VLF Hipot Tester

Huazheng Electric Manufacturing (Baoding) Co., Ltd

 Introduction
I. Thank you for using our products, so you have our comprehensive technical support and
service.
this product manual is applicable to series of ultra-low frequency and high voltage generators.
before using this product, please read the instruction manual carefully and keep it for reference.
this product is a test instrument for high-voltage electrical equipment. Please operate according
to the operation instructions and strictly abide by the relevant national regulations. Improper use
may endanger equipment and personal safety.
if you have any doubts in the process of reading the operation manual or using the instrument,
you can consult our company.
 Contents

I. Overview.................................................................................................................................................... 1
II. Advantages of 0.1Hz ultra-low frequency withstand voltage technology.......................................2
III. technical parameters of series products............................................................................................ 3
IV. Product features.................................................................................................................................... 4
V. Instrument structure and function description....................................................................................5
VI. Power cable withstand voltage test method................................................................................... 15
VII. Transportation and preservation..................................................................................................... 17
VIII. Quality assurance............................................................................................................................. 17
IX. Paper change method of printer....................................................................................................... 18
X. Packing List........................................................................................................................................... 19
I. Overview
High voltage withstand test of electrical equipment is one of the most important items specified in
insulation preventive test.
The withstand voltage test can be divided into ac withstand voltage test and dc withstand voltage
test. The ac withstand voltage test can be divided into power frequency, frequency conversion
and 0.1hz ultra-low frequency test technology, of which 0.1hz ultra-low frequency technology is
the latest technology recommended by the current international electrotechnical commission. Our
company's new generation of ultra-low frequency and high voltage generator is the core product
independently developed with the latest American technology. It adopts 7-inch touch screen, the
latest arm7 single chip microcomputer, high-speed ad acquisition circuit, and is equipped with
background management software. It overcomes many shortcomings of domestic similar
products (see table 1), and its cost performance is much higher than that of similar imported
products. It is especially suitable for withstand voltage test of electrical equipment with large
insulation equivalent capacitance (such as power cable, power capacitor, large and medium-
sized generator and motor, etc.), which conforms to the national standard of electric power
industry, general technical conditions for ultra-low frequency and high voltage generator (d) newly
issued in 2004 l / t849.4-2004.

0.1Hz HV control High Energy saving Noise Lifespan Electrical

voltage- method voltage life
withstand waveform
equipment
type
mechanical HV Square Not energy-saving: High short Short
mechanical wave consume excess
switch energy with high-
switching power resistors
polarity
Electronic HV Sine Energy saving: feed A No Long
electronic wave back excess power to little lifespan,
switch the grid can use
switching long-
polarity term

Table 1 performance comparison between mechanical type and electronic type of 0.1Hz
voltage withstand test equipment

1
II. Advantages of 0.1Hz ultra-low frequency withstand
voltage technology
In fact, the ultra-low frequency insulation withstand voltage test is an alternative to the power
frequency withstand voltage test. In the power frequency withstand voltage test of large and
medium-sized generators, motors, power cables and other test objects, due to their large
capacitance in the insulation layer, a large capacity test transformer or resonance transformer is
required. Some of these huge equipment is not only heavy and expensive, but also inconvenient
to use. In order to solve this contradiction, the method of reducing the test frequency and the
capacity of the test power supply is widely used in the world. It has been proved from many years
of theory and practice at home and abroad that replacing power frequency withstand voltage test
with 0.1Hz ultra-low frequency withstand voltage test can not only have the same equivalence,
but also greatly reduce the volume and weight of the equipment, theoretically, the capacity is
about one fifth of the power frequency, and the operation is simple. This is the main reason why
this method is widely used in developed countries.
According to the actual situation of China's power system, the national development and Reform
Commission has formulated the industry standard of ultra-low frequency (0.1Hz) withstand
voltage test method for 35kV and below XLPE insulated power cables. In 2004, the industry
standard DL / T 849.4-2004, general technical conditions for ultra-low frequency and high voltage
generators, which is being promoted in China. Although the DC voltage withstand test equipment
has the advantages of small size, light weight and low cost, the DC voltage withstand test is also
the most destructive to the insulation of the tested object. (see Table 2) therefore, the latest
national regulations on preventive test of electrical equipment have expressly stipulated that DC
high voltage is no longer used for voltage withstand test of electrical equipment, and AC voltage
withstand test is recommended.

The new generation of 0.1Hz ultra-low frequency high voltage generator developed by our
company adopts the latest power electronic components and the latest ARM7 single-chip
technology, further reducing the volume and weight of the equipment, fool operation, more stable
performance, overcoming the shortcomings of the first generation of mechanical booster, such as
short service life, high failure rate and large volume. Through years of practice, a large number of
user feedback shows that: - 80kV ultra-low frequency high voltage technology is leading in the
country, with the highest cost performance!
Table 2 performance comparison of various withstand voltage test equipment:

2
 Frequency
Power frequency 0.1Hz withstand DC withstand
Compare content withstand
withstand voltage voltage voltage
voltage

Equivalence good Good Good Bad

Insulation
small small small big
destructive

Operation safety low low high A little low

Most
Wiring Complicated Most easy complicated
Complicated
Volume and Light and small Light and small
Heavy and big Heavy and big
weight size size

III. technical parameters of series products

Ground voltage generator

Rated
Model Voltage Load Fuse Weight

0.1Hz,≤1.1µF

40kV Controller：6Kg
40KV /1.1 0.05Hz,≤2.2µF 8A
（Peak
Value） Booster：20Kg
0.02Hz,≤5.5µF

0.1Hz,≤1.1µF

50kV Controller：6Kg
50kV/1.1 0.05Hz,≤2.2µF 10A
（Peak
Value） Booster：45Kg
0.02Hz,≤5.5µF

0.1Hz,≤1.1µF

80kV
80KV/0.5 0.05Hz,≤2.2µF 20A Controller：4Kg
（Peak
Value）
0.02Hz,≤5.5µF booster：50Kg

3
1) Select products of appropriate specifications according to the subjects
When in use, the capacitance of the test object shall not exceed the rated capacitance of the
instrument. If the capacitance of the test object is too small, the output waveform will be
affected. If it is less than 0.05 μ F, the instrument will not output normally. At this time, 0.05 μ f
capacitor (provided by the company) can be connected in parallel for auxiliary output. See
Table 4 and table 5 for the estimation of capacitance of common electrical equipment.

Table 4 single phase earth capacity of different types of generators.

Steam turbine generator Hydro generator

Capacity 125-
200 300 600 85 300 400
（MW） 150
Single phase
0.18- 0.31-
ground 0.198 0.69 1.8-1.9 1.7-2.5 2.0-2.5
0.26 0.34
capacitance(uF）

Table 5 capacitance of XLPE insulated single core power cable (μ f / km)

capacitance Cross-
(uf/Km) sectional
area
（mm）
16 25 35 50 70 95 120 150 185 240

Voltage(KV)

0. 0.1 0.2 0.2 0.2

10 0.15 0.19 0.26 0.32 0.38
17 8 1 4 8

0.1 0.1 0.1

35 — — — 0.11 0.14 0.16 0.17
2 3 5

2) Estimation method of test object current:

Calculation formula: I = 2 π FCU

IV. Product features

 Advanced technology: digital frequency conversion technology, microcomputer control,
pressure rise, pressure reduction, measurement, protection, etc
 The test process is fully automated.

4
 Easy to operate: simple wiring, fool operation.

 Comprehensive protection: multiple protection (over-voltage protection, over- current

protection at high and low voltage sides), rapid action (when acting)
 Room ≤10ms), the instrument is safe and reliable.

 Safety and reliability: the controller is connected with the low voltage of the high voltage
generator, with photoelectric control, safe and reliable use.
 The high and low voltage closed-loop negative feedback control circuit is adopted,
and the output has no capacity rise effect.
 Complete configuration: capacitive touch screen, LCD Chinese character display,
automatic storage, automatic printing.
 Large test range: 0.1Hz, 0.05Hz and 0.02hz multi frequency selection, large test range.
 Small volume and light weight: it is very convenient for outdoor operation.

V. Instrument structure and function description

The instrument consists of two parts: controller and booster. The structure and function of
the two parts are as follows:
1. The layout of each part of the controller panel is shown in Figure 1, and the function
description of each part is as follows:

Figure 1 Schematic diagram of controller panel

“ ” －Grounding terminal: it is connected with the earth when in use.

"Switch" - power switch: built-in indicator light, on when on, off when "AC220V" - power
input socket, built-in fuse.
“Printer” - print test reports.

5
 "Capacitive touch screen" - display test data and output waveform, and can be operated
directly on the screen by hand.
"USB" - its function is used to communicate with the upper computer. "Stop" - for
emergency stop test.
2. Structure diagram of booster

Figure 2 Schematic diagram of booster structure

Operation instructions
1. Ultra low frequency output wiring method

Figure 3 wiring diagram

Wiring instructions: connect the control output special line, high voltage output special line and

6
grounding wire equipped with the product according to the method shown in Figure 3. The
power cord of the power socket is connected to the AC of 220V / 50Hz.
2. Operation procedure

(1) startup, shutdown and reset

After connecting all the lines according to the above method, the power switch can be turned
on. After the microcomputer is powered on or reset, the instrument will automatically enter
the interface as shown in Figure 4. When connecting wires, removing wires, or temporarily
not using the instrument, turn off the power supply. The power socket is equipped with a
safety tube. If there is no display on the start- up screen, check whether the fuse is broken
first, and the size of the fuse shall be replaced according to the data provided in Table 3.

Figure 4 Schematic diagram of touch screen

(2) Set parameters

7
 Figure 5 parameter setting interface

First, click the "setting" button on the screen of Figure 4 to display the setting parameter interface
shown in Figure 5. In Figure 5, the output frequency, test time, test voltage, overcurrent
protection value and overvoltage protection value on the high voltage side can be set according to
the needs of the test. The modification method is as follows:

★There are three options for frequency: 0.1, 0.05 and 0.02, and the unit is Hz.

★Timing modification range: 0-99 points. It specifies the duration of the test, in minutes.
★Set voltage: range from 0 to rated value, unit: kv. It sets the test voltage we want to raise.
When the instrument rises to this set voltage limit, it will no longer boost voltage, and maintain
constant amplitude sine wave output at this peak value.

★ Set voltage limit: the setting range of voltage protection value is from 0 to rated value, and
the unit is kv. It specifies the upper limit value of the voltage passing the test object. When the
voltage exceeds this setting, the instrument will automatically cut off the output.

★Setting current limit: the setting range of current protection value is from 0 to rated value, and
the unit is ma. It specifies the upper limit value of current passing through the test object. When
the current exceeds this setting, the instrument will automatically cut off the output.
(Note: the above voltage, current and measurement data displayed by the instrument are all peak
values.)
(3) automatic boosting

After pressing the "start" key in Figure 4, the instrument will carry out the boosting test under

8
the control of the computer as follows:
Self-inspection →boosting →constant amplitude output →shutdown The
specific process is as follows:

1) Self inspection process

The controller automatically enters the load detection. If no load is detected, the prompt message
"load not connected" in the status bar of Figure 6 indicates that the booster or capacitive test
sample is not connected.

Figure 6 the controller indicates that the load is not connected

2) Boosting process

After the self-test is successful, the instrument will automatically enter the boosting state, as
shown in Figure 7, and the prompt message in the status bar is "boosting". At the same time,
the timing began.

9
 Figure 7 the controller indicates that the voltage is boosting

3) Equal amplitude output

The controller will raise the voltage to the set value in several cycles, and the
instrument will output the equal amplitude, as shown in Figure 8. The prompt message
in the status bar is "equal amplitude output".

Figure 8 constant amplitude output of controller prompt

4) Downtime

When the timing reaches the set time, the instrument will stop automatically, as shown in
Figure 9, and the prompt message in the status bar is "stop the test".

Figure 9 controller prompts to stop the test

10
The instrument stops the high-voltage output and automatically discharges the test object, as
shown in Figure 10. The prompt message in the status bar is "discharging".

Figure 10 the controller indicates that it is discharging

After the shutdown, as shown in Figure 11, the prompt message in the status bar is "test passed"
and the data history is saved.
Note: during the test, if there is no abnormal voltage, no discharge or overcurrent protection,
the test can be considered as passed.

Figure 11 controller prompt test passed

11
This instrument provides two shutdown modes:

★ timed shutdown: when the timing reaches the set time, the instrument will stop automatically.
★ manual shutdown: click the "shutdown" key to stop the machine. The two
shutdown modes are normal shutdown.
★ there are also two kinds of abnormal shutdown: over-voltage protection shutdown and over-
current protection shutdown.
★ overvoltage protection shutdown

In the process of test, when the output high pressure exceeds the set limit, the instrument will
automatically cut off the output after starting and shutting down the command, and then execute
the data history saving. After shutting down, as shown in Figure 12, the prompt message in the
status bar is "over voltage protection" and execute the data history saving.

Fig. 12 controller prompts over voltage protection

★over current protection shutdown

In the process of test, when the output current exceeds the set limit, the instrument will
automatically cut off the output after starting and stopping the command, and then

12
execute the data history saving. After the shutdown, as shown in Figure 13, the prompt message in
the status bar: "overcurrent protection" and execute the data history saving.

Fig. 13 over current protection prompted by controller

(4) printing

Click the "print" key in Figure 3 to print the data on the display into a test report. Under the
status of viewing historical data, click the "print" key to print the historical data currently
displayed on the screen.
(5) view historical data

Figure 14 historical data interface

All the data instruments that have been shut down by timing, clicking the "stop" key, over-voltage
protection and over-current protection will automatically save them as historical data. It can save

13
up to 64 times of measured data, and the previous 64 times will be deleted automatically. Click the
"view" key in Figure 3 to open the interface in Figure 13 to view the historical data of the latest 64
tests.
(6) Clocksetting

Figure 15 date and time setting interface

Click the "clock" button in Figure 3 to open the setting interface in Figure 15, which is used to set
the date and time of the system.
3. Upper computer background management software

This instrument is equipped with VLF super low frequency and high voltage generator upper
computer background management software, as shown in Figure 15. The software supports
Windows XP \ 2000 \ 2007 and other operating systems. The software can be installed on the
computer and connected with the USB of the controller through the USB connection line. All the

14
operation functions of the controller can be operated on the software, such as setting parameters,
starting the boosting test, saving historical data, etc.

VI. Power cable withstand voltage test method

1. Disconnect all electrical equipment connected to the tested cable.

2. Use a megger to test the insulation parameters of each phase of the cable, and carry out the
ultra-low frequency withstand voltage test only after the test is qualified.
3. Set the test voltage value: Umax = 3uo, where uo is the rated phase voltage of the cable.
Example 1: cable parameter: the rated line voltage is 10kV, and the rated phase voltage uo =
6kV, so the test voltage setting value is:
Umax = 3uo = 18kV

See Table 4 for the setting value of 0.1Hz ultra-low frequency test voltage of various rubber and
plastic insulated power cables.
Table 4 0.1Hz ultra-low frequency test voltage and time of various rubber plastic insulated
power cables.

Handover test Preventive experiment

Rated
Test Test
voltage multi Test time multip Test time
voltage voltage
U0/US(kV) ple （mins） le （mins）
（kV） （kV）

1.8/3 3U0 5 60 3U0 5 15

3.6/6 3U0 11 60 3U0 11 15
6/6 3U0 18 60 3U0 18 15
6/10 3U0 18 60 3U0 18 15
8.7/10 3U0 26 60 3U0 26 15
12/20 3U0 36 60 3U0 36 15
21/35 3U0 63 60 3U0 63 15

26/35 3U0 78 60 3U0 78 15

Note: UN is the rated voltage of the cable, and uo is the phase voltage of the cable.

4. Test time: 60 minutes for handover test and 15 minutes for preventive test.

5. Setting current value of overcurrent protection:

15
Estimation method of capacitive current (or leakage current) of ultra-low frequency withstand
voltage test article:
Io=2πfCU=2×3.14×0.1CU(mA)….....................................(formula 1)

C is the electric capacity of the cable to the ground, unit: UF; u is the effective value of the test
voltage, unit: kV.
Example 2: a 10KV (UN = 10kV, uo = 8.7kv) cable is 4km long, with a single phase to ground
capacitance of 0.21uf/km and 0.1Hz super
If the low frequency test voltage is 26kv (peak value), the leakage current is
approximately:
Io=2πfCU=2×3.14×0.1CU=0.628×0.21×4×26/ 2=9.69（mA）
Setting current value of overcurrent protection: I=kIo
........................................... (formula 2)

16
VII.Transportation and preservation
(1) transportation

The product must be packed during transportation. Cartons can be packed in cartons or wooden
boxes, and foam proof layer should be placed in the packing box. The packed products shall be
able to be transported by road, railway and air. It shall not be placed in the open truck during
transportation. The warehouse shall be protected from rain, dust and mechanical damage.
(2) storage

When the instrument is not used at ordinary times, it should be stored in a room with ambient
humidity of - 20 ℃ ~ + 60 ℃, relative humidity of no more than 85%, ventilation and no corrosive
gas. Storage should not be close to the floor and walls.
(3) moisture proof

In humid areas or wet seasons, if the instrument is not used for a long time, it is required to turn
on and power on once a month (about two hours) to make the moisture emission and protect
the components.
(4) anti exposure

When the instrument is used outdoors, direct sunlight exposure shall be avoided or reduced as
much as possible. When the instrument is used outdoors, direct sunlight exposure shall be
avoided or reduced as much as possible.

VIII. Quality assurance

(1) the instrument is manufactured in strict accordance with national standards and enterprise
standards, and each instrument is subject to strict factory inspection.
(2) the instrument enjoys a one-year warranty period, the company will provide free
warranty within warranty time and offer life-long after-sales service.
(3) within the service life of the instrument, the company will provide the maintenance,
use training, software upgrade and other related services of the instrument for life.
(4) if you find any problems in use, please contact our company in time, and we will solve the
problems asap.

17
IX. Paper change method of printer
The operation of replacing the paper roll of the printer is very simple. It does not need to take
out the whole printer. Just press the open button to open the front cover. Open the front cover
as shown in Figure A and take out the remaining paper core. Then install the new paper roll as
shown in Figure B and close the front cover as shown in Figure C.
Note: when closing the front cover, make the printing paper stretch out from the paper outlet, put
it in the middle position, and let the rubber shaft fully press the printing paper, otherwise it can't
be printed. When the thermal printer is loading paper, it must be confirmed that the thermal
coating of the thermal paper is on it, and then put the thermal paper into the printer paper bin. If
the thermal coating is not on

the correct side, no writing will be printed. If the printing paper deviates, you can open the
front cover again and adjust the position of the printing paper.

A How to open the front cover

B Printer in roll

C Close the front cover of the printer

18
X. Packing List

No. Name Qty

1 Controller
1

2 Booster
1

3 HV Cable
2

4 LV Cable
1

5 Power Cable 1

6 Discharge Rod 1

7 Grounding Wire 1

8 Capacitor 1

9 Fuse 4

10 Print Paper 2

19