HVFS - Variable Frequency Resonant Test System

User’s Manual
Variable Frequency Resonant Test System(On-site test system)
Variable Frequency Resonant Test System
User’s Manual
Yangzhou Xinyuan Electric Co., Ltd.

Address: Wujian industrial park, Yangzhou City, Jiangsu Province, China
Website: www.powerhv.com Email: sales@powerhv.com
Tel: 86 021 61812129 – 601 Fax: 86 021 61812129 – 608
User’s Manual
CONTENT
FORWARD ...............................................................................................................1
1. SAFETY NOTICES .....................................................................................2
2. TECHNICAL PARAMETERS .....................................................................2

2.1 USE CONDITIONS ............................................................................................... 2
2.2 TECHNICAL SPECIFICATIONS ............................................................................... 2
2.2.1. Variable frequency power supply HVPF-200 ..................................................................... 2
2.2.2. Exciter transformer ZB－200/8.8/13.3/26.5 ........................................................................ 2
2.2.3. Capacitive voltage divider TAWF－2000/250*2 ................................................................. 3
2.2.4. Blocking impedance LS-500-10000/7.5 ............................................................................. 3
2.2.5. HV reactor XZF－1725/230 ................................................................................................ 4
3. VARIABLE FREQUENCY POWER SUPPLY.............................................4

3.1. FEATURES......................................................................................................... 5
3.2. DEFINITION OF MODEL AND HOW TO SELECT THE MODEL ........................................ 5
3.3. CONNECTING TERMINALS .................................................................................... 6
3.4. PROTECTIONS ................................................................................................... 7
3.5. SAFETY NOTICES ............................................................................................... 8
3.6. THEORY OF WORKING......................................................................................... 8
3.7. COMPONENTS ................................................................................................. 10
3.7.1 Control box........................................................................................................................ 10
3.7.1.1 Buttons .................................................................................................................................... 11
3.7.1.2 Display screen ......................................................................................................................... 12
3.7.1.3 Menu ....................................................................................................................................... 13
3.7.1.4 Buzzing.................................................................................................................................... 13
3.7.1.5 Emergency stop ...................................................................................................................... 14
3.7.2 Variable frequency cabinet ............................................................................................... 14
3.12.1 Power source .......................................................................................................................... 16
3.12.2 Control unit in variable frequency cabinet ............................................................................... 16
3.12.3 Transition amplifier unit ........................................................................................................... 17
3.7.3 Connection via optical fibers ............................................................................................. 17
3.7.4 HV measuring terminal ..................................................................................................... 18
3.8. OPERATION NOTICE ......................................................................................... 18
3.8.1 Preparation before operation ............................................................................................ 18
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3.8.2 Procedure of operation ..................................................................................................... 19
3.9. PD TEST ......................................................................................................... 20
3.10. NOTICES ......................................................................................................... 21
3.11. MAINTENANCE ................................................................................................. 22
3.12. SOLUTION FOR FAULTS ..................................................................................... 23
3.12.1 Usual faults ....................................................................................................................... 23
3.12.2 Other faults ....................................................................................................................... 24
3.12.2.1 Voltage does not rise .............................................................................................................. 24
3.12.2.2 How to find out damaged amplifier board (take bridge arm 1,2 as example) ......................... 25
3.12.2.3 How to find out fault bridge arm with multi-meter.................................................................... 25
3.12.2.4 How to find out damaged triode .............................................................................................. 25
3.13. LIFTING IN TRANSPORTATION ............................................................................ 26
3.14. COMMISSIONING INTERFACE ............................................................................. 26
3.15. STATUS ON DELIVERY ....................................................................................... 27
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FORWARD
The key components of variable frequency resonant test system are variable frequency power
supply and air-core resonant reactors. The system described in this manual takes use of hi-fi linear
power amplifier type variable frequency power supply, output in purely sine wave. By adjusting
testing frequency, inductive current and capacitive current of the testing circuit is made balanced,
so as to reduce the current required in the test.
The resonant reactor is air-core type. It is compact in dimension and light in weight. It is especially
designed for on-site test. Insulating cylinder type reactors could be used in parallel, or stacked to
use in series.
The whole test system is comprised of variable frequency power supply, exciter transformer, HV
reactor, divider, etc.
Fig 1 Electrical drawing of variable frequency resonant test system
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1. Safety Notices
1) People who operates on the test system must be professional. Special attention should be paid
on safety during tests.
2) In the testing area, obvious and clear HV warning marks must be there for everybody in the
area to see. During test, nobody is allowed to enter the HV area.
3) Before apply voltage, carefully check in all details if there wiring and connections are correct.
Pay special attention to the earthing wire and connection wires in HV part.
4) If abnormal phenomenon happens during test, cut off the power before all other actions.
2. Technical Parameters
2.1 Use conditions

Altitude: ≤1000m
Ambient temperature: -5℃～45℃
Relative humidity: ≤95%(at 25℃)
Sunshine: 0.1%W/cm2
Max daily temperature difference: <25℃
No electricity conductive dust
No risk of fire or explosion
No gas that corrodes metal and insulations
With a reliable grounding point
Use location: outdoors, and stored indoors
Stored in: -20℃～50℃
2.2 Technical specifications
2.2.1. Variable frequency power supply HVPF-200

Rated input voltage: three phase, AC 380V±15%, 50Hz;
Output voltage: 0～350V, single phase
Rated output power: 200kW
Frequency adjustable range: 15～300Hz
Frequency adjustable accuracy: 0.1Hz
Running time at full load: 1h ON, 1h Off, 3 cycles per day
Output waveform: standard sine wave
Output waveform distortion: ≤3%
Instability of output voltage: ≤1%
Noise level: < 85dB ( while forced air cooling)
－200/8.8/13.3/26.5
2.2.2. Exciter transformer ZB－
Low voltage winding: 0.35kV
High voltage winding: 8.8kV / 13.3kV / 26.5kV
Capacity of iron core: 200kVA
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Phase: single phase
Operating frequency: 15~300Hz
Impedance voltage: 7.5%
Voltage ratio error: ±0.3%
Cooling method: ONAN
Temperature rise: Temperature rise of winding is less than 65K after continuous operation at
rated capacity for 60min, Temperature rise of oil surface is less than 55K
Noise level: ≤65dB(A)
Insulation level:
HV winding: 1.1 times of rated voltage withstanding for 1min.;
LV winding: applied AC testing voltage 5kV for 1min.
PD level: ≤10pC at rated voltage
Operation time: 1h ON, 1h Off, 3 cycles per day
At HV side the exciter transformer is equipped with capacitive bushing and measuring branch
circuit to measure voltage and PD
Yokes on sides of the core is elastically fixed, so that it gets enough mechanical strength, accurate
location and low noise during transportation and operation.
LV winding is wound by multiple wires in parallel, to avoid additional loss caused by lateral
magnetic leakage.
－2000/250*2
2.2.3. Capacitive voltage divider TAWF－
Rated voltage: 250kV *2
Capacitance: C1=2000pF+5% (total 2 stages, each 4000pF)
Working frequency: 15～300Hz
Insulation level:1.1 times of rated voltage/1min
System measurement error: ≤±1%(50Hz)
Dielectric loss:≤0.5%
Ratio of LV arm: 2000:1
Base: stable enough, could keep balanced on uneven floor, easy to assemble and
disassemble, with wheels for easy movement
The voltage divider is in two stages. Single stage is available of separate use, with additional
shielding rings. The divider capacitor also functions as coupling capacitor in PD measurement.
The capacitor capacitance can be the basic load of the system, so that the system is able to
operate without load.
2.2.4. Blocking impedance LS-500-1000/7.5

Rated voltage:500kV
Quantity: 1
Rated current: 7.5A
Rated inductance: Approx. 1000mH
The blocking impedance functions as protection device. Moreover, it forms HV filter with capacitive
voltage divider to suppress nose from HV side.
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－1725/230
2.2.5. HV reactor XZF－
Rated voltage:230kV
Rated current:7.5A
Rated capacity:1725kVar
Inductance: 147H (at 33.2Hz)±2％, nonlinearity of inductance ≤1％
Type: Insulating case
Insulation level: Reactor body: 1.1 times of rated voltage/1min
Base: 40kV/5min
Operation frequency range:15~300Hz
System quality factor: Qsystem>45
Tolerable temperature rise at rated capacity: for the coil ≤65K, for oil ≤55K
Running time:1h ON, 1h Off, 3 cycles per day
The HV reactors are without core, with windings made of quality copper wires, ONAN. The reactors
could be used in single unit, or several units in series/parallel. The outer shell is made of epoxy
resin tube. The tube gets enough electrical and mechanical strength. Cooling and margin for oil
expansion are also considered. The top and bottom lids of reactor are made of non-magnetic
aluminum alloy sheets. The reactor is equipped with lighting parts . The outer tube is painted in
required color (usually orange red).
Shielding rings are made of aluminum alloy. They prevent corona at rated voltage. These shielding
rings are easy to disassemble. During transportation, they are put in special case.
On bottom of reactor it is base and insulation supports. They are robust enough to stand the whole
weight of reactors. The base is made of non-magnetic stainless steel. Measures are taken to
prevent heating under eddy current. Base and insulation supports are easy to disassemble for
transportation.
3. Variable Frequency Power Supply
HVFS series variable frequency power supply is critical part of variable frequency resonant test
system. The system could be used in AC voltage test and PD test. Frequency variation could be
done under power. Power-off is unnecessary.
By changing the testing frequency, the system is able to carry out tests power consumption equal
to 30~200 times of actual output power, which is a big benefit for on-site test.
Functions of HVFS-400 variable frequency power supply:
- It could be used for tests (AC voltage test and PD test) on power transformers up and below
500kV class.
- Together with suitable compensation, it could test on power cables, compensation capacitors,
large generators, and other high capacitance power devices.
- It could be used separately as medium frequency signal source or medium frequency power
supply.
- Initial switch-on voltage and voltage waveform are in line with international standards. The
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whole variable frequency power supply set is featured by light weight, compact structure, easy
operation, and multiple functions. It is kind of highly appreciated test equipment.
3.1. Features
Fine equivalency: output voltage of variable frequency power supply is in sine wave, distortion
of which is less than 3%. It distinguishes it from other kind of variable frequency power supply
which outputs square-wave. During test, peak value measurement is not necessary.
Control is done via optical fibers. The HV circuit and LV control circuit is totally isolated.
Small in dimension, light in weight, convenient for transportation, which make the device most
suitable for on-site use.
Easy to operate, simple connections, which improves the working efficiency by 50% compared
with motor-generator set.
Safe and reliable with various protections: discharge and breakdown protection, over voltage
protection, output short-circuit protection, start-from-zero, power curve protection, etc. Once
any of these protections takes act, it cuts off power of the main circuit to guarantee safety of
the people and testing equipment.
The device uses special chip to generate signals, controlled by micro-computer. The output
frequency is very stable, which is up to 0.001Hz.
Output voltage of the device is controlled via high speed micro–computer from TI (Texas
Instruments). Unstableness of output voltage is less than 1%.
3.2. Definition of model and how to select the model
Fig 2 Definition of model of variable frequency power supply
Selection of model
Efficiency of the variable frequency power supply is about 75%. Relation between its output current
I0 and the feeding current I is I0=1.414I. During test, try to keep the power voltage above 380V (it is
better if you could keep it above 400V. When the test starts, the power voltage might reduce a little),
or the output voltage of variable frequency power supply may be below 350V.
Table 1 Power required for feeding source
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Output capacity of VF Output current of VF Current of feeding Power of feeding
power supply power supply source source
50kW 144A 100A 66kW
100kW 286A 202A 130kW
200kW 571A 403A 260kW
260kW 743A 525A 345kW
300kW 857A 606A 390kW
400kW 1142A 807A 532kW
450kW 1286A 909A 598kW
800KW 2286A 1616A 1063KW
3.3. Connecting terminals
Input terminal: three phase, AC 380V, 50~60Hz; phase sequence does not matter, the three
phase could be connected in any way. Select wire of suitable cross-section bases on testing
current.
Output terminal: single phase, with clear marks on the panel of VF power supply cabinet
Input and output terminals are not allowed to be grounded, or the variable frequency power
supply will get damaged.
Select wire of suitable cross-section and make reliable connections.

Grounding end in variable frequency power supply cabinet must be grounded during
operation.
Note: close to the grounding end, there is a filtering switch (it is in order to reduce interference
that the variable frequency power supply output is grounded after non-inductance capacitor
and filtering switch). If the switch at input is equipped with trip-for-leakage function, do make
the filtering switch open, or during operation the switch at input will act to trip and cut off the
power.
Synchronous source is available for PD measuring, output voltage of which is 100V, power at
100W. Output frequency is the same with that of variable frequency power supply. During
work, pay attention to prevent short circuit.
Isolating power source is especially available for PD measuring and other instruments.
Voltage is 220V, power at 500W. the isolating power source is with fuse to avoid short circuit.
Waveform measuring unit (not available for all models) is used to monitor output voltage
waveform of variable frequency power supply. Its output varies 0~12V matching 0~350V of
variable frequency power supply. The unit could be directly connected with oscilloscope. The
voltage is red from isolating transformer at output of variable frequency power supply. Pay
attention to prevent short circuit during operation.
Control is powered from AC 220V mains. On control panel there are two pints separately for
HV measurement and variable frequency power supply. Plugs and pins are specially to avoid
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mix. Please notice the marks on panel. Do not insert or pull out the pins live with electricity.
HV measurement is done by means of capacitive voltage divider.
Current measuring unit (not available for all modes) uses clamp type CT to connect with
measuring end. The CT should be connected to LV such as grounding wire, measuring wire.
3.4. Protections
The variable frequency power supply is equipped with multiple protection circuits to ensure safety
of people and device.
Protections for HV discharge and breakdown: if test object discharges or breaks down during
test, it cuts off output voltage from variable frequency power supply. Meanwhile it cuts off
power source as well. On the screen it notices “HV DISCHARGE”. Energy stored in high
voltage circuit will be released via intermediate transformer and freewheel circuit. Over voltage
is prevented to influence other devices.
Over voltage protection: the test system is able to tune the testing voltage, preventing
voltage-rise caused by external reasons. If the testing voltage exceeds the setting value, the
variable frequency power supply automatically cuts off the circuit. On the screen it notices
“OVER VOLTAGE”.
Over current protection: if short circuit happens at the output during test, the variable
frequency power supply cuts off the power quickly. On the screen it notices “ OUTPUT
CURRENT FAILURE”. The protection is accomplished within 20µs, which may bring that
protection circuit acts by mistake when the variable frequency power supply restarts. In this
case, shut it down and wait for about three minutes, and then restart it again.
Internal protection: if some internal components are wrong, the controlled silicon in DC circuit
would act to cut off DC power, and then cut off AC power, preventing deterioration. On the
screen it notices “BRIDGE ARM 1, 2,… FAILURE”. The protection is accomplished within
20µs.
Communication failure protection: if the communication fibers are not connected /correctly
incorrectly, or there is no power feeding, it notices on the screen. In this case, the variable
frequency power supply is open without output voltage.
Phase fault protection: if phase B is missing in three phase power source, on the screen it
notices “PHASE B MISSING”. If phase A or C is missing, the system can not work. On the
screen it notices “ COMMUNICATION FAULT”.
Quick-break: if AC short circuit happens or the control circuit gets short circuit, the main power
switch will break very quickly. It is kind of are switch, cutting off quickly in case of fault. Control
circuit and ventilation power circuit are equipped with their own switches.
Start-from-zero: once the variable frequency power supply is started, before tuning the voltage
the output voltage of variable frequency power supply will be always zero.
Over voltage protection setting: the max output voltage is limited below 400V. Higher output
voltage is prohibited.
During resonant test, when the voltage is over 90% testing voltage, frequency tuning is not
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allowed to avoid over voltage.
Accidental operation: in the process of automatic voltage rise during series resonant test,
push any of the buttons on control panel, the voltage rise stops. It continues to rise unless the
user pushes the voltage-up button once more.
3.5. Safety notices
Only professional people are allowed to operate on the test system. During operation, all
regulations must be obeyed. Please carefully read the manual before operation. To avoid potential
danger, the test system is only used in certain limited conditions.
During transportation, collision is forbidden. Do not constrict on cabinets, control parts, etc.
Select suitable cross-section of wire, in case overheat brings out fire.

Before operation, please make sure it is correctly earthed.
Pay attention to rated parameters. Run the device within those parameters.
Pay attention to prevent fire.
Before connection and disconnection, please first make sure the power is off. Operation with
alive electricity is forbidden.
During test, the people should try to be as far as possible from the main cabinet.
Before repair or maintenance, please carefully discharge it to avoid electric shock.

Before start, the dust-proof door at the ventilation tube must be open. If the ventilation tube is
blocked, the high power triode of variable frequency power supply will be damaged because
of over hear in very short time.
Do not operate in circumstances easy to get fire or explosion.

Do not operate or store in wet or corrosive circumstances.
Please do keep the device clean and dry.

Please place the device on smooth and hard floor or similar things.
If the ambient temperature is too low below 0℃, please push the switch to heat centralized
control of the device, or it will not work normally.
If the device is not in service for long, please remove the power connection.
If fault happens, please make clear the problems before next movement. If you could not
solve the problem by yourselves, please contact the supplier.
3.6. Theory of working
The variable frequency power supply is high power output device, taking advantage of step-by-step
amplifier(see Fig 3). The fine signal source is amplified for multiple times, till the output is high
enough for the testing need.
The signal source sends out standard sine wave signal with function generator. Suitable relays are
used for adjustment of voltage (equivalent to adjustment of voltage and frequency during test).
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Output frequency of variable frequency power supply is in line to that of signal source. Adjustment
of voltage and frequency is accomplished with signal source. Output of signal source activates the
primary amplifier to get output power. The primary amplifier works in double ways at the same time.
On one side, it works as synchronous power supply for PD test. On the other side, it activates
bridge amplifier circuit (see Fig. 4) which is the critical component for power output. During test, the
bridge amplifier circuit largely gives out heat, so forced air cooling system is necessary.
Fig 3 Theory of working for HVFS variable frequency power supply

DC+
Q1 Q2
T1 T2
OUT1 OUT2
Q3 Q4
T3 T4
DC-
Fig 4 Drawing of bridge amplifier circuit
In Fig 4, Q1～Q 4 stand for four equivalent triodes, matching four bridge arms of variable frequency
power supply. Each bridge arm is paralleled with hundreds of triodes. Measures are taken to
balance the current. In positive half wave, primary amplifier moves base of Q1～Q 4 triodes via
driver transformers T1~T4, then Q2 and Q3 get blocked, Q1 and Q4 get breakover. The current
flows from Q1 to the load, then to Q4, forming the positive semicircle of sine wave. In negative half
wave, simulation signal moves base of Q2 and Q3, then Q1 and Q4 get blocked, Q2 and Q3 get
breakover. The current flows from Q3 to the load, then to Q2, forming the negative semicircle of
sine wave. In this way, a full sine wave is accomplished.
Bridge amplifier circuit has to be fed by DC source. The variable frequency power supply is fed by
three phase AC source which is changed to pulse DC voltage after being rectified. The rectifier
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circuit which contains filtering inductors and capacitors changes the pulse DC voltage to smooth
DC voltage. Since the capacitance of filtering circuit is up to thousands of uF, it brings large
charging current at the moment of switch-on, which would result in trip of the main power source.
To solve the problem, a pre-switch circuit is added to charge the filtering capacitors in lower current.
Once charging is finished by 80%, close the switch. In this case there will be no pulse high current.
After the switch is open, charge stored in filtering capacitors are gradually released via discharge
resistor. The user has to push only the START button, then all movements will be done
automatically including start of cooling fan, pre-switch, switch-on.
DC voltage feeding bridge amplifier circuit is controlled through fast over current protection, thus
the working power is quickly cut off in case of fault to protect the secondary circuit.
OUT 1 and OUT2 of bridge amplifier circuit is connected to LV side of step-up transformer, HV side
of which is connected to testing circuit. Testing circuit and step-up transformer will not cause open
circuit. Since inside the variable frequency power supply there is always high power follow current
circuit, charge release channel is available in the testing circuit all the time. Either internal fault
happens in variable frequency power supply or the external power fails, the resonant circuit will not
be cut off, which makes it distinguished from conventional AC test system with test transformer.
Moreover, there will not be over voltage caused by forced zero current.
3.7. Components
The variable frequency power supply is mainly composed with variable frequency cabinet and
control box, which are connected via optical fibers. The variable frequency cabinet outputs high
power, while on the control box the user operate and monitor the working status of variable
frequency cabinet. Output (AC 380V, single phase) of variable frequency cabinet is connected to
test circuit. The control box works at AC 220V.
3.7.1 Control box

The control is realized by high speed micro computer. The operations are displayed on the screen.
Pay attention that do not use in direct sunshine or at very low ambient temperature. The control
circuit is separately fed by AC 220v, 50Hz source. Close the lid when not in use. While in
transportation, fix it to avoid shack.
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3.7.1.1 Buttons
Fig 5 Control box of variable frequency power supply
On the left top, there are two plugs for external fiber connection, separately for HV
measurement and Variable frequency cabinet (see Fig. 6). The two plugs are different from
each other to avoid mixture.
Fig 6 Plugs for optical fiber connection

On the right top there are two mushroom buttons to start/stop the variable frequency power
supply (see Fig 7). Once you push the START red button, it automatically accomplishes “start
of cooling fan”, “pre-switch”, and “switch on”. Meanwhile on the screen it displays “STARTING”.
When the system is successfully started, the red lamp lights. Meanwhile on the screen it
displays “STARTED, READY TO RISE VOLTAGE”. Once you push the STOP green button,
the variable frequency power supply will be tripped immediately. Several seconds later
(release of charge stored in capacitors), the cooling fan stops as well.
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Fig 7 Mushroom buttons on control box panel

At middle bottom there are four blue buttons, separately for operations of “fine/coarse
adjustment”, “menu”, “timer” and “single phase operation”. (see Fig 8)
Fig 8 Four buttons at middle bottom of control box
At the right bottom there are four yellow buttons, separately for operations of adjustment of
voltage or frequency (see Fig 9). If the buttons are kept pressed, the operation such as
frequency up/down will be continuous.
Fig 9 Buttons for frequency and voltage adjustment
3.7.1.2 Display screen

On the screen it displays working status of the variable frequency power supply. Push the START
button, on the screen it firstly comes the welcome words.
While working, on the screen it notices below parameters (see Fig 10):
Output voltage, output current of variable frequency power supply. Output current is the actual
display, while the output voltage is based on voltage ratio.
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Output frequency of variable frequency power supply, also as the testing frequency.
Phase, expressing ration between output voltage and output current, usually between
-180~180°
Peak value and peak/√2, voltage of variable frequency power supply;
Output waveform, changing with actual load;
Coarse adjustment of frequency and voltage, push the “fine/coarse adjustment “button on the
panel to change to fine adjustment.
Temperature at outlet, which is temperature of air flowing through the cooling fan;
Time and date at the moment of test
3.7.1.3 Menu
After start the control box, push the blue button “MENU” to enter below interface (see Fig 11). Use
the yellow buttons to change the settings. When all the parameters are correctly set, push the blue
button “MENU” again to go back to the working display interface as in Fig 10. When it is on menu
interface, the variable frequency cabinet can not start; vice versa. In case of fault, “MENU”
operation is prohibited, unless the control box is restarted.
Fig 10 Menu of control screen

If HV voltage and current measurement is not required, the user could close the function on menu
screen.
3.7.1.4 Buzzing
Different kinds of buzzing indicate different working statues of the variable frequency power supply.
connect the power, switch on the main switch and the small air switch on the right of variable
frequency cabinet, then it gives out continuous sound like De-dee
switch on the power switch of control box after correct fiber connection, sound of De-dee stops;
the screen displays the welcome words and the quickly goes to working interface;
if the small air switch is not closed and the control box is started, it gives out clipped warning
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sound; on the screen it notices “ COMMUNICATION FAULT”. Close the air switch then the
sound disappears.
In case of fault, it gives out continuous alarm
If time is nearly over (10s left in withstand test), it gives out alarm.
3.7.1.5 Emergency stop
Power switch of the control box could also be used as emergency stop. During test if the high
voltage test has to be interrupted immediately, switch off power of the control box, and then the
high voltage is cut off. Meanwhile, from inside the variable frequency cabinet it comes continuous
clipped buzzing.
3.7.2 Variable frequency cabinet

Variable frequency cabinet is where the output power is generated. It is mainly composed by
thousands of triodes in parallel, AC control unit, rectifier and filtering circuit, and fast protection
circuit. The structure is very complicated, containing a plenty of elements. The amplifier part is
composed by decades of radiator boards with triodes. The radiator boards are divided into four
bridge arms. If any triodes get wrong in any of the bridge arms, on the control screen it notices
bridge fault.
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6
Fig 11 Variable frequency cabinet
1. dust-proof cover: if the variable frequency cabinet is not in use, expand the cover over the
cabinet; while in work, fold it to the top. Pay attention to prevent it from covering the
ventilation.
2. ventilation: keep it unblocked
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3. door: in work, close the door
4. connection box
5. shock-absorbing feet
6. dust-proof door for ventilation: in work, the door must be removed and be away from the
ventilation to keep the ventilation unblocked.
Fig 12 Connection box: input, AC 380V three phase, no matter of phase sequence, no null line
3 4
8
1
2 9
5 10 6 7
0
Fig13 Connection box: output
1. 220V isolating power, 2A fuse
2. 220V isolating power, output plug

3. 100V/100W synchronous power source
4. fiber communication port
5. earthing end
6. variable frequency OUT1（no earthing）;
7. variable frequency OUT 2（no earthing）;
8. parallel / single unit use change-over

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9. parallel plug（variable frequency cabinets of the same power could be used in parallel）;
10. filtering switch（if the feeding source is equipped with leakage protection, leave this switch
open）;
3.12.1 Power source

The variable frequency cabinet is connected to the mains via an air switch (the master switch)with
fast fuse. Remote switch-on is available via the control box. Control circuit inside the variable
frequency cabinet is a small air switch, controlling low current circuits such as power for control
circuit, power for cooling fan, etc.
Master power switch
Remote control contactor
Fig 14 control switch in main power circuit
Control circuit switch
Fig 15 control switch or low current circuits
3.12.2 Control unit in variable frequency cabinet

Signal source and LV control circuits are gathered on circuit boards in control unit inside variable
frequency cabinet. The circuit boards communicate directly with the control box via fibers. They
also receive orders from control box to control the whole variable frequency cabinet. The control
unit is inside shield case. In work, the control unit has to be powered first (close the main power
switch and control circuit switch). If the communication between control box and variable frequency
cabinet is abnormal, from inside the control unit it gives out sound like De-dee. The sound will not
stop unless the communication becomes normal. Elements inside the control unit do not work at
very low temperature. If the ambient temperature is very low below zero degree Celsius, warm it
first.
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Fig 16 Control unit in variable frequency cabinet
3.12.3 Transition amplifier unit

The signal from control unit of variable frequency cabinet is very week. It has to be amplified before
it goes to high power elements. The transition amplifier unit is the secondary stage of the amplifier
circuit. It is very important to adjustment of voltage and frequency.
Push to amplify
Synchronously
amplify
Fig 17 Transition amplifier unit
3.7.3 Connection via optical fibers

In total the connection terminal includes optical fiber and photolectric transducer. Pay attention to
the hand gesture when inserting or pull out the fiber(see Fig 19). When inserting the terminal,
slightly push inside and you will hear the sound of locking. When removing the terminal, slightly pull
it out. Do not use too much force or directly pull the fiber.
Two ends of the fiber are inter-changeable.
Fig 18 Hand gesture in inserting fiber connection terminal
Optical fiber is not durable. Pay attention not to bend, twist ,squeeze or tread on it. Keep it far from
heat. When inserting, aim at the terminal hole, do not use too much force. When test is over, clear
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User’s Manual
it tidy and place at suitable position(see Fig 20). Make sure it free from moisture, pressure, dust or
dirty.
CORRECT WRONG
Fig 19 Connection fibers
3.7.4 HV measuring terminal
2
7
5
4 6
Fig 20 Connection terminals of HV measurement
（1）battery, remove it when not in use

（2）input from divider, voltage already divided is fed from here
（3）grounding, make it reliable in test
（4）power switch, turn off it when test is over
（5）input from divider by plug,
（6）indication lamp, if battery is low, color of lamp changes;
（7）optical bier, connect to control box
3.8. Operation notice
3.8.1 Preparation before operation

Get ready of all safety measures
Open the ventilation door, close other doors
Check if the variable frequency power supply is mechanically damaged
Check if power switch of variable frequency cabinet if off
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User’s Manual
Feed AC 380V power source to variable frequency cabinet from input connection box; while
the output is not connected
Connect the variable frequency cabinet and control box via optical fiber
Check if grounding cable is reliably fixed
Feed AC 220V power source to the control box
Based on actual test need, select suitable HV and LV connection terminals for step-up
transformer
Fig 21 Test circuit with variable frequency power supply
3.8.2 Procedure of operation

before close the power switch, make sure all components in the system are fine, and the
safety measures are ready.
connect the variable frequency cabinet to AC 380V three phase power source, and close its air
switch.
power on the control box, go to the working interface; the user could preset the frequency
close to the testing frequency, but voltage regulation is not allowed.
when variable frequency cabinet is powered, it gives out short and clipped buzzing; when the
control box is also powered, the buzzing stops. At the moment, stop button on right top of the
control box is lit in green, there is no electric charge in HV circuit.
Push the yellow “MENU” button and go to the menu interface; set the testing voltage and
rectification voltage; set the dividing ratio and test duration time; then push the yellow “MENU”
again to go back to working interface. (at menu interface, the variable frequency cabinet can
not started by pushing the “START” red button; once the variable frequency cabinet is started,
the control box can not go to menu interface by pushing the yellow “MENU” button. In this case,
if you want to go the menu interface, push the “STOP” button and then go the menu interface)
push the “START” red button to start the variable frequency cabinet; it takes 5s to start the
variable frequency cabinet. During the 5s, the screen shows “ system starting……”
During test, push blue “TIMER” button, then on bottom of the screen it displays:
When the system is successfully started, “STOP” button light off, and “START” button is lit in red.
At this moment the HV circuit is alive. On the screen it shows “ system started, ready for voltage
rising”.
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User’s Manual
When test is over, reduce the voltage to the minimum, and then push the “STOP” button.
When ‘STOP” button is pushed, the HV circuit is firstly cut off. Five seconds later, the cooling fan
stops. During the five seconds, charges stored inside variable frequency power supply get
released.
3.9. PD Test
Make the connections as in Fig 27, and then the test could be carried out.
First, rise the voltage no-load without test object. This step is to calibrate the testing voltage which
is red from LV arm of divider.
Second, connect the test object, preset the frequency at 150Hz. Close the power switch. When the
voltage is risen to about 20V, adjust the frequency. Meanwhile, watch change of the output current.
At the beginning, take “ coarse adjust”. If the output current goes down, it means the direction of
frequency adjustment is correct. Continue to adjust in the direction until it is very close to the testing
frequency. Then take “fine adjust” till finally the output current is at the minimum(the phase angle at
the minimum as well). Frequency at the moment is the testing frequency, usually no less than
100Hz. Subsequently rise the voltage to the testing voltage. Take an eye on the output current and
alert about current pulse. Based on actual conditions, the frequency could be slightly regulated,
keeping the output current around its minimum.
In the step of frequency adjustment, if the output current does not change obviously, set the
frequency between 130~150Hz. Optionally you could add compensation reactor at LV side of test
object (showed in Fig 27). In this case the testing frequency might more than 150Hz.
Internal loss of the variable frequency power supply could be reduced by making the output voltage
above 300V during PD test, which could be realized by presetting suitable ratio of step-up
transformer.
Fig 22 Electrical drawing for PD test with Variable frequency power supply
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User’s Manual
3.10. Notices
Please carefully red the manual before operation. Pay special attention to the red words and
sentences which are especially important for safe operation.
Only professional people are allowed to operate on the device.
Since the variable frequency cabinet is fed directly by AC 380V power source without isolation,
both output ends of the cabinet can not be earthed or short-circuit. Or the variable frequency
cabinet will get damaged.
Before test, check if the feeding source is equipped with leakage protection. If so, cancel the
protection temperately and restore it when the test is over. Optionally, you could close the
filtering switch in Fig 14. If not, the current of filtering capacitance to the earth at the moment of
starting will cause action of leakage protection, thus the power will be cut off.
In series resonant test, do not rise the voltage too high before figure out the resonance point.
Or the voltage will rapidly go up when the resonance point is figured out, in which case it is had
to control the voltage rising speed. Normally figure out the resonance point at low voltage and
then rise to testing voltage when the resonance point is figured out.
If the test takes long time and output voltage of variable frequency cabinet is low, triodes inside
the cabinet will get damaged because of the rising loss. Thus the output voltage must be kept
above 300V. Preset the ratio of step-up transformer to solve the problem.
Refer to Fig 28 for load capacity of the variable frequency power supply. High-current load is
prohibited at low voltage. In the figure, the lower part is the safety area, load outside the part
will bring into rising loss of triodes inside variable frequency cabinet. In bad conditions, the
triodes may burn. If actual output current is above the curve in fig 28, on control screen it
displays “power curve protection”. Meanwhile, it gives out warning sound like De-dee. The user
should reduce the voltage or cut off the power. The test could not be continued unless ratio of
step-up transformer is changed or the load current is down.
Fig 23 Load capacity curve of variable frequency cabinet
To stress on the point that output power of the variable frequency power supply is 400kW other
than 400kVA. No purely capacitive nor inductive load! If the load is purely reactive, it should
not be more than 400kVA. Or the triodes will be damaged due to large loss. Do make sure
21
User’s Manual
during test the reactive load is within the limit.
When test is over, first reduce the voltage to zero and then cut off the power.
Working frequency of the variable frequency cabinet is between 20~300Hz. Frequency outside
the range is prohibited.
Do not touch the conductive part of the variable frequency cabinet within 5min since the power
is cut off, in case there is charge left in capacitive elements.
Before repair or maintenance, make sure charge in each capacitive element is totally released.
If the power of variable frequency cabinet trips, get the fault information from the notice of
control box. If the variable frequency itself has to be checked, first make sure everything is
normal inside the hard wares, and then remove the load, only energize the variable frequency
cabinet itself. If the no-load test is passed, go on the on-load test.
Wait for at least ten seconds before restarting the variable frequency cabinet if the power has
been cut off. If the interval time is too short, it might not restart successfully.
Control switch in fig 16 is only applicable to low current circuits. If the switch is open, the
variable frequency cabinet can not start. From the control box it gives out warning sound, and
notice “ communication fault”.
3.11. Maintenance
DO NOT work for long time if the variable frequency power supply is mistuning (equivalent to
purely reactive).
Periodically check wiring inside the variable frequency cabinet and screws at each connection
point.
Place the device in dry, clean circumstances which is free from raining. If not in use, take the
dust-proof cover for ventilation.
While in transportation, use special strips to fix the cabinet. The fixed cabinet should not skip
or be loose.
If the user can not solve any problem themselves, contact the supplier in time.
Do not expose screen of control box in strong sunshine for too long. During transportation,
measures should be taken to avoid shock on the control box.
The communication fiber and plug is vulnerable. Be careful while operation. Pay attention to
prevent dirty things entering the plug hole.
Do not bend, twist or squeeze the fibers. Keep the fibers away form fire. Aim at the hole first
before plug-in. Do not use too much force. When test is over, clear the fibers and put at
suitable places.
Direct HV current measurement via clamp CT is not allowed.
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User’s Manual
3.12. Solution for faults
3.12.1 Usual faults
Notice on screen Potential reasons Solution

Bad contact at fiber terminal, or broken Insert the terminal again, or replace
fiber the fiber
Communication fault
of VF power supply Shut down the control box, power the
Variable frequency cabinet is not
variable frequency cabinet, restart
powered.
the control box
Low battery Replace the battery
Power switch at measuring terminal is Close the power switch at measuring
HV communication
open terminal
fault
Bad contact at fiber terminal, or broken Insert the terminal again, or replace
fiber the fiber
Expert is required;
A temporary solution: shut down HV
HV measurement Measuring gate is wrong, or gate fiber voltage measurement; add an
communication fault is broken external high resistance voltmeter for
voltage measurement. The solution is
unable of auto voltage rise and auto
resonance tuning
A temporary solution: shut down HV
HV current HV current measuring gate is wrong, or current measurement; add an
communication fault the gate fiber is wrong external clamp ammeter for current
measurement
Lower the ratio of step-up
transformer (exciter transformer),
Load is too large, outside the load
Power curve fault making the output voltage of variable
capability
frequency power supply rises and
output current drops.
HV discharge or breakdown of test Cut off the power and check the test
object object
Variable frequency cabinet is not Switch on power of the variable
powered or Phase B in the power frequency cabinet, or replace the
source is missing; fiber is broken fiber
1. Check the primary amplifier
circuit
fault in bridge arm Interfered when starting （ possibly
1,2,3,4 Transition amplifier unit is wrong） 2. voltage is low at end due to too
long power cable: shorten the power
cable or user thicker power cable
Test object is inductive, so output
Lower the ratio of step-up
waveform is very bad (especially in
transformer
series resonant test)
Several triodes are damaged(low
Check the amplifier board
possibility)
fault in bridge arm1,2 Triodes on bridge arm 1,2 are damaged 1. Replace the damaged triodes
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User’s Manual
or can not put up high voltage 2. repair the HV inspection circuit
Triodes on bridge arm 3,4 are damaged on arm 1,2 or 3,4
fault in bridge arm 3,4
or can not put up high voltage
Cut off the power, check the HV
Output current is too high
circuit to analyze the problem
Output current fault HV discharge or breakdown of test
Cut off the power and restart
object
Mistake protection action while starting Cut off the power and restart
Voltage rises too fast; change to fine
Rectification voltage Output voltage exceeds the rectification
adjust when the voltage is close to
exceeded value
rectification value
Cut off the power, analyze the
Voltage at HV side drops too fast
Breakdown problem
Discharge on test object Check components in HV circuit
Incorrect wiring happening in auto
Circuit fault Check the wiring in HV circuit
resonance tuning
Phase B missing Phase B missing Check the feeding power
Communication fault when the variable Connect the fiber, switch on the
Sound like De-dee frequency cabinet is powered control box
from inside variable
frequency cabinet If there is still De-dee sound when fiber Fiber single phase fault, or the
is connected terminal contact is not good
Shut down the leakage protection, or
main switch trip while Leakage protection acts near the main
shut down the filtering switch of
starting power switch
variable frequency cabinet
3.12.2 Other faults

3.12.2.1 Voltage does not rise
Fault description: The control screen is at working interface. Switch on the power, but no output
voltage.
Potential reason: no signal or signal gate is damaged
Solution:
1) make sure the whole test circuit is in normal working conditions, and communication works well
2) check if fuse in Transition amplifier unit is burnt, if so replace with a new one with the same
model. If the fuse is already back, there might be short circuit or high current in secondary part.
Be cautious!
3) Check if power of transition board is normal, if not then the feeding transformer may be wrong
4) Open the control box to commissioning interface(do not start variable frequency cabinet), rise
the voltage and measure with multi-meter if there is voltage between IN1 an IN2 on transition
board. If there is voltage in between (usually several or decade Volts), the circuit is normal. U
5) Measure with multi-meter if there is voltage between IN01 and IN02 on transition board (usually
change between 0~20V with rising step of relay). If there is no voltage in between, the signal
source is wrong and need to be replaced.
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User’s Manual
6) Press “Voltage up” yellow button, if the voltage does not rise, the button may be damaged.
3.12.2.2 How to find out damaged amplifier board (take bridge arm 1,2 as example)
1) Follow notice on the screen to find bridge 1,2 (usually at right of variable frequency cabinet)
2) Remove the green plate; draw with special tool all amplifier boards outside about 15cm. Notice
do not draw the amplifier boards totally out of the cabinet
3) Get a thyristor performance tester; connect the terminal c on black radiator board, and
terminal e to any resistor
4) Push the button “×100” of thyristor performance tester, and watch the display. If it points above
“8” (800V) , the test is passed. If it pointes to “7” and below, the test fails. (the test result is
influenced by ambient humidity and dust on amplifier board)
5) Remove the failed amplifier board from the cabinet. Do not touch any elements on radiator
board. Restore all amplifier boards that pass above test. To keep balance, the user should
remove any amplifier board from the other bridge arm even if it is not damaged.
3.12.2.3 How to find out fault bridge arm with multi-meter
Follow below instructions: remove all load at output side of variable frequency power supply;
measure with multi-meter DC resistance at each bridge arm (measurement point is at terminal
board above the central controller ). The measurement result at bridge arm 1 is resistance between
DC+ and OUT1, at bridge arm 2 for resistance between DC+ and OUT2, at bridge arm 3 for
resistance between DC- and OUT1, at bridge arm 4 for resistance between DC- and OUT2.
normally these measurement should be above 200Ω. If it is below 200Ω, then the corresponding
bridge arm is wrong. If there is damaged triode in any bridge arm, the resistance should be nearly
zero. Find out damaged amplifier board and remove it. Then check if all the DC resistances are
normal.
3.12.2.4 How to find out damaged triode
Remove the radiator board, get a thyristor performance tester and take voltage test on each
amplifier board. Structure of amplifier board is as Fig 29. The test result should be eight zero
voltage withstand or low voltage withstand.
In case that the amplifier board withstands zero voltage, use multi-meter to find out damaged triode
inside. Connect one end of multi-meter to collector c in Fig 29, and the other end to emitter.
Normally the resistance should be 3~5Ω. If test result of any triode is zero or only around 1Ω, then
the tested triode is damaged and has to be replaced.
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User’s Manual
Fig 24 Structure of amplifier board
In case that the amplifier board withstands low voltage, unsolder the emitter and base, find out the
row where the damaged triode is in. Then unsolder each tube to find out the damaged triode. If
there is only several triodes that are damaged, we suggest not to replace it but just remove it. If
number of damaged triodes reaches several decades, replace those damaged triodes at one time.
3.13. Lifting in transportation
Fig 30 shows typical fixing of test system during transportation. While fixing the variable frequency
cabinet, tie on the four lifting rings at the same time, or the cabinet may disfigure.
Fig 25 Variable frequency power supply while transportation
3.14. Commissioning interface
Before switch on the power of control box, push at the same time four yellow buttons on the panel
(the buttons to rise/reduce voltage and frequency), then switch on the power (meanwhile, keep the
four yellow buttons pressed for 3s), the control screen will go to commissioning interface. The only
difference of commissioning interface from working interface is display of output voltage and
ambient temperature.
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User’s Manual
NOTE: Do not carry out HV test at commissioning interface.
While at commissioning interface
Unavailable of zero-position protection
Unavailable of power curve protection
Available of all other functions as at working interface
Start of variable frequency cabinet:
Press “Timer” & “frequency down” to start cooling fan
Press “Timer” & “voltage up” to start to pre-switch the power

Press “Timer” & “frequency up” to switch the system
Able to display voltage on four bridge arms and step numbers of relay, able to display version
of lower computer.
3.15. Status on delivery
Main power switch and remote contactor are both open

Control switch for low current circuits is closed
Parallel / single change-over switch is at single use

“HV voltage measurement” and “HV current measurement” in system menu are both OFF.
Other parameters are randomly set. The user has to finish those settings before test.
27

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User’s Manual

Variable Frequency Resonant Test System(On-site test system)

Variable Frequency Resonant Test System

Yangzhou Xinyuan Electric Co., Ltd.

1. SAFETY NOTICES .....................................................................................2

2. TECHNICAL PARAMETERS .....................................................................2

3. VARIABLE FREQUENCY POWER SUPPLY.............................................4

Fig 1 Electrical drawing of variable frequency resonant test system

2.1 Use conditions

2.2 Technical specifications

2.2.1. Variable frequency power supply HVPF-200

2.2.4. Blocking impedance LS-500-1000/7.5

3. Variable Frequency Power Supply

3.2. Definition of model and how to select the model

Fig 2 Definition of model of variable frequency power supply

Table 1 Power required for feeding source

3.3. Connecting terminals

Select wire of suitable cross-section and make reliable connections.

3.5. Safety notices

Select suitable cross-section of wire, in case overheat brings out fire.

Before repair or maintenance, please carefully discharge it to avoid electric shock.

Do not operate in circumstances easy to get fire or explosion.

Please do keep the device clean and dry.

3.6. Theory of working

Fig 3 Theory of working for HVFS variable frequency power supply

Fig 4 Drawing of bridge amplifier circuit

3.7.1 Control box

Fig 5 Control box of variable frequency power supply

Fig 6 Plugs for optical fiber connection

Fig 7 Mushroom buttons on control box panel

Fig 8 Four buttons at middle bottom of control box

Fig 9 Buttons for frequency and voltage adjustment

3.7.1.2 Display screen

Peak value and peak/√2, voltage of variable frequency power supply;

Output waveform, changing with actual load;

Fig 10 Menu of control screen

3.7.2 Variable frequency cabinet

Fig 11 Variable frequency cabinet

1. 220V isolating power, 2A fuse

2. 220V isolating power, output plug

6. variable frequency OUT1（no earthing）;

7. variable frequency OUT 2（no earthing）;

8. parallel / single unit use change-over

3.12.1 Power source

Master power switch

Remote control contactor

Fig 14 control switch in main power circuit

Control circuit switch

Fig 15 control switch or low current circuits

3.12.2 Control unit in variable frequency cabinet

Fig 16 Control unit in variable frequency cabinet

3.12.3 Transition amplifier unit

Fig 17 Transition amplifier unit

3.7.3 Connection via optical fibers

Two ends of the fiber are inter-changeable.

Fig 18 Hand gesture in inserting fiber connection terminal

3.7.4 HV measuring terminal

Fig 20 Connection terminals of HV measurement

（1）battery, remove it when not in use

3.8. Operation notice

3.8.1 Preparation before operation

Fig 21 Test circuit with variable frequency power supply

3.8.2 Procedure of operation

Fig 23 Load capacity curve of variable frequency cabinet