Phenix Technologies 600 SERIES User manual

6CP100/50-10
USER’S MANUAL
AC DIELECTRIC TEST SET
600 SERIES
Model Number
6CP100/50-10
VERSION 3.0
Phenix Technologies, Inc.
75 Speicher Drive
Accident, Maryland 21520
Copyright © Phenix Technologies, Inc.
Rev 4/29/2018
JSH

6CP100/50-10
TABLE OF CONTENTS
DESCRIPTION SECTION NUMBER
DANGER / GENERAL SAFETY PRECAUTIONS
TECHNICAL SPECIFICATIONS 1
UNCRATING PROCEDURE 2
CONTROLS AND INDICATORS 3
INITIAL SET-UP—MECHANICAL / ELECTRICAL 4
OPERATIONAL VERIFICATION / GENERAL TEST 5
CALIBRATION 6
TROUBLESHOOTING 7
MECHANICAL MAINTENANCE 8
CHECKING OIL PURITY / SPECIFICATIONS 9
TRANSPORTING/STORAGE OF EQUIPMENT 10
CIRCUIT DIAGRAM SYMBOLS 11
ELECTRICAL DIAGRAMS 12
PARTS ORDERING INFORMATION 13
RECOMMENDED SPARE PARTS 14
PARTS LIST 15
RETURNED MATERIAL 16
CUSTOMER COMMENTS / SUGGESTIONS 17
ATTACHMENTS
` PTC 13 Timer Manual

6CP100/50-10
DANGER / WARNINGS
WARNING !!
Grounding of this unit is necessary for the safe
operation of this equipment. Disconnect inputs before
ungrounding this equipment
DANGER

6CP100/50-10
GENERAL SAFETY PRECAUTIONS


HIGH VOLTAGE
This equipment is capable of providing POTENTIALLY LETHAL VOLTAGES!
Improper operation or test practices may result in injury or death to the operator or
surrounding personnel.
The operation of High Voltage test equipment should only be performed by personnel
familiar with HIGH VOLTAGE testing and safety procedures. The operator of this
equipment must be aware of all hazards associated with High Voltage testing. The
operator is responsible for himself and others in close proximity of the testing area.
Some General Safety Practices for working with High Voltage Test Equipment have
been listed below for your reference.
Become familiar with your instrument before performing an actual test
Know your work area, check that all circuits are de-energized and locked out.
Never work alone; always work with another qualified worker.
Mark off entire work area with barriers and warning tape.
Make all personnel aware of your testing activities.
Be aware of dangerous conditions that may arise from energizing a test
specimen.
Never modify test equipment, modifications to equipment could introduce an
unknown hazard or hinder a designed-in safety feature.
DO NOT operate damaged equipment. Remove power, and do not use the
equipment until safe operation can be verified by service-trained personnel.
Phenix Technologies, Inc. assumes no liability for unsafe or improper use of test
equipment.

6CP100/50-10
1-1
SECTION 1: TECHNICAL SPECIFICATIONS
Input
220 - 240 volts, single phase, 50/60 Hz, 30 amperes
Output Rating
0 - 50 kilovolts, 200 milliamperes
0 - 100 kilovolts, 100 milliamperes
Duty Cycle –Capacitive Loading
5 minutes ON /15 minutes OFF @ 10 kVA
15 minutes ON / 1 hour OFF @ 7.5 kVA
1 hour ON / 1 hour OFF @ 5 kVA
Type of Cooling
ONAN (Oil Natural / Air Natural Convection)
Operating Ambient Temperature
10 –40 degrees C
Output Termination
2” Polished Ball – 50 kV
3” x 12” High Voltage Spinning –100 kV
Metering - Digital
Output Voltmeter: 3 ½ Digit LCD, Accuracy ±(0.8% of reading + 0.2% of range)
Output Currentmeter: 3 ½ Digit LCD, Accuracy ±(0.8% of reading + 0.2% of range)
4 Ranges: 0-200µA, 2mA, 20mA, 200mA
Sizes and Weights
Control/Regulator Section: 21.25” (540mm) W x 16.75" (426mm) D x 13.75" (350mm) H;
63 lbs. (29 kg)
High Voltage Section: 19” (483mm) W x 19” (483mm) D x 29” (734mm) H;
280 lbs. (127 kg)
Additional Equipment
Cart: 22.5” (572mm) W x 29.25” (743mm) D x 50” (1270mm) H;
70 lbs. (32 kg)
Cables: 30 lbs. (14 kg)

6CP100/50-10
2-1
SECTION 2: UNCRATING PROCEDURE
1. Exercise care in removing shipping materials so as not to damage unit.
2. Perform visual inspection to determine if unit was damaged during shipment. If there are any
signs of physical damage (such as dents, scratches, oil leaks), contact the Service Department at Phenix
Technologies before proceeding.

6CP100/50-10
3-1
SECTION 3: CONTROLS AND INDICATORS
Control Panel
Figure 3-1




 
 







 



!




!















 


 





TECHNOLOGIES

PHENIX


















The following descriptions are keyed to Figure 3-1:
1. Main Power Indicator.
2. Main Power Circuit Breaker
3. F1, F2
Control Power Fuse.
4. Transformer Power Circuit Breaker
5. Measurement Divider Switch
Selects proper overload and voltmeter circuitry for the H.V. output terminal being used. Match switch
setting to output being used on HV transformer.
6. Overload Trip
Use for presetting desired Overcurrent trip setting. Range approximately 10-110% of rated current.

6CP100/50-10
3-2
CONTROLS AND INDICATORS
Control Panel (Cont’d)
1. Reset
Will light when Overcurrent trip setting is exceeded. Push to reset. Lamp must be extinguished for
H.V. ON.
2. Emergency Off
Push down to stop test immediately. Button must be pulled up to activate High Voltage Output.
3. High Voltage On Switch and Indicator Lamp
Turns on H.V. when Ready indicator is illuminated.
4. High Voltage Off Switch and Indicator Lamp
Turns H.V. off, indicator shows when all conditions are met to turn H.V. ON. (External Interlock closed,
Reset Lamp off, Emergency Off Button pulled up, Voltage Control at Zero).
5. Voltage Control
Adjusts Output Voltage and must be set at zero to turn High Voltage on.
6. Currentmeter Range Selector
7. Output Currentmeter
8. Output Voltmeter
9. SX1 External Interlock
Provides for user connection of external interlock or auxiliary safety control device such as Emergency
Off Switch, Gate Switch, Footswitch, Dead man Switch, etc.
10. Output to Transformer
High Voltage Transformer power connection.
11. Main Input
Main input cable connects here.
12. Ground Terminal
13. TX1
Signal/ Metering cable between H.V. Unit and controls connects here.
14. Timer
Press START/RESET to start the timer after test voltage has been reached. Press START/RESET
again to reset timer to the original setting. Press HV OFF BYPASS to allow high voltage to remain on
after the timer has expired. Test time can be set using the buttons on the face of the timer.

6CP100/50-10
3-3
CONTROLS AND INDICATORS
High Voltage Transformer
Figure 3-2
The following descriptions are keyed to Figure 3--2:
1. Power Connector
Connect the Power Cable from ‘Output to Transformer’connector on control box at this point.
2. High Voltage Unit Ground Point
A Ground cable from facility ground or earth ground must be connected here.
3. Guard Binding Post (GRD)
Currents associated with this connection bypass the current meter (meter bypass connection). See
Section 5 for more information on these connections.
4. Ground Binding Post with Jumper Clip (GND) - This binding post is connected to ground. See
Section 5 for more information on these connections.
NOTE: The Jumper Clip must always be connected from Ground to either Return or Guard.

6CP100/50-10
3-4
CONTROLS AND INDICATORS
High Voltage Transformer (cont’d)
5. Return Binding Post (RTN)
Low potential side of test specimen connects here. This connection routes current through the Current
Meter circuit (metered connection point).
6. TX1 Connector
Signal / Metering cable connects from here to TX1 on control box.
7. 50 kV TAP
For 0 –50 kV output at 0 –200 mA –the Measurement Divider switch on the control panel must be set
to 50 kV/200 mA position.
8. 100 kV Tap
For 0 –100 kV output at 0 –100 mA - the Measurement Divider switch on the control panel must be
set to 100 kV / 10 mA.

6CP100/50-10
4-1
SECTION 4: INITIAL SET-UP--MECHANICAL
1. Set up object under test.
2. The area to be used for the test must provide sufficient mechanical and electrical clearances. The
approximate weight of each section is available from the nameplates or the Specification Page.
3. If the unit is to be operated indoors, be sure the floor will be strong enough to support the unit.
If outdoor operation is to be used, the site for the base must be capable of supporting the unit
without any settling that would tilt the assembly.
4. Position the High Voltage Transformer Tank and Control Unit as necessary for operation.
5. Clean entire High Voltage Unit using nothing stronger than ordinary household cleaner to remove all traces
of any surface contamination. This cleaning should also include the High Voltage Electrodes.

6CP100/50-10
4-2
INITIAL SET-UP--ELECTRICAL
1. Grounding Connections:
- Tie ground post on control case to ground stud on high voltage cylinder base using copper braid or
jacketed cable with current capacity equal to or greater than the input current.
- Tie ground stud on the high voltage cylinder base to facility ground using copper braid or jacketed
cable with current capacity equal to or greater than the input current.
2. Select the Standard or Guard current metering configuration (see following pages for explanation).
3. If the external interlock function is to be used, remove the jumper on the male cable end of the SX1
connector and connect the external security circuit at these points.
WARNING:
Ground the output of the High Voltage Transformer until set-up is complete! Be sure the Main
Power Circuit Breaker is in the OFF position before proceeding. This equipment should only be
operated by personnel familiar with High Voltage testing and safety procedures.
WARNING !
DO NOT OPERATE THE TEST SET
WITHOUT REMOVING HIGH-VOLTAGE
TRANSFORMER FROM THE CART.
THE HIGH-VOLTAGE TRANSFORMER
MUST BE POSITIONED A SAFE DISTANCE
FROM PERSONNEL AND OTHER OBJECTS.

6CP100/50-10
4-3
INITIAL SET-UP--ELECTRICAL
NOTE: The external interlock circuit must consist of a closed loop of dead contacts; an open circuit
prevents the high voltage output from being energized. When the control power is on, the external
circuit will be energized with 120 volts AC.
4. Connect signal / metering cable between High Voltage Transformer TX1 connector and TX1 connector
on the controls.
5. Connect the power cable from the High Voltage Transformer to the ‘Output to Transformer’ connection
on the control box.
6. Connect the test object to the output termination of the high voltage transformer using supplied output
cable. Ensure that the ground connection is applicable for test level and type of test and that the
connection has sufficient safety clearances for the voltage rating. Two high voltage output connections
are possible:
50kV, 200mA: The 50kV tap is located on the side of the high voltage cylinder. Set the Measurement
Divider switch (See Section 4) to the 50 kV/200mA position when using this output.
This sets the metering and overload properly for the output being used.
100kV, 100mA: The 100kV tap is located on the top of the high voltage cylinder. Set the Measurement
Divider switch (See Section 4) to the 100 kV/100mA position when using this output.
A wire can be used to make this connection; however, for best results (less corona leakage current),
route a wire down the center of a one-inch diameter pipe (aluminum or copper) and solidly connect the
ends of the wire to the output tap and the test specimen. The pipe should also be solidly connected at
each end.
7. Connect the input main power cable to the Main Input connection at the control box and then to the
facility power source.

6CP100/50-10
4-4
INITIAL SET-UP--ELECTRICAL
CURRENT METER GUARD CIRCUIT
There are three terminals on the base of the high voltage transformer; white GRD (Guard), green GND
(Ground), and a red RTN (Return). There is a metal jumper that must always be connected between either the
GND and GRD terminals or the GND and RTN terminals.
Refer to Figure 4-1 on the next page:
Standard Mode
In this configuration the current meter measures all leakage current from the high voltage electrode.
Measured current includes specimen leakage and stray leakage.
Guarded Mode
In this configuration only the leakage current from the high voltage electrode through the test specimen
to the RTN terminal is measured by the current meter. Any stray leakage current to ground is guarded
out (bypasses the meter) and is not measured. Stray leakage current to ground can be from several
sources. The high voltage transformer has some capacitive leakage to ground. The high voltage
connection might have some leakage due to partial discharge (corona). The test specimen might have
some leakage current to ground and your application requires that this “stray” leakage not be
measured.
Electrical Setup
In either configuration, the high voltage transformer’s ground stud must always be connected to earth
ground. The GND terminal referred in the following two paragraphs is internally connected to the
ground stud.
For standard current measurement, connect the jumper between the GND and RTN terminals.
Connect the test specimen return (low voltage side) to the RTN terminal.
For guarded current measurement connect the jumper between the GND and GRD terminals.
Connect the test specimen return (low voltage side) to the RTN terminal. Do not connect the specimen
return to ground. The test specimen must be totally isolated from ground.

6CP100/50-10
4-5
INITIAL SET-UP--ELECTRICAL
CURRENTMETER GUARD CIRCUIT
Figure 4-1

6CP100/50-10
5-1
SECTION 5: OPERATIONAL VERIFICATION PROCEDURE
1. Make sure that Main Power Circuit Breaker on the Control Panel is in OFF position.
2. Make sure that all electrical connections have been properly made between the Controls and High
Voltage Unit, including grounds. Remove Ground from HV Transformer output if it is grounded. There
is to be no connection to the high voltage outputs at this time. There must be adequate clearance from
the High Voltage Unit to allow voltage to be raised safely.
3. Place currentmeter in RTN mode. (Connect jumper of RTN/GND/GRD binding posts between RTN
and GND.)
4. Connect Main Input Power Cable to Controls and to Power Source. Switch the Main Power Circuit
Breaker on the Control Panel to On position. Main Power indicator lamp should illuminate. Check that
the Transformer Power Breaker is on, Emergency Off button is pulled up, Voltage Control is at Zero,
Reset Lamp is Off, and EXT INTLK CKT is complete or has shorting jumper in place. HV Off lamp
should be illuminated.
5. Press HV On switch. Indicator lamp should illuminate. Press the HV Off switch. HV On indicator lamp
should extinguish and HV Off / Ready lamp should illuminate.
NOTE: The following conditions must be met before High Voltage will engage: External Interlock loop
must be closed, Emergency Off switch must be closed (mushroom button up), Overload Reset Lamp
must be off, Voltage Control at Zero Start, and Transformer Power Circuit Breaker on.
6. Set Measurement Divider Switch to 100 kV / 100 mA
7. Press the HV On switch.
8. Manually raise the Voltage Control dial on the Control Panel to approximately 50 (50%). Voltmeter
should indicate voltage change, and show approximately 45 to 55 kV.
9. Select 50 kV / 200 mA on Measurement Divider Selector Switch. At 50 on Voltage Control Dial,
voltmeter should read approximately 22 to 28 kV.
10. Return Voltage Control to Zero. Press HV Off switch.
11. Turn Main Power Circuit Breaker off and connect a short between the 50kV High Voltage Output and
Ground. Measurement Divider Switch is to be set at 50 kV / 200 mA.
12. Set Overcurrent Trip to low (1) setting.
13. Turn Main Power Circuit Breaker on. Press HV On switch and slowly raise voltage with the dial on the
Control Panel. Output Current Meter will indicate changed value, and at approximately 10% of output
current rating, the High Voltage will trip off and the Overcurrent Indicator Lamp will illuminate. With the
front panel Overload Selector Switch set at 50 kV/200 mA, the trip point should be at approximately 20
mA. Return Voltage Control to zero and turn off Main Power Circuit breaker.
WARNING:
This equipment should only be used by personnel familiar with High Voltage testing and safety
procedures.

6CP100/50-10
5-2
OPERATIONAL VERIFICATION PROCEDURE
14. Move short from 50 kV output to 100 kV output and ground. Repeat step 13. Unit should trip off at
approximately 10 mA.
NOTE: Do not attempt to check 110% level of current trip under shorted output conditions. Rated output
currents are only available through a capacitive load of sufficient value. Shorted current values should
never exceed 50% of rated currents for the High Voltage Tap being used. If desired to test at 110% of
current rating, the 50kV/200mA tap must be connected to a High Voltage Capacitor of approximately 6.5
nanofarads rated at 50 kVAC or higher (for 50 Hz).
15. Turn Off Main Power Circuit Breaker on Control Panel.
END OF OPERATIONAL VERIFICATION TEST!

6CP100/50-10
5-3
GENERAL TEST PROCEDURE
1. Make sure that Main Power Circuit Breaker on the Control Panel is in the Off position.
2. Make sure that all electrical connections have been properly and securely made, and that the test
specimen is properly connected to the High Voltage Transformer (refer to Initial Set-up Procedures).
Make sure the Guard / Ground / Return Jumper Clip is set properly for test being performed. Make
sure all personnel are clear of danger and test area is clearly marked.
3. Connect Input Cable to Controls and to Power Source. Switch the Main Power Circuit Breaker on the
Control Panel to the On position.
4. Set Measurement Divider switch to the position that matches the High Voltage output being used.
5. Set Overload Trip dial to desired trip-out level.
NOTE: In setting this device, it is important to take into account the capacitive current that the sample
under test will require. Set the dial to a high enough value to preclude false failure indications. If this
value is not known, it is recommended that the dial be left in a higher setting.)
6. Press the HV On switch.
NOTE: The following conditions must be met before High Voltage will engage: Security Circuit Loop
must be closed, Emergency Off Switch must be closed (mushroom button up), Overload Reset Lamp
must be off, Voltage Control at Zero Start, Transformer Power Circuit Breaker on, and Ready lamp
illuminated.)
7. Raise the manual Voltage Control knob on the Control Panel until desired test voltage level is
reached. Keep voltage at desired level for required duration. Record data if desired.
8. After completion of the test, manually return the Output Voltage to zero or its lowest level via the
Voltage Control knob.
9. Press HV Off momentary switch.
10. If during the test a failure should occur or if the Overcurrent Trip setting is exceeded, the High Voltage
will automatically shut off. In order to regain High Voltage, the Reset pushbutton must be pressed and
Voltage Control knob returned to Zero.

6CP100/50-10
6-1
SECTION 6: CALIBRATION
All calibrations have been done at the factory. Periodic calibration of the output voltmeter and output
currentmeter should be done annually.
NOTE: Refer to Electrical Diagram Section for schematics pertaining to the model number of your test set.
Locating the Calibration Adjustments
The calibration points are shown in the following diagram.
1. Output Voltmeter
Connect a precision high voltage voltmeter across the output to ground on 50 kV output, with
Measurement Divider switch set to 50 kV. Raise the output to approximately 80% of the output rating.
Adjust the reading on the panel meter (M2) by means of potentiometer R17 to a corresponding reading.
Repeat procedure with precision high voltage voltmeter connected between the 100 kV output and
ground with the Measurement Divider switch set to 100 kV. Adjust R19 to match precision voltmeter at
80% of output rating.
2. Output Currentmeter
It is necessary to connect adequately rated High Voltage loads (isolated from ground) to the high voltage
unit that will allow each full range current to be drawn at approximately 15% or higher output voltage.
This allows sufficient resolution to adjust current levels. All ranges can be calibrated from 50 kV output.
Place Binding Post Configuration in GUARD MODE. (Jumper clip is installed between “GRD” and “GND”
posts.)
Connect a precision ammeter between the low potential side of the appropriate high voltage load and the
“RTN” post. Select the 200 uA meter range. Raise the output to approximately 80% of the range rating.
Adjust the reading on the panel meter (M1) by means of potentiometer R78 to a corresponding reading.
Repeat for 2 mA, 20 mA and 200 mA ranges adjusting R80, R82 and R84, respectively. (High Voltage
load will need to change when changing range).
NOTE: An optional method is to use current injection between RTN and GND (Guard Mode).
Do not turn High Voltage on for this method!
R19
100 kV
VM
R17
50 kV
VM
R113
VOLT
OFFSET
R84
200mA
CM
R82
20mA
CM
R80
2mA
CM
R78
200µA
CM
R77
CURRENT
OFFSET
R87
RANGE
OVLD
R72
110%
OVLD
R69
10%
OVLD
CAUTION:
Calibration should only be done by persons familiar with High Voltage testing and safety
procedures.

6CP100/50-10
6-2
CALIBRATION
3. Overcurrent
This calibration should not need adjustment (factory adjusted). If the Overcurrent Circuit is out of
calibration, perform the following steps. To recalibrate the Overcurrent Circuit with the High Voltage Unit it
will be necessary to connect an 8 nanofarad capacitor rated at 50 kVAC or higher to the 50 kV / 150 mA
output of the High Voltage Unit. If the capacitor is isolated from ground at the low potential end, the low
potential end can be connected to the RTN post. The Guard Post Jumper may be connected to GRD
(Guard Mode). If the low potential end of the capacitor is grounded, the Ground Post Jumper must be
connected to RTN post.
a. Set front panel Measurement Divider switch to 50 kV/150mA. When current trip dial is set to
minimum (1) current trip level should be approx. 15mA. When dial is set to maximum (11) trip
level should be approx. 165mA.
b. Set the Overload Trip potentiometer (R15) on the front panel to "1" and the Current Range
switch to 200 mA.
c. Turn on HV On and adjust the output current slowly until 10% of rated current
is displayed on the current meter (15 mA).
d. Adjust potentiometer R69 until the Reset lamp illuminates and
high voltage is shut off.
e. Set the Overcurrent Trip potentiometer (R15) on the front panel to "11."
f. Turn on HV On and adjust the output current slowly until 110% of rated current is
displayed on meter (165 mA).
g. Adjust potentiometer R72 until the Reset Lamp illuminates and
high voltage is shut off.
h. Repeat steps "b" through "g" if necessary until both settings are calibrated.
4. Range Overcurrent:
R87 sets an overcurrent for the ranges and should be set to trip at approximately 112% of full range
current on medium range setting with current trip potentiometer set at “11.”
5. Voltage offset adjustment (R113):
The voltage offset should be done with the voltage output lead connected to board ground. This typically
can be done by connecting the output to the guard terminal. Once connected, the offset should be
adjusted until the output meter reads nearest to zero. This offset adjustment should be done before
adjustments to the voltage ranges are made. Test point T10 may also be used to make this adjustment.
6. Current offset adjustment (R77):
The current offset should be done with the current input connected to board ground. This typically can be
done by placing a jumper from the guard to the return terminal. Once jumped, the offset should be
adjusted until the output meter reads nearest to zero. This offset adjustment should be done before
adjustments to the current ranges are made. Test point T37 may also be used to make this adjustment.