VLF HIPOT TESTER

USERS MANUAL

Content
I. Product Advantage--------------------------------------------------.1
II .Technical parameters-----------------------------------------------2
III. Attentions-----------------------------------------------------------4
IV. Instrument structure ---------------------------------------------- 4
V.Wiring methods------------------------------------------------------9
VI. How to test cables-------------------------------------------------12
VII. How to test generator--------------------------------------------14
VIII. Operation procedure--------------------------------------------17
IX. Operating Instructions of Discharge Rod----------------------26
X. Printer Instruction--------------------------------------------------27
XI. Accompanied accessories----------------------------------------29

I. Product Advantage
1. VLF means Very Low Frequency and 0.1Hz to 0.02Hz
is considered to be very low frequency.
2. VLF HV Generator is suitable for testing cables,
transformers, switchgear,rotating machinery,and other
electrical apparatus.
3. The product combines modern advanced digital variable
frequency technology and micro computer control together,
therefore, it can realize the full automatic voltage boost,
stepdown, measurement and protection as well as the manual
intervention in the process of automatic voltage boost. The
full electronic design ensures the small size and light weight.
The big LCD screen ensures the clear and visual display, and
can display the output wave form. The printer outputs test
reports. In addition, the product has features as follows:
Data of current, voltage, wave form can be directly
sampled at high voltage side, so the data is real and
accurate.
Overvoltage protection: If the output exceeds the set limit
of voltage, the instrument will shut-down to protect itself,
the actuation time is less than 20ms.
Overcurrent protection: it is high-low voltage dual
protection in the design, the accurate shut-down
protection can be made according to the set value at high
voltage side; If the current on low voltage side exceeds

the rated current, the instrument will take shut-down

protection, the actuation time are both less than 20ms.
A high voltage output protective resistor is provided in
the voltage boost body in the design and this eliminates
the need of additional protective resistor connected
outside.
True sine wave output.
Storage of test results for later retrieval and print.
AC testing does not degrade good cable insulation.
Harmful space charges are not injected into the cable
insulation.
No traveling waves are generated during testing.
Rugged and reliable design less prone to failure from
transients.

II. Technical parameters

1. Input: 220V 10% Volts AC, 50/60 Hz, single phase.
2. Output-VoltageSee below table 1
3. Output frequency: 0.1Hz, 0.05Hz, 0.02Hz.
4. Stability of frequency: Fluctuation < 0.5%
5. Measurement accuracy: 3%.

6. Positive and negative voltage peak errors: 3%.

7. Voltage waveform distortion: 5%
8. Construction: In two units: Controller and Booster..
9. Ambient conditions of use: temperature Indoor and
outdoor : -10C to + 50C.
10. Humidity:85%
Table 1
Type

VLF30/1.1
VLF40/1.1
VLF50/1.1
VLF60/0.5

Output
Voltage/
Current
(Peak)

Load Capacity

Control Unit

Frequency/
Capacitance

Booster
Fuse
Tube

Dim.
(cm)

Wt
(kg)

Dim.
(cm)

Wt
(kg)

0.1Hz 1.1uF
0.05Hz 2.2uF
0.02Hz 5.5uF

283722

331834

25

8A

40KV/29mA

0.1Hz 1.1uF
0.05Hz 2.2uF
0.02Hz 5.5uF

283722

352036

45

50KV/59mA

0.1Hz 1.1uF
0.05Hz 2.2uF
0.02Hz 5.5uF

283722

372439

45

10A

60KV/59mA

0.1Hz 0.5uF
0.05Hz 1.0uF
0.02Hz 2.5uF

283722

331834
331834

25+45

20A

25+45

20A

25+45

20A

25+48

20A

30KV/29mA

0.1 Hz, 0.5F

VLF70/0.5

70KV/59mA

VLF80/0.5

80KV/59mA

VLF90/0.5

90KV/59mA

0.05Hz, 1.0F
0.02Hz, 2.5F

283722

0.1 Hz, 0.5F

0.05Hz, 1.0F
0.02Hz, 2.5F

283722

331834
352036
331834
372439

0.1 Hz, 0.5F

0.05Hz, 1.0F
0.02Hz, 2.5F

283722

331834
392639

* Special technical parameters can be customized.

III. Attentions
1. Power supply requirement: AC 220V 50/60Hz or AC
110V 50/60Hz (as per buyers requirement before booking),
stability of frequency: fluctuation less than 0.5%
2. When using it, it is prohibited to boost voltage without
load, or to connect with resistive load.
3. When using it, the capacitance of the DUT should not
exceed the rated capacity of the instrument. The overlow
capacitance of the DUT will affect the output wave form. If
the capacitance is less than 0.04F, the instrument cannot
output normally, at this time, please paralleling connection
with a 0.04F compensating capacitor supplied by us (Free),
then the equipment can output normally.
4. Before testing, please pour a litte dielectric oil
(transformer oil) into the tube (see below picture) , making
the tube almost overfill oil when insert the white input
connector. May demage the equipment if it is dry in tube.

Inpour transformer oil

White Connector

IV. Instrument structure

1. Structure: the instrument includes 2 units: Controller +
Booster
(1) 1 controller + 1 booster (as shown in figure 1): the
instrument has only 1 controller and 1 booster when the rated
voltage is less than or equal to 50kV, the wiring method of 1
booster is called "Single connection" or "single" (as shown in
figure 6-1 & figure 6-2).

Figure 1

(2) 1 controller + 2 booster (as shown in figure 2): the

instrument has 1 controller and 2 booster when the rated
voltage exceeds 50KV, the wiring method of 2 booster
together is called "Connection in series" or "series" (as
shown in figure 6-2).

Figure 2

Each booster of 2 boosters can be respectively used to test

DUT according to the requirements in the methods of series,
for example:
1x 80KV instrument includes 1 x 30KV and 1 x 50KV
booster
it is called "Series" when both of 2 booster is jointly used to
test rated voltage 80KV (30KV +50KV); it is also called
"Single" when it is separately used to test 30KV or 50KV
voltage.
3. Controller panel schematic

Panel of Single Connection

Panel of Connection in Series

Figure 3

Schematic of parts and function description in figure 3:

(1) Ground: Grounding terminal, which is connected with
ground when being used.
(2) Output: The output multi-core socket, which is
connected with the input multi-core socket when being used.
(3) Contrast: The contrast adjusting knob, which is used
for the adjustment of contrast of the LCD.
It will automatically adjust contrast if there is no adjusting
knob on the panel.
(4) Function key: The function is prompted at
corresponding location at prompt column on the display.
(5) AC 220V: The power input socket with inbuilt fuse
tube.
(6) Power: power switch with inbuilt indicator light, which
illuminates upon open and extinguishes upon close.
(7) Printer: print the test report
(8) LCD: It displays test data and output wave form.

4. Schematic of booster structure

Figure 4

5. Schematic of LCD display

Figure 5

V. Wiring method
Wiring Method of Single booster:
The method of wiring shall be according to figure 6-1 &
figure 6-2 if the rated Voltage is less than or equal to 50kV.
When only 1 booster of the instrument will be used in the
method of series, it especially needs to click"Single
connection" or "Single" selection at Column of Parameter
Setting after the equipment is power on (as shown in figure
below).

Figure 6-1 (30KV Test Wiring drawing)

Figure 6-2 (50KV Test Wiring drawing)

Wiring Method of connection in series

The user should adopt the method of connection in series
when the rated Voltage exceeds 50kV. After completing
wiring according to figure 6-3,
click"connection in series" or "Series" selection (as shown in
figure 9) at Prompt Column of Parameter Setting when the
power of equipment is put on.

Figure6-3(60KV connection in series)

Figure 6-3 (70KV80KV Wiring drawing)

VI. How to test Cables

A. Comparison Table of Power Cable's Capacitance
mm 2
F/Km
16

25

35

50

70

95

120

150

185

240

270

10

0.15

0.17

0.18

0.19

0.21

0.24

0.26

0.28

0.32

0.38

35

0.11

0.12

0.13

0.14

0.15

0.16

0.17

0.19

Class(KV)

B. Cable testing mothods:

1. Removing the electrical equipments connected with test
cable.
2. Measuring insulation resistance of each cable phase with a
Megohm meter,then VLF withstand test can be taken if test
cable is considered to be in good condition.
3. Test peak voltage formula: max3o,
o: A fixed value of cable phase. For example: A rated
voltage 10kV cable, single-phase rated voltage: o
10 3 kV5.774kV,
so the test voltage peak value: max3o17.32kV.
4. Test time: according to test requirements. For instance:
A new cable test should be tested 60 minutes.
5. Each phase test can be measured. Cable test can be

synchronously taken after paralleling cable cores of 3phases if Cable capacitance doesn't exceed the rated
capacitance of VLF Tester.
6. Cable test connection according to the method shown in
Figure 6-3. supplying the power, setting the test frequency,
time and voltage and high side over-current protection value,
over-voltage protection value, and then start to boosting test.
During boosting,high-voltage loop should be closely
monitored, meanwhile, surveying whether cable has
abnormal noise or not. The equipment will begin to record
test time and test voltage reading value when it goes to the
test voltage.
7. When test time is up, the instrument will automatically be
shutdown. It is considered to be passed the test if there is no
damaging discharging.
8. Please stop the equipment immediately if finding the
following things during boosting: output waveform distortion
abnormally, abnormal increasing strong current, voltage
instability, cable peculiar smell/smoke/abnormal
noise/flashover.
If these phenomena are caused by poor cable insulation, it is
considered that the withstand test failed; should be clean and
dry handling test materials cable, then testing if determining
test cable caused by air humidity or surface dirt and others.

Figure 6-4 (Schematic of Cable test wiring method)

VII. How to test generator

A. Comparison Table of Generator Capacity
Generator
of Thermal Power
Generator
Capacity
MW
Monophase
Ground
Capacitanc
F

200

0.20.25

Generator
of Hydropower

300

600

85

125150

300

400

0.180.26

0.310.34

0.69

1.8-1.9

1.72.5

2.02.5

B. Testing Generator methods:

1.Generator connection method as shown in Figure 6-5.
2.In accordance with the requirements of the regulations, the
test voltage peak can be determined to follow the formula:
max 2 Uo,
Umax: 0.1Hz peak voltage (kV);
: 0.1Hz and 50Hz voltage equivalent factor, usually
taking 1.2;
K: usually take 1.3 to 1.5, generally take 1.5;
Uo: generator stator windings rated voltage (kV), for
example:
A rated voltage 13.8 kV generators, VLF test voltage
peak value is:
max 2 1.21.513.835.1(kV)

3.It's considered to pass withstand test if there is no

following things during withstand test: no abnormal noise,
peculiar smell, smoke, data show instability. In order to
better understanding the situation insulation, should be as
comprehensive as possible monitor the surface insulation
state, especially air-cooled units. Experiences tell you that
the appearance of surveillance can discover the generator
insulation abnormal phenomena such as surface corona,
discharge and so on.

Figure 6-5 (Schematic of Generator

connection method)

VIII. Operation procedure

(1) Open, close and reset
After completing the wiring of all the circuits in the method
mentioned above, the power switch can be put on. The
instrument will automatically enter into the limit setting
interface as shown in figure 7 when the microcomputer is
electrified and reset.
Note: The power shall be shut-down under wiringremoval
of lines or temporary non-use of the instrument. The power
socket is provided with fuse tube, in case there is no display
on the screen upon start-up, the first check shall be made on
the fuse tube. The rating of the replaced tube shall be
according to the data in Table 1.
(2) Limit parameter setting

Figure 7 (Limit setting interface)

On limit setting interface as shown in figure 7, the user can

set output frequency, test time and voltage, overcurrent
protection value on high-voltage side and overvoltage
protection value according to test requirement. The
modification methods are as follows:
(A) Click Selection key, and the special selective box can
be shifted among the parameters in cycle. The selected
parameters
can
be
modified
through
data
modification(change) key.
(B) Click Change key and the parameter selected by the
special box can be modified in cycle according to
incremental method.
There are three options for the frequency: 0.1, 0.05 and
0.02. It specified the output frequency of the instrument.
The unit is Hz.
Timing modification scope: 0-99 mins. It specified the
time of test. The unit is minute.
Range of test voltage is from zero to rating, unit is kV. It
specified the test voltage to be boosted. When the voltage
of the instrument reaches to this set value, it will stop
boosting, maintain at this peak value and output uniform
amplitude sine wave.
The setting scope of current protection value is from 0 to
the rating, the unit is mA. It specified the upper limit of
the current of the sample. If the current exceeds this set

value, the instrument will automatically cut off the output

and shut down.
The voltage protection value is from 0 to the rating, the
unit is kV. It specified the upper limit of the voltage of
the sample. In case the voltage exceeds the set value, the
instrument will automatically cut off the output and shut
down.
"Single" and "Series" connection. Selecting "Single"
means that one of two boosters will be respectively used
(Setting method as shown in figure 8); Selecting "Series"
means that both of 2 boosters will be jointly used
according to requirements (Setting method as shown in
figure 9)

Figure 8

Figure 9

(C) Click Return key, the instrument will enter into voltage
boost standby interface as shown in figure 10.
(3) Standby interface

Figure 10 (Standby Interface)

The Standby Interface has three functions as follows:

(A) Click Boost key, the instrument will enter into
automatic boost procedure.

(B) Click Setting key, the instrument will return to set limit
sub-interface as shown in
figure 7 to re-modify parameter.
(C) Click Check key to check the test data in the last nine
times.
(4) Automatic boost
Click Boost key as shown in Figure 10, the instrument will
enter into boost test under microcomputer control according
to the procedures as follows:
Self checkboostuniform amplitude outputshutdown
(A) Self check

Figure 11

On self-check, the instrument outputs a detecting voltage to

check the system. If the condition is normal, the instrument
will boost. If the condition is abnormal, the instrument will

shut-down, and the prompt message load unconnected will

appear as shown in figure 11, in case the booster or the
capacitor sample (DUT) is not connected or there is a failure
with the instrument.
(B) Boost

Figure 12

Figure 13

If the self-check has passed successfully, the instrument will

automatically enter into boost status, as shown in Figure 12.

It will take several cycles to increase the voltage to the set

value for the instrument. During boost process, click Pause
key as shown in Figure 12 can pause the boost process, and
the instrument will have uniform amplitude output. At the
same time, the key will be automatically turned into boost
key, which can be re-clicked to continue the boost process
until the set voltage of the instrument is reached. The two
functions are alternative. Click Timing key in boost
process, the instrument will begin timing process, or you can
wait until the voltage is increased to the set value, then the
instrument will have automatic timing. At the same time the
timing key will be turned into Stop key as shown in
Figure 13.
(C) Voltage fine adjustment
In case the output voltage cannot satisfy the requirement,
click Up(slight increase) or Down (slight decrease) keys
to adjust the voltage. After each click, an observation of at
least one cycle shall be made, then make the adjustment until
achieving satisfied condition.
(5) Shut-down
Two shut-down modes are available for this instrument:
Timing shut-down: the instrument will shut down at
specified set time.
Manual shut-down: click Stop key can stop the
instrument.
These two shut-down methods are normal ones. After shut

down, the prompt interface Test Passed will appear as

shown in Figure 14. In general, it will be considered that
the instrument has passed the test if there is no electrical
discharge overvoltage or overcurrent protection on the
DUT (sample).

Figure 14

Additionally there are two abnormal shut-down:

overvoltage and overcurrent protective shut-down
functions. In case of shut-down, the prompt interface will
appear as shown in Figure 15.
After start-up shut-down command, the instrument will
automatically cut off the output, then execute the historical
data storage.

Figure 15

(6) Print
Click Print key according to tips as shown in Figure 14,
the user can print the data shown on the display as test report.
On historical data checking status, click Print key, the user
can print the historical data as shown on the screen.
(7) Historical data check
Data displayed on condition of timing shut-down, click key
Stop, overvoltage and overcurrent protective shut-down
will be stored by the instrument as historical data. Data of
last nine times will be stored, and previous data will be
automatically eleminated. Click the Check key as shown in
Figure 10, the user can check the historical data of tests in the
last nine times.

IX. Operating Instructions of Discharge Rod

It is necessary to discharge with discharging rod after
finishing withsand testing, and then the wires can be
removed.
Usage Method of Discharg Rod:
1. Pull out the extension pole completely.
2. Insert the Banana Jack into the hole of the Rod. Connect
Earth cable clip to a good Earth Terminal. Then Discharge
the electrified body.
3. Re-connect the Earth cable with the top of Discharge Rod,
then discharge the electrified body completely.
4. For discharging the DUT/cable under test, bring the tip of
the rod in close proximity. A spark should take place and it
should die out.
5. Caution: in case the spark does not die out, never touch the
tip directly to DUT/cable under test.

X. Printer Instruction
1.Features

Line thermal print method.

Print paper: thermal paper, width: 57.5 0.5mm,
outside diameter 40mminner diameter12mm
Power supply: DC5V5%, average current 2A, peak
value current 5A.
Indicator : SEL (on/off line selection); LF: (paper
feeding); red light is on/off line indicator, green light is
power indicator.

Open Button
SEL (Red Indicator)
LF (Green Indicator)

Figure 16

Panel of Printer

2. Loading paper :
Operation of loading paper for printer is very easy. It is not
necessary to take off the printer from the panel. Open the
front cover simply ,take out the paper just as Fig 17-1 shows
and then load the paper as Fig 17-2 shows, close the front
cover as Fig 17-3 shows.

Figure 17-1 Open front cover

Figure 17-2 Put in paper roll

Figure 17-3 Close the cover

Notice : Let the paper spread out of the paper exit or else
it can not print.
Before loading the paper, must make sure the thermal coat
of the paper is on the top, then put the paper into the paper
depot. If the thermal coat is not on the top, the printer can
not print out. If the paper has departed from the correct way,
please open front cover again, then adjusting the position of
paper.

XI. Packing List

Sr.no

Description

Quantity

Control unit

unit

Booster (50KV or below 50KV set)

unit

Discharging rod

unit

Capacitor, 0.05F

unit

Test/Connection Cables

set

Earth cable

unit

Fuse

unit

Maunal

unit

Print paper

unit

Calibration report

unit

10