Operating Instructions MANUAL KIT DKU 4.0 and Accessories
Title KIT DKU 4.0 and Accessories Release date 2018-05-14 Modification: 02 Author M.Ahl
Contents CONTENTS 3 FOREWORD 5 SAFETY 6 Warnings... 6 Safety... 7 Grounding Instructions... 7 Five Basic Safety Rules... 7 GENERAL INFORMATION 8 Product Description... 8 ASSEMBLING AND OPERATING INSTRUCTIONS 9 System Overview... 9 Pressure Vessel Parameters... 9 Dimensions... 10 Used Materials Which Have Contact with the Filed Gases... 10 Allowed Gases... 10 Feature... 10 Operation... 11 Open the Vessel... 11 Close the Vessel... 11 Vacuum and Pressure... 12 Current Measurement... 12 Electrode Set and Insert... 13 Electrode Set Configurations... 14 Oiltesting CUP (Option)... 15 Corona Cage (Option)... 16 Open the Corona Cage... 16 Operation without the Tube of the Pressure Vessel... 17 TIGHTNESS AND SAFETY TESTS 17 Routine Test... 17 Type Test... 17 STATE DESCRIPTION AND ADJUSTMENT 18 MAINTENANCE 19 Utility Services... 19 KIT DKU 4.0 and Accessories Contents 3
Support, Maintenance... 19 Cleaning... 19 Repairs... 19 Spare Parts... 20 ONWARD TRANSFERS 21 Resale... 21 Shut Down Procedure... 21 Taking Back... 21 TRAINING, EDUCATION 22 Training... 22 Education... 22
Foreword Welcome as a new user of the High Voltage Construction KIT 4.0. Thank you for placing your confidence in our product. With the purchase of this system you have opted for all the advantages that had built a world-wide reputation for Haefely Hipotronics Instrument: Robustness, performance and quality is assured. As a result this system provides a solution which achieves the optimal combination of traditional know-how and leading edge technology. Any correspondence regarding this system should include the exact type number, system serial number and firmware version number. With the exception of the firmware version number, this information can be found on the registration plate on the right panel of the system. The design of this system will be continuously reviewed and improved where possible. Therefore there may be small differences between the operating manual and the actual system. Although all efforts are made to avoid mistakes, no responsibility is accepted by Haefely Hipotronics for the accuracy of this operating manual. This operating manual is designed for completeness and easy location of the required information. Customers who already have experience with this kind of equipment will find this document to be of assistance as an extended help. A keyword index at the end of the operating manual greatly eases use. If you find a mistake or inconsistency in the operating manual then please feel free to inform our Customer Support department with your corrections so that other users may benefit. Haefely Hipotronics accepts no responsibility for any damage that may be caused during use of this document. We reserve the right to amend the operation, functionality and design of this system without prior notice. If discrepancies are noticed between the on-line help provided by the system and the operating manual, then the on-line help should be followed. All rights reserved. Any use of this manual other than for operation of the system requires prior written authorization from Haefely Hipotronics. 2018, Haefely Hipotronics, Switzerland KIT DKU 4.0 and Accessories Foreword 5
Safety Warnings High voltage can be lethal! Only trained persons are allowed to work with this equipment! The customer is responsible that the employees, which work with this equipment, are trained. The training has to be repeated in regular intervals; the training has to be documented. When working on high-voltage test equipment, at least two persons must always be present, one of them bears responsibility for the test. Never open a cover or a case in which the line voltage is present before having disconnected the power supply! Before entering the test area, after high-voltage tests have been performed, it has to be made sure that the power supply is definitely switched of at the control unit (see operating instruction control unit) and the emergency button is pressed. After high-voltage tests have been performed the first thing which has to be done after entering the test area is making sure that all high-voltage parts in the test area have to be grounded! Before the high voltage is connected, the responsible person for the test must verify that: - The test circuit is assembled correctly - The test object is connected correctly - All safety systems are operable - The manual grounding rod has been removed. - Short circuit cables from the capacitors have to be removed. - All persons have left the test area. The DKU 4.0 for KIT can be pressurised or under vacuum. Before the usage an optical inspection for damages has to be done. A damaged DKU cannot be used anymore. Pressurised gases can expose high energies. Before opening the DKU for KIT 4.0 the pressure in the vessel has to be according to the pressure to
the atmosphere. Before opening the vessel it has to be disconnected of the vacuum or pressure support. The valve has to be open the manometer has to be checked for zero pressure. The DKU is not designed for continuously operation under pressure and vacuum for long time durations. After each experiment cycle the vessel has to be depressurized to the atmosphere pressure and the top header has to be opened. The DKU is no storage for gases Under pressure or vacuum the place of the insert has not to be changed Safety All safety aspects are related to the current KIT 4.0 manual. Grounding Instructions Grounding connections have to be made without forming loops. The ground connection of the measuring and control system, frequency converter, high-voltage transformer, floor pedestal, test object and DKU should be arranged in star connection, where the central point is grounded. The grounding rods have to be connected to the central earth point, too. For earthing of components copper foil or copper mesh is recommended. Five Basic Safety Rules Always remember the five basic safety rules for working with high voltage: 1) Disconnect mains! 2) Prevent reconnection! 3) Test for absence of harmful voltages! 4) Ground and short circuit! 5) Cover or close off nearby live parts KIT DKU 4.0 and Accessories Safety 7
General Information Product Description The DKU 4.0 for KIT is a pressure and vacuum vessel which is designed to operate different experiments in an artificial gas environment. As an insert with different electrodes or a corona cage (option) can be used. Also an oil testing cup (option) is available.
Assembling and Operating Instructions System Overview The standard DKU set consist the pressure vessel, the insert with the electrode set and a hose with a manometer. Additional the Corona cage can be used. Pressure Vessel Parameters Rated AC voltage Rated DC voltage Max rated pressure Operating temperature range 100 kv (RMS) 140 kv (Peak) 5 bar rel. (pressure relief valve triggering at 5.5 6 bar rel.) 10 C 30 C KIT DKU 4.0 and Accessories Assembling and Operating Instructions 9
Cylinder volume (empty) Maximum duration current 7.8 L (20.6054 gal lqd) 100 ma Dimensions - Total height: 705 mm - Diameter: 300 mm - Inner diameter tube: 140 mm - Inner height from insulation/ contact pin to cap: 497 mm Used Materials Which Have Contact with the Filed Gases - Flanges: Aluminium (AL) - Tube: Polycarbonate (PC) - Insulation/ contact pin: Polyvinylchloride (PVC-U) - Sealing: Nitrile compound (NBR-70) - Hose: Polyurethane (PU) - Hose fittings/ manometer: Steel/ stainless steel/ brass Allowed Gases - Air Feature - Nitrogen N2 - Carbon dioxide CO2 - Noble Gases For other gases cannot be given a guarantee! No liquids are allowed! After a time in operation the polycarbonate tube can change the colour. Then the tube should be replaced by a new one (See: Maintenance) - Digital manometer (WIKA DG-10-E) - Pressure/ Vacuum range: -1 10 bar rel. - Accuracy ±0.5 % of span ±1 digit - To ground insulated contacted pin for current measurement - Compatible with KIT insert and KIT oil testing cup (different electrode arrangements possible) - Compatible with KIT corona cage - Tube and sealing is changeable by the customer - Matching to KIT K, KIT DK 10 Assembling and Operating Instructions KIT DKU 4.0 and Accessories
Operation Open the Vessel Before opening the vessel it has to be disconnected of the vacuum or pressure support. The valve has to be open. The pressure has to be checked on the manometer. - Open the 6 screws on the top header (for opening an Alan key can be used) Close the Vessel - Check the sealing on the top flange of damages and a perfect fit in the grove - Check the surface on the polycarbonate tube - Place the top header on the top flange and tighten the 6 screws crosswise with a maximum Torque of 20 Nm (for closing an Alan key can be used) KIT DKU 4.0 and Accessories Assembling and Operating Instructions 11
- Check every screw several times of tightness - The perfect fit can be checked when the gap between top flange and top header is closed Vacuum and Pressure The pressure vessel is equipped with a valve, a manometer and a hose ½ in outside threading (cylindrical). The pressure and vacuum supply has to be done by the customer. For safely operation please note the DKU parameter and the safety notes. - For pressure and vacuum the supply has to be connected to the hose and the valve should be open - During pressure and vacuum the manometer has constantly be checked for the limits. For more details check: www.wika.com (supplier homepage) or the according manual to the WIKA DG 10 manometer - For pressure operation a pressure reduction is mandatory - After measurement the vessel has to depressurised and opened/ flooded with air - In case of harmful gases has to be disposed according to the laws and standards Manometer Valve Current Measurement - On the bottom flange is the possibility to measure the current to the ground 12 Assembling and Operating Instructions KIT DKU 4.0 and Accessories
Pin for current measurement - With a jumper it s possible to bridge the connection (Pin) to ground or not. For the measuring instrument banana cables can be used Electrode Set and Insert The insert is placed in the inside of the vessel. With the insert and the electrode set it s possible to measure different high voltage breakdowns in different electrode arrangements. Long term flashes should be avoided and damped with a KIT damping resistor with the minimum resistance of 2.5 MΩ. KIT DKU 4.0 and Accessories Assembling and Operating Instructions 13
- For easier lifting a hook is placed on the top Electrode Set Configurations - For the insert different electrode configurations can be done. All electrodes are equipped with a metric thread - Different high adjustment can be done by configure the length of the spacers. - The bottom and top spacer can be screwed out with a pin. The pin in magmatic and can be stored at the bottom of the insert 14 Assembling and Operating Instructions KIT DKU 4.0 and Accessories
Oiltesting CUP (Option) - The Oiltesting Cup for the insert should be mountend like in the shown picture below - The shorter support should be screwd in the top flange at the insert, the longer into the bottom - By livting up and truning the oiltesting cub can be putted in and out of the insert - The electrode distance can be adjusted by turning the electrodes KIT DKU 4.0 and Accessories Assembling and Operating Instructions 15
Corona Cage (Option) The corona change is an insert for the DKU pressure vessel. With the corona cage different lightning phenomena in different atmospheres can be shown. The corona cage is only made for short time use. Long term flashes should be avoided and damped with a KIT damping resistor with the minimum resistance of 2.5 MΩ. Open the Corona Cage - The corona cage can be opened by opening three Trox screws on the top header - In the middle of the cage different wires with different diameters can be mounted 16 Assembling and Operating Instructions KIT DKU 4.0 and Accessories
1) Cut the wire to the correct length by using the two markers on the side of the flanges. The wire should be as long as the distance between the markers (small groves) 2) The two metal cylinders could be taken out. (one by opening the cage) 3) The wire can be fixed in the holes with a small Alan key screw 4) Cage can be close again 5) From the top the two metal can be insert in the cage Operation without the Tube of the Pressure Vessel - Remove the tube of the pressure vessel by open the top flange and putting out - Install the white rings by opening the corona cage on the top and the bottom flange - The rings should fit tight on the 45 edge on the flanges Tightness and Safety Tests Routine Test - Tightness test with 12 bar rel. - Adjustment of pressure relief valve Type Test - SF6 losses lower than 0.6 ppm/h at 2 bar rel. - Vibration test according to ISO - Climate test according to IEC (max. temperature 60 C; min. temperature - 20 C) KIT DKU 4.0 and Accessories Tightness and Safety Tests 17
State description and adjustment State Description Solution Lose pressure, vacuum over time (over very long durations it can be normal) Sealing is damaged, tube surface on the edge is damaged, Torque of header is not correct Replace sealing, Replace tube, use the correct Torque, tight the screws again Tube changes colour Manometer doesn t work Ozone, and aggressive gases can be react with the polycarbonate tube Battery empty, auto off is set Replace the tube by a new one Replace battery, set auto off, off (manual pressure indicator) 18 State description and adjustment KIT DKU 4.0 and Accessories
Maintenance Utility Services The concerning information has to be taken from the manuals of the individual components. Support, Maintenance The Polycarbonate tube of the DKU can be change the colour during operation with different gases. For that reason the tube has to be changed when the colour change can be recognised. The polycarbonate tube can be easily changed by opening the top header and pulling out the tube. The time for the colour change can be different and depends on the gas and the duration how long the gas is inside. Cleaning According to the sensitive surface of the Polycarbonate cylinder no chemical cleaner are allowed. Repairs A specialist should generally only do reparations. This means, by a specialist of Haefely Hipotronics or by a Haefely Hipotronics authorised person. The action has to be taken from the respective component manual and/or to be discussed with the customer support of Haefely Hipotronics. To warrant adequate servicing, no general instructions for repair can be given! KIT DKU 4.0 and Accessories Maintenance 19
Spare Parts Basically, only original replacement parts can be used. Original or equivalent replacement parts can be obtained by Haefely Hipotronics. For an efficient work, the customer support needs the following system specific information: - Project number of system. - Client s name. - System name plate information of the main components, which contains the replaceable part. - Detailed description of the component that has to be replaced, if possible with picture. - Type of installation. 20 Maintenance KIT DKU 4.0 and Accessories
Onward Transfers Resale Haefely Hipotronics has to be informed if the test equipment will be sold to a third company. In case of a resale the equipment has to be sold complete including all operating instructions, test reports etc. If the equipment is resold without information to Haefely Hipotronics, Haefely Hipotronics rejects any warranty, liability and claims. Shut Down Procedure If the KIT DKU 4.0 has to be stored the following items have to be checked: - Disconnect measuring cables. - The floor of the storage place must be suitable concerning the load capacity - The storage temperature has to be in range of -5... +40 C - The maximum humidity should be <90 % (non condensing) The component specific recommendations have to be taken from the concerning manuals. Taking Back The question of taking back has to be discussed individually. Please contact the customer support of Haefely Hipotronics. KIT DKU 4.0 and Accessories Onward Transfers 21
Training, Education Training Before a person works with or on a system or its components, it is absolutely necessary to instruct him/her by a trained person. Education If the system is operated irregularly, periodic training helps to prevent user faults and increases user security visibility. 22 Training, Education KIT DKU 4.0 and Accessories