenance.
The device may be operated only by authorised, appropriately qualified
persons.
The device and the associated peripheral equipment must at all times be in
an impeccable condition in technical respect.
Only genuine parts may be used in the device and the associated
peripheral equipment, because non-original parts may endanger the
required safety. It is not permitted to handle or operate the device in any
way which may affect its safety.
The person using the device shall be obliged to immediately report to the
competent supervisor any changes noticed on the device.
The operator shall also be obliged to put the device immediately out of
operation if an incident occurs which may affect the safety of personnel.
The device may be put back into operation only after the cause of the
incident has been eliminated.
ELECTROTECHNICAL INSTRUCTIONS
The device and all accessory equipment must be connected in conformity
with the applicable regulations. The respective DIN and VDE regulations
must be observed.
Before starting any repair or maintenance work on the device or other
equipment, be sure to isolate it from the power supply (verify equipment is
dead). Only qualified electricians in the sense of UVV may carry out such
work. A qualified electrician in the sense of UVV is a person who, due to its
training, knowledge and experience as well as familiarity with applicable
regulations, is in a position to assess the work to be performed and to
identify possible hazards.
2
Neumann Elektrotechnik GmbH
INSTRUCTIONS TO RADIO INTERFERECE
The KPG 38kV VLF is a device of class A to EN 55011. Radio interference
may occur when the „VLF“ test method is used. In this case, the operator of
the device will have to carry out protective measures (see 3.3 Avoiding
radio interference).
1.1.1
General safety regulations
Maintenance and repair work shall primarily be governed by the relevant
accident prevention regulations.
Mark components before starting repairs.
When reassembling fittings and devices, always use only new gaskets and
locking elements.
Fit screwed connections only in dry condition (use no lubricants).
Only duly trained and qualified personnel may be assigned for performing
maintenance and repair operations.
Check system for proper functioning after each maintenance and repair
work.
Isolate and secure the equipment.
Before carrying out any work on electrical equipment, isolate the parts on
which work is to be performed.
This also applies to seemingly minor repairs.
Take effective measures to prevent unintentional energising of the point(s)
isolated.
After disconnecting the equipment from the power supply, make sure that
all poles of the items of equipment at the place where work is to be carried
out are dead before commencing work.
Perform the check with a voltage tester or measuring instrument, the
serviceability of which has been checked shortly before use on a live part of
the equipment.
KPG 38kV VLF
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3
Fuses
It is not permitted to rewire or bridge fuses and to use rewired fuses.
If fuses have to be replaced, only fuses of the same or lower design current
and type (slow, quick-acting, superfast) may be used. Substituting adaptor
screws with screws for fuses with a higher design current is not
permissible.
Fuses must not be disconnected or withdrawn under load. It is not
permitted to use fuses for switching circuits.
Instructions for handling permanently installed and flexible cables
and leads
Mains cables and their clamps must not be used for fastening, attaching or
suspending devices, clothing and the like.
When disconnecting cables, protect them against kinking. Take measures
to prevent ingress of moisture at ends of cables. Provide a suitable
moisture protection, if necessary.
During operation and transportation of the devices, make sure that loose
supply cables will not be subjected to impermissible pull. Never suspend
the devices on the supply cables and, when disconnecting plugs, never pull
on the cable for pulling them out of the socket outlet.
Regulations for handling cable connections
Portable electrical equipment may be connected to the power supply only
via the connectors (plug, socket outlet) provided for this purpose.
It is not permissible to use adapters and plugs fitting into socket outlets for
other voltage levels.
When exchanging cable connections, make sure that connection is made in
correct phase sequence.
Regulations for handling cable accessories
Secure cable clamps by retaining washers and spring lock washers against
becoming loose by vibrations. When reconnecting cables to devices and
equipment, make sure the cable shield is earthed and that the cable entry
fitting is tight (in accordance with degree of protection of pertaining device).
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Neumann Elektrotechnik GmbH
1.1.2
Identification used in the description
Important instructions relating to personal and operational protection as
well as to technical safety are identified as follows in the text:
CAUTION!
CAUTION! This symbol appears whenever
working instructions and procedures must be
strictly observed to avoid harm to persons. Nonobservance may result in serious personal injury
or death and/or damage to the unit.
WARNING! This symbol appears whenever working instructions and procedures must be strictly
observed to avoid damage to or destruction of the
unit and/or associated equipment.
WARNING!
NOTE:
KPG 38kV VLF
NOTE: Appears whenever it is necessary to draw
your attention to certain technical requirements to
be observed when working with the unit.
07-2009
5
6
Neumann Elektrotechnik GmbH
2 Technical description
2.1
2.1.1
Description of device
Designation of device
KPG 38kV VLF
Meaning:
2.1.2
●
●
●
●
●
●
●
●
●
●
KPG
38kV
VLF
german: “Kabelprüfgerät” (Cable Test Set)
max. AC output voltage (r.m.s.)
Very Low Frequency
Scope of supply
Operating unit
Protective bag
High-voltage unit
High-voltage connecting cable (shielded), standard 5m
Connecting cable between operating unit and high-voltage unit
(permanently connected to operating unit), standard 3m
Mains cable (permanently connected to operating unit), standard 3m
Connecting cable between operating unit and protective ground
Connecting cable between high-voltage unit and station ground
Service kit
User Manual
2.1.3
Fields of application – Test methodes
The portable Cable Test Set KPG 38kV VLF is mainly used for insulation
testing of Medium Voltage Power Cable Systems. A sheath test can be
performed with this device too.
Fields of application include:
- Testing of newly fit cables prior to commisioning
- Re-commisioning after repair and maintenance
- Re-commisioning of temporarily shut-down cables
- Regular preventive testing
KPG 38kV VLF
07-2009
7
It can be tested with the following test methods:
- VLF (0,1 Hz AC voltage testing)
- DC testing
The test methods are described in more detail:
VLF – Test
suitable for:
Ÿ MV-Cables with plastic insulation (XLPE, PE, EPR, HEPR)
Ÿ MV-Cables with Paper-Oil-Insulation (PILC)
Ÿ mixed Cables
Requirements of DIN VDE 0276-620 and DIN VDE 0276-621 for voltage
test on the insulation:
Frequency of testing voltage:
Testing voltage:
Testing time:
Requirement:
0,1 Hz
3 x U0 r.m.s. value*
60 minutes
no Breakdown
Cable rating
U0 / U*
3.6 / 6 kV
6,3 / 11 kV 8.7 / 15 kV 12 / 20 kV 12.7/22 kV
VLF Test voltage
11 kV rms
19 kV rms
26 kV rms
36 kV rms
38 kV rms
* U0 = cable rating phase to ground
U = cable rating phase to phase
VLF is the very best and most effective method for insulation testing of
medium voltage power cables with extruded (plastic) insulation.
Using 0,1 Hz VLF test voltage, weak spots in XLPE, PE and also oil
impregnated paper insulated cables are quickly brought to a controlled
breakdown without causing additional damage or aging to the remaining
cable insulation.
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Neumann Elektrotechnik GmbH
DC – Testing
suitable for:
Ÿ MV-Cables with Paper-Oil-Insulation (PILC)
Requirements of DIN VDE 0276-621 for voltage test across the insulation:
Testing voltage:
Testing time:
Requirement:
see table:
15 to 30 minutes
no Breakdown shall occur during testing period
Cable rating U0 / U
3,6 / 6 kV
6 / 10 kV
8,7 / 15 kV 12 / 20 kV
DC-Test voltage
max. permissible leakage current (per Core)*
20-29 kV
34-48 kV
67-96 kV
76-108 kV
500µA/km
700µA/km
700µA/km
700µA/km
* Practical values, not required in the DIN VDE
DC-Polarity:
Testing voltage on conductor: negative
Cable shield on station ground: positive
Cable Sheath – Testing
suitable for:
Ÿ MV-Cables with PE or PVC-Sheath (Jacket)
Requirements of DIN VDE for voltage test across Cable sheath (Jacket):
PVC-Sheath:
PE-Sheath:
Testing time:
Requirement:
≤ 3kV DC voltage
≤ 5kV DC voltage
10 minutes (Practical value)
no Breakdown shall occur during testing period
Limits for leakage currents*:
PVC at 3kV:
max. 800µA / km
PE at 5kV:
max. 20µA / km
* Practical values, not required in the DIN VDE
Polarity:
Cable shield on negative potential,
Station ground on positive potential
KPG 38kV VLF
07-2009
9
2.2
Construction of device
The Cable Test Set KPG 38kV VLF consists of the operating unit and highvoltage unit.
On the operating unit, all operating, control and indicating elements of the
device are provided in a clear arrangement.
The high-voltage device accommodates the following oil-insulated devices:
high-voltage transformer, high-voltage switch, rectifier, measurement
divider and discharge device. The bottom region of high-voltage unit
contained an oil-to-air heat exchanger with forced circulation.
Both devices of the unit are connected by a control cable, which is
permanently connected to the operating unit.
µA
kV
On
HV
100 µA
1 mA
10 mA
Off
VLF Current
Cancel
< Select >
measurement
On
Mains
Off
Enter
10 A tr.
Figure: View of high-voltage unit (left) and operating unit (right)
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Neumann Elektrotechnik GmbH
2.3
Function
For operating the device, the operating unit and the high-voltage unit must
be properly grounded. The unit is provided with an internal grounding
safety circuit which allows the unit to be operated only if a sufficient lowresistance connection exists between the protective ground and station
ground.
The device has a number of further protective functions such as mains
voltage monitoring and power-on disable if a residual or external voltage is
present at the output. Only when all specified parameters are met, the highvoltage can be turned on.
The design provides for redundancy of all important safety functions.
In the high-voltage unit, the test voltage is generated by means of a highvoltage transformer, rectifier and high-voltage switch. This voltage may
either be a low-frequency alternating voltage (0.1 Hz) or a direct voltage of
positive or negative polarity.
On completion of a test or tripping of a protective device, the connected
equipment under test is also automatically discharged via the discharge
device, which is also integrated in the high-voltage unit.
KPG 38kV VLF
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11
2.4
Specifications
Power supply:
Mains voltage:
Current input:
12
Power input:
230 V ± 10% / 50/60 Hz
max. 8 A (nominal current)
max. 13 A (peak current)
max. 3000 VA
Output voltage
VLF:
DC:
5..38 kVr.m.s. , appr. sinusoidal, 0.1Hz
` 0...50 kV dc
Maximum load (VLF)
06 kV
18 kV
19 kV
26 kV
36 kV
38 kV
0.1 Hz
5.0 µF
3.8 µF
3.7 µF
3.0 µF
2.0 µF
1.8 µF
Max. output current (DC)
Overcurrent tripping:
± 10 mA
Measuring ranges
Voltage (analogous):
Voltage (display)
Current:
-50 ... 0 ... +50 kV
± 55 kV
± 100 µA / 1 mA / 10 mA
Measuring error
Current / voltage
±5%
Discharge device
Max. discharge capacity:
6250 J (i.e. 5 µF @ 50 kV dc)
Operating temperature:
Storage temperature:
-20°C ... +40°C
-25°C ... +55°C
Weight
Operating device
High-voltage device
17.7 kg
48.5 kg
0.05 Hz
9.0 µF
6,8 µF
6.7 µF
5.4 µF
3.6 µF
3.2 µF
(option)
Neumann Elektrotechnik GmbH
cable capacity in µF
max. cable capacity
10
9
8
7
6
5
4
3
2
1
0
6
12
18
0.1 Hz
24
30
36
test voltage in kVr.m.s.
0.05 Hz
shape of the test voltage curve
60
Voltage in kV
40
20
0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
-20
-40
-60
time in s
KPG 38kV VLF
07-2009
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Neumann Elektrotechnik GmbH
3 Preparing for use
3.1
Operating requirements
It is not permissible to leave the operating unit in the protective bag during
operation of the unit. Make sure that the device is adequately ventilated. Do
not cover the ventilation slots. After putting down the device carrying
handle can be locked in 30°-steps by using spring bias. Pulling on handle
unfixes the lock. The operating unit may be operated either in the vertical
position (with the operator panel facing upwards) or in the horizontal
position (with the operator panel facing towards the front).
The connecting cables are kept in the front pocket. When packing in the
cables, in particular the high-voltage connection cable, make sure that it will
not be kinked.
The high-voltage unit must always be set up in the vertical position and
secured during operation against inadvertent contact. Make sure that the
high-voltage device is placed on a clean surface so that it is protected from
dirt and moisture and that no foreign matter may get into the air intake and
outlet openings.
Make absolutely sure that the clearances between
the high-voltage terminal and grounded or live parts
are kept in accordance with DIN VDE 0104.
CAUTION!
During the test, warning signs with the text:
HIGH VOLTAGE!
Caution! Danger to Life!
must be put up, and the area of testing must be cordoned off with a barrier.
Set up the operating unit at a distance of approx. 3 m from the barrier. It
should preferably be set up on a surface which is at operating height.
KPG 38kV VLF
07-2009
15
3.2
Connecting the test device
Before connecting the device, make sure that the oil level can be seen in
the middle of the oil-level lens. If this is not the case, it is not permitted to
carry out measurements.
1 / 2*
µA
kV
On
HV
100 µA
1 mA
10 mA
Off
VLF Current
Cancel
< Select >
measurement
On
Mains
Off
Enter
10 A tr.
3
(1)
(2*)
(3)
(4)
(5)
4
5
High-voltage connection socket
On rear side: Oil-level lens
Ground terminal of high-voltage unit (station ground)
Socket for cable connecting operating unit to high-voltage unit
Ground terminal of operating unit (protective ground)
Before connecting the test device, isolate and secure the equipment in
conformity with DIN VDE 0105. The requirements of DIN VDE 0104 and
DIN VDE 0105 must be met. To connect the device, carry out the following
steps in the order given:
1.
Ground and short-circuit the test object conductors which will not be
tested as well as the cable shield (connect to station ground or
auxiliary earth point). The device can be used for testing of unearthed
equipment only, if an auxiliary earth is created.
2.
Establish a conductive connection between the station ground or
auxiliary earth and the ground terminal of the high-voltage unit [3].
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Neumann Elektrotechnik GmbH
3.
Establish the connection between the ground terminal of the operating
unit [5] and the protective ground (PE) potential.
4.
Establish the connection between the high-voltage terminal [1] and the
test objects conductor which will be testet. To this end, plug highvoltage plug into high-voltage connection socket [1] and screw it in
place.
5.
Connect the connecting cable, which is permanently fitted to the
operating unit, to the high-voltage unit (connection socket [4]).
6.
Connect operating unit to the power supply.
Test object
µA
kV
On
HV
100 µA
1 mA
10 mA
Off
VLF Current
Cancel
< Select >
measurement
On
Mains
Off
Enter
10 A tr.
Mains
Protective Ground
(PE)
Fig.:
Station ground
Example of connection of test set
KPG 38kV VLF
07-2009
17
Before testing, measuring voltage transformers and
power transformers must be disconnected!
WARNING!
3.3
Ending the cable in an enclosed switchgear, so this
test requires the agreement of the contracting
authority with the manufacturers of switchgear.
Avoiding radio interference
The KPG 38kV VLF is a device of class A to EN 55011. Radio interference
may occur when the „VLF“ test method is used. In this case, the operator of
the device will have to carry out the following protective measures:
1.
Before starting measurements or tests, check whether in the near-by
area there are any facilities sensitive to radio interference such as:
- transmitting facilities,
- receiving facilities
- personnel and building protection facilities,
- air traffic radio installations,
- medical facilities,
- residential buildings
and advise the parties in question that there may be radio interference
or that electronic equipment may be affected. Such checks and the
notification of parties affected should be documented each time the
unit is to be used.
2.
If need be, increase the distances between the unit and the cable to
be checked and the facility which will possibly be affected.
3.
Generally, when using the unit in industrial facilities, make sure that a
protective distance of 30 m to radio-sensitive facilities is maintained.
4.
Generally, when using the unit in residential areas, make sure that a
protective distance of 60 m to radio-sensitive facilities is maintained.
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Neumann Elektrotechnik GmbH
4 Operating instructions
4.1
4.1.1
Control and indicating elements
Overview and designation of elements
1
2
4
5
6
7
8
9
14
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
13 12
11
3
10
Ammeter
Voltmeter
Alphanumerical display
EMERGENCY STOP button
Signal lamp „Power ON“ (white)
Signal lamp „Ground connection“ (yellow)
Illuminated pushbutton „HV On“ (green)
Illuminated pushbutton „HV Off“ (red)
Mains switch (lockable)
Rotary encoder for function selection and parameter input
„Enter“ button for menu control
„Cancel“ button for menu control
Range selector switch for ammeter
„VLF Current measurement“ button
KPG 38kV VLF
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4.1.2
Description of functions
(1)
Ammeter:
- indicates leakage current
- measuring ranges:
-100µA...+100µA / -1mA...+1mA / -10mA...+10mA
(2)
Voltmeter
- indicates output voltage (instantaneous value)
- measuring range: -50kV...+50kV
(3)
Alphanumerical display
- 4 x 20 characters
- background illumination
- functions: see 4.2
(4)
EMERGENCY STOP button
- slam button for interrupting main circuit (mains supply), cannot
be defeated
- with turn-to-reset feature
- ON-OFF indication by green marking ring
- causes immediate activation of discharge device
(5)
Signal lamp „Power ON“ (white)
- illuminates when the device has been switched on with the
mains switch (9) and mains voltage is applied
(6)
Signal lamp „Ground connection“ (yellow)
- illuminates when operating device and high-voltage device are
properly grounded
(7)
Illuminated pushbutton „HV On“ (green)
- button for switching on high voltage
- illuminates when ready for switching on
(8)
Illuminated pushbutton „HV Off“ (red)
- button for switching off high voltage
- illuminates when high voltage is switched on
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Neumann Elektrotechnik GmbH
(9)
Mains switch „Mains“
- key-operated switch; key may be pulled off only at Off position
(10)
Rotary encoder for function selection and parameter input
- incremental encoder without end stop
- turning it counterclockwise/clockwise will shift the cursor or
change a parameter
(11)
„Enter“ button for menu control
- button for correcting a selected function or a selected parameter
(12)
„Cancel“ button for menu control
- button for correcting a selected function or a selected parameter
(13)
Range selector switch for ammeter
- 3-stage rotary switch for selecting the measuring range for the
leakage current
(14)
„VLF Current measurement“ button
- function: see 4.3.1 Testing with alternating voltage (VLF)
4.2
Menu control via alphanumerical display
The dialogue between the user and the control of the device is via the
alphanumerical display. It serves for menu-prompted parameterising of the
device. During a measurement, it provides information on the most
important measuring variables and displays possibly occurring faults.
Thanks to the simple structure of the menu, the user can determine the
required test parameters in just a few steps.
The entire selection of functions and parameterisation are performed with
the rotary encoder [ < Select > ] and the buttons [Enter] and [Cancel].
Turning the rotary encoder counterclockwise or clockwise, as appropriate,
will shift the cursor (highlighting of a function) or change a parameter. The
rotary encoder has no end stop.
KPG 38kV VLF
07-2009
21
Pressing the button [Enter] will acknowledge a selected function or a
selected parameter. That is, you get to the next menu level.
By pressing the button [Cancel], you can cancel the selection of a function
or of a parameter. Each time you press this button will bring you one further
level back in the menu.
4.3
Sequence of operations
Before each measurement, select the greatest current measuring range
(10mA).
Switch on the mains switch [Mains]. The white signal lamp illuminates. At
the same time, the yellow signal lamp illuminates if grounding has been
carried out properly and if connection to ground exists. If the lamp does not
illuminate, check all grounding connections.
On the display the start screen and, after a few seconds, the main menu
appears.
MAIN MENU
►1) Test Parameters◄
2) Operating hours
3) Select Language
In menu item „3) Select language“, you can select the language to be used
for menu control. „German“ and „English“ are available by default. Other
languages are possible on request.
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4.3.1
Testing with alternating voltage (VLF)
1.
Select „1) Test parameters“ in the main menu (see above). [Enter].
2.
Select test method „VLF“.
METHOD OF TESTING
►1) VLF
◄
2) DC
3.
Select Frequency of VLF voltage (Option, not installed on all devices!)
TEST FREQUENCY:
►1) 0,1 Hz
2) 0,05 Hz
4.
[Enter].
◄
[Enter].
Select operating mode.
MODE OF OPERATION:
►1) Mains
◄
2) Generator
[Enter].
Selects whether the device is to be operated on the mains or on an
emergency generation set.
5.
Select test voltage (r.m.s. value).
TEST VOLTAGE:
►
38.0 kV
◄
[Enter].
VLF test voltage can be chosen between 5 to 38kV in 0.5kV-steps.
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6.
Set test time.
TEST TIME:
►
060 min
◄
[Enter].
The maximum test time is 300min.
7.
Data recording (Option, not installed on all devices!)
Select whether the test data should be recorded and stored in the built
in memory of the device or not.
DATA RECORDING
►1) yes
2) no
◄
[Enter].
Configure, between phases is tested:
Test between
► 1) L1 » L2 L3 E ◄
2) L2 » L1 L3 E
3) L3 » L1 L2 E
4) L1 L2 L3 » E
5) L1 L2 » L3 E
6) L1 L3 » L2 E
7) L2 L3 » L1 E
8) *S L1 » E
9) *S L2 » E
10) *S L3 » E
11) *S L1 L2 L3 » E
e.g. •
•
•
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[Enter].
L1 » L2 L3 E means insulation test of phase L1 against Ground,
L2 and L3 grounded
L1 L2 L3 » E means insulation test of all 3 phases against Ground
*S L1 » E
means sheath test, cable shield of L1 against Ground
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8.
Display of selected test parameters.
VLF TEST
Frequency: 0.1 Hz
Voltage:
38.0 kV
Test Time: 060 min
Acknowledge parameters with [Enter], (or correct with [Cancel]).
9.
The green illum. pushbutton [HV On] signals readiness for switch on.
Start with
[HV On]
10. Operate button [HV On]. The high-voltage is connected, the discharge
switch opens. The red illuminated pushbutton [HV Off] illuminates and
signals „High voltage is on“. At the same time, the green illuminated
pushbutton extinguishes.
11. The device automatically carries out a load test in which the capacity
of the tested object is determined internally.
Load Test
1.4 µF
If the load capacity is within the permissible range (see Specifications),
the VLF test will now start automatically.
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OUTPUT VOLTAGE:
38.0 kV rms 0.1 Hz
TEST TIME:
21:16 of 060 min
The measured output voltage is displayed as true r.m.s. value in the
upper area of the screen.
In the lowermost display line, the selected test time and test time that
has already expired are indicated.
12. Leakage current measurement (option)
During the VLF test the ammeter is disabled, otherwise the charging
current and not the leakage current would be displayed.
But during the VLF test, you can also measure the leakage current. To
this end, press the button [VLF Current measurement].
The VLF test will then be continued up to the next negative voltage
half-wave. Shortly before the peak voltage is reached, the device stops
to activate the ammeter. After a few seconds, the leakage current can
be read. If need be, the current measurement range has to be
changed with the selector switch. Note: After completing the
measurement, do not forget to select again the greatest measurement
range (10mA). The leakage current measurement is automatically
completed after 30 seconds. However, you can also prematurely abort
the measurement by pressing the button [VLF Current measurement].
The VLF test will then be automatically resumed.
13. Breakdown detection
If the test object is damaged or defective, the insulation will be
punctured during the test, the breakdown will be automatically
detected and the time at which the breakdown occurred determined.
Breakdown!
after 011:13 min
at 38.0 kV
14. see 4.3.3 Terminating the test!
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4.3.2
1.
Testing with direct voltage (DC)
Select test method „DC“.
METHOD OF TESTING
1) VLF
►2) DC
◄
[Enter].
2.
Select polarity of direct voltage.
DC POLARITY
►1) negative
2) positive
◄
[Enter].
3.
Set test time.
TEST TIME:
►
045 min
◄
[Enter].
The maximum test time is 300min.
4.
Display the selected test parameters.
DC TEST
Polarity: negative
Test Time: 045 min
Confirm parameters with [Enter] (or cancel with [Cancel]).
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5.
Data recording (Option, not installed on all devices!)
Select whether the test data should be recorded and stored in the built
in memory of the device or not.
DATA RECORDING
►1) yes
2) no
◄
[Enter].
Configure, between phases is tested:
Test between
► 1) L1 » L2 L3 E ◄
2) L2 » L1 L3 E
3) L3 » L1 L2 E
4) L1 L2 L3 » E
5) L1 L2 » L3 E
6) L1 L3 » L2 E
7) L2 L3 » L1 E
8) *S L1 » E
9) *S L2 » E
10) *S L3 » E
11) *S L1 L2 L3 » E
e.g.
6.
• L1 » L2 L3 E means insulation test of phase L1 against Ground,
L2 and L3 grounded
• L1 L2 L3 » E means insulation test of all 3 phases against Ground
• *S L1 » E
means sheath test, cable shield of L1 against Ground
The green illuminated pushbutton [HV On] signals readiness for
connection.
Start with
[HV On]
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[Enter].
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7.
Operate the button [HV On]. High voltage is connected, the discharge
switch is opened.
The red illuminated pushbutton [HV Off] illuminates and signals „High
voltage is on“. At the same time, the green illuminated pushbutton
extinguishes.
To set the test voltage, slowly turn the rotary encoder clockwise. While
doing so, observe the rise of voltage and current on the instruments.
Output Voltage:
38.4 kV
Polarity: negative
1:04 of 45 min
The voltage can be read on both the analogue instrument and on the
display.
After the predetermined test voltage is reached, select the current
measuring range with the selector switch. Now you can read the
leakage current of the test object on the ammeter.
When the maximum output current is exceeded (10mA), the
overcurrent release trips. Tripping of the overcurrent release indicates
that the test object is defective.
Overcurrent Trip!
after 11:13 min
at 47.8 kV
When the nominal test voltage of the device is exceeded (at 52.5kV),
the overvoltage release trips.
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4.3.3
Terminating the test
You can terminate testing at any time (by hand) by operating the button
[HV Off]. The message: „Test terminated “ appears.
The test ends automatically upon expiration of the test duration. Message:
„Test completed! Test time expired “
Testing is also automatically terminated when a fault occurs. The following
error messages may occur:
·
·
·
No Earth!
Supply-Undervoltage!
Overvoltage!
In a VLF test:
· Short-circuit at output
· Breakdown!
ê
Test object defective
In a DC test:
· Primary Overcurrent!
· Overcurrent Trip!
ê
Test object defective
Any time testing is terminated (manually or automatically), the high voltage
will be automatically switched off (red signal lamp [HV Off] extinguishes),
and the discharge device is activated.
You can follow the discharge operation on the voltmeter. When the highvoltage reading has dropped to 0 volt, the test object can be grounded.
NOTE:
30
If testing at a large load has been carried out for a
long time, the unit should be left switched on (only
[Mains On] ! ) for an adequate period of time (510min). The cooling system of the high-voltage unit
will then remain active and provide for rapid cooling
of the transformer oil and enclosure.
Neumann Elektrotechnik GmbH
After grounding and switching off the device, you can disconnect the
connection to the test object.
The high-voltage plug must not be plugged in or
pulled in the live condition.
CAUTION!
In case of an emergency, a second operator must switch off the high
voltage by actuating the EMERGENCY STOP button.
4.3.4
Safety measures
Please refer also to the general safety directions given in Section 1.
Only qualified electricians according to DIN VDE 0105 may operate the
device. It may be operated only in rooms which are safeguarded or cordoned off and marked in accordance with DIN VDE 0104 and DIN VDE 0105.
In case of an emergency, a second operator must switch off the device by
actuating the EMERGENCY STOP button or red button [HV off] and shortcircuit the device.
NOTE:
Never put device which are moist from condensation
into operation!
In addition to an appropriate shock-hazard protection, reliable grounding of
the device is required at all times.
When testing a cable, make sure that the other end
is also reliably protected against shock-hazard!
CAUTION!
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Always bear in mind when carrying out capacitive tests that residual
charges may still be present after discharging.
Cables laid parallel to one another may also still be
charged after testing!
CAUTION!
Before each test, the oil level must be visually checked (oil level in middle
of oil-level lens ± 5mm).
4.3.5
Operating hour counter
In each test (or at the end of the test), the operating hour counter adds the
expired timer minutes to the counter value which is stored. This means that
it is not the on-time of the device which is determined but the real sum of
test times.
If the interval of service is exceeded, this is signalled by the operating hour
counter immediately upon powering up of the device .
Service interval à see 5.2.2 Works service
4.3.6
Data Recording (Option)
If the device is equipped with the „Data Recording“, so the non-volatile built
in memory of KPG 38kV VLF is able to store about 100 records à 1h.
Recording of measurement data is already described in sections 4.3.1 and
4.3.2.
To transfer data, to delete the internal data memory or setting of the
internal clock, please proceed as follows:
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1.
Switch On Operating Unit, the HV Unit does not need to be connected.
In the MAIN MENU select „4) Data Recording“ .
1)
2)
3)
►4)
2.
MAIN MENU
Test Parameters
Operating hours
Select Language
Data Recording ◄
[Enter].
Transfer Data from built in memory to USB Flash Drive
To transfer data connect the included USB Flash Drive on the side of
Operating Unit, then select 1) transfer data.
DATA RECORDING
►1) transfer Data
2) set Clock
3) delete Data
4) Memory-Info
◄
[Enter].
MEMORY ->> USB
„MEMORY->> USB“ indicates that data is copied from device
memory to the USB stick. USB stick not remove!
TRANSFER OK !
„TRANSFER OK!“ confirmed that the data was correctly copied to the
USB stick. The USB stick can now be removed.
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3.
Setting Date and Time
Date and time are always displayed on the startup screen when you
turn the device.
The name of each data file consists of the date and time from the start
of the Test. This allows easy categorization of the data files by name
already.
DATA RECORDING
1) transfer Data
►2) set Clock
3) delete Data
14:37
◄
[Enter].
24.07.2009
Each of the selected range can be adjusted with <Select>.
With [Enter], the marker moves on next position.
4.
At Data transfer all stored data files will be copied from built-in memory
to the USB Flash Drive. That means, older data files were not deleted
automatical while Data transfer and the built in memory fills up slowly.
If the data files has been successfully copied to a PC, it is recommended to delete the built-in memory of the device:
DATA RECORDING
2) set Clock
►3) delete Data
4) Memory-Info
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◄
[Enter].
Neumann Elektrotechnik GmbH
5.
Memory-Info displays free device storage space:
DATA RECORDING
2) set Clock
3) delete Data
►4) Memory-Info
◄
[Enter].
A data file of a 60-minute measurement requires a space of approximately 2.4 kB.
250 / 256 kB free
NOTE:
Please use always the included USB Flash Drive for data transfer. With
this, we guarantee full functioning. We as manufacturers have successfully
tested a wider range of USB Flash Drives market at the time. However, due
to the enormous diversity in the market does not ensure total compatibility
with all brands.
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5 Care, maintenance and service
5.1
Care
The KPG 38kV VLF is a test instrument and must be carefully treated and
maintained as such.
Prevent the surface of the device from becoming soiled, and do not expose
it to moisture, direct sun radiation and ambient temperatures in excess
of 40 °C.
5.2
Maintenance and service
5.2.1
Maintenance by user
The only repairs which can be performed by the user are the replacement
of fuses and lamps in the operating unit. Fuses and incandescent lamps for
replacement are provided in the service kit. The operating unit need not be
opened for replacement.
Before carrying out any repair or maintenance work,
always disconnect the device from the power supply
by pulling the mains plug!
CAUTION!
For exchanging fuses, open the bayonet locks of the fuse holders on the
front panel of the unit with a screwdriver. Defective fuses may be
exchanged exclusively against fuses of the same type.
For exchanging incandescent lamps, use the lamp puller provided in the
service kit. Get hold of cap with lamp puller and pull vertically upwards.
Exchange lamp. Position pressure cap in place (do not turn!), and press it
in.
It is principally forbidden to carry out repairs on the high-voltage unit. In
case of oil leakage, mechanical damage on the enclosure or other visible
defects on the high-voltage device, the test may possibly have to be
immediately terminated. Any further use of the device is strictly forbidden!
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If the KPG 38kV VLF is defective, you have to send the complete device,
that is, the high-voltage unit, operating unit and also the pertaining cables,
to have it repaired.
5.2.2
Manufacturer’s service
After expiration of a service interval of 200 operating hours or after 24
months, the device should be sent to the manufacturer to have it serviced.
Send the complete KPG 38kV VLF, i.e., the high-voltage unit, operating
unit and the pertaining cables.
NOTE:
Manufacturer‘s service is performed exclusively by
the manufacturer.
Within the framework of manufacturer’s service, the following activities are
performed:
- Renewal of transformer and switch oil
- Check and, if necessary, exchange of high-voltage switching
contacts
- Updating of software, if necessary
- Complete functional test
- Calibration of device
5.3
Important transport directions
The KPG 38kV VLF should always be handled with great care during
transport. Greater mechanical loads such as shocks or dropping to the
ground must be strictly avoided!
The high-voltage device may be transported and
stored only in the vertical position.
WARNING!
38
Non-observance of this requirement may cause
leakage of transformer oil from the safety valve!
Moreover, if the position deviates extremely from the
vertical position, the high-voltage winding of the
transformer may become irreversibly damaged.
Neumann Elektrotechnik GmbH
6 Troubleshooting
If the device does not work properly or cannot be put into operation, carry
out the following simple checks and mind the hints given before sending
the device to the manufacturer.
Fault:
No function, signal lamp „Mains ON“ does not illuminate:
·
Has the device been properly connected to the mains, and is mains
voltage existing?
·
Is EMERGENCY STOP button released?
·
Are fuses properly inserted? Is any fuse defective?
Fault:
Signal lamp „Ground connection“ does not illuminate:
·
Are test object, high-voltage unit and operating unit properly
grounded?
·
Is the high-voltage unit properly connected to operating unit, is
connector locked?
·
In case of power supply from inverter or emergency generator set:
Has protective ground been connected to the operating unit?
Fault:
Undefined behaviour of control
ê
To reset the control, switch the unit off with the mains switch
[Mains], and then switch it on again after about 5 seconds.
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