Fully Automated 600 kV Impulse Voltage Generator with IEC and UL Certification for Lightning Surge Testing
| Weight: | 15 Kg | Current capacity: | 0-10A |
| Voltage accuracy: | ±1% | Current accuracy: | ±1% |
| Dimensions: | 400mm X 300mm X 200mm | Frequency range: | 50/60 Hz |
1.1 This parameter applies to the equipment subject to this quotation, providing technical specifications covering its functional design, structure, performance, installation, and testing.
1.2 This equipment complies with current international standards, national standards, and relevant industry standards.
- GB311.1-1997: Insulation Coordination for High-Voltage Power Transmission and Transformation Equipment
- GB/T 16927.1-1997 High Voltage Testing Technology: General Test Requirements
- GB/T 16927.2-1997 High Voltage Testing Technology: Measurement System
- GB/T 16896.1-1997 Digital recorder for high-voltage impulse testing
- ZB F24 001-90 Detailed Implementation Rules for Impact Voltage Measurement
- GB191 Packaging and Transportation Marking
- GB4208 Case Protection Rating
- GB813-89 Oscilloscope and Peak Meter for Impact Testing
This impulse voltage generator test system is primarily designed for full-wave lightning impulse voltage testing of power products rated at 110 kV and below, and can also be used for impulse testing of other products.
- The altitude shall not exceed 1500 m
- Ambient temperature: -15°C to +50°C
- Relative air humidity: ≤90%
- Installation and Usage Location: For indoor use only; portable.
- A shielded control room and a reliable grounding point must be installed, with a grounding resistance of <1Ω!
- Nominal lightning surge voltage: HGCJ-600kV
- Nominal capacity (energy): 40 kJ
- Grade capacitor: 1.5μF, 100kV (MWF100kV-1.5μF), dry-type fully insulated package
- Grade voltage: ±100 kV
- Series/Stage Capacity: 6 / 7.5 kJ
- Output waveform: ±1.2/50 μs standard lightning impulse voltage full-wave, with an efficiency exceeding 90%; A steep wave with a slope greater than or equal to 3500 kV/μs; Standard lightning impulse waveform cut-off at 2–6 μs.
- Synchronization range: greater than 20%
- Duration of Use: It can operate continuously at voltages below 80% of the rated operating voltage. It can operate intermittently when the voltage exceeds 80% of the rated operating voltage.
- The amplitude adjustment error voltage difference shall be less than 1%, and the minimum output power shall not exceed 10% of the equipment's nominal voltage.
- Synchronous false trip rate: less than 1%
- Base: 2 m * 1.5 m (movable on casters). Height: Approximately 3.3 meters. Weight: Approximately 560 kg.
- The main circuit design employs the SGS series from Swiss company HAEFELY, achieving an overall ultra-compact size.
- The low-speed gear-rack transmission mechanism operating at one revolution per minute enables precise adjustment of ball clearance across all levels, offering not only noise-free operation and minimal wear but also rapid and accurate positioning.
- The wave-shaping resistor is secured using a spring-clamped, easy-to-insertion-and-extraction mechanism, ensuring reliable contact and producing a smooth, burr-free output waveform.
- The pulse amplifier integrated with the HGCS2008 control system provides a trigger range of over 20% for the synchronous ball gap, ensuring reliable triggering and enabling convenient, reliable fully automatic control.
- The synchronous ball gap triggers the non-polarity effect without requiring bilateral triggering.
- The main capacitors are high-density solid-state capacitors, each with a capacitance of 1.5 ± 0.05 μF and a DC operating voltage of ±100 kV. These capacitors feature an inherent inductance of less than 0.2 μH, offering lightweight and compact design—a pioneering innovation in China.
- Under normal operating conditions and environments, the deformation of capacitors due to surface irregularities shall be less than 1 mm.
- The capacitor features a solid insulating medium and a dry, fully insulated enclosure, eliminating issues such as oil leakage or deformation.
- The wave head and wave tail resistors possess sufficient thermal capacity to ensure the generator operates continuously for extended periods.
- The charging resistor possesses sufficient thermal capacity to ensure the generator operates continuously for extended periods.
- The wave head and wave tail resistors feature a plate-shaped structure, wound with non-inductive Kang copper wire, with an external insulation resin vacuum cast layer. The joints employ spring crimping technology for easy installation.
- The connectors for the wave head and wave tail resistors are manufactured using 3 mm stainless steel wire cutting.
- A total of one set of half-wavehead resistors and two sets of half-wavetail resistors are used for lightning surge protection, along with one set each of charging resistors and protective resistors.
The HGCS2008 fully automatic control system provides comprehensive control functions for the main unit of the impulse voltage generator, fully meeting all requirements for impulse testing. The HGCS2008 control system employs imported components and connects to the equipment main body via a two-core optical cable.
4.2.4.1 The HGCS2008 fully automatic control system employs Mitsubishi Corporation's FX2N series programmable controllers as its core component, resulting in a compact design housed within a standard 19-inch 4U international chassis, functioning as an independent unit. The controller supports both manual and automatic control modes and features a computer interface for integration with dedicated software packages, enabling intelligent computer-controlled operation. These software packages can be used in conjunction with peak voltage meters and oscilloscopes for measurement and waveform analysis, achieving integrated computerized measurement and control in the impulse voltage testing system.
The HGCS2008 fully automatic control system's main operating unit (and auxiliary operating unit) employs Mitsubishi Corporation's graphical human-machine interface display as its input/output control device. The unit features a compact design with a standard 19-inch 7U chassis compliant with international specifications, where all control commands and status displays are presented via the interface display. The unit connects to computers via an RS232 interface, and specialized control software packages enable computers to perform all fully automated measurement and control operations.
4.2.4.2 The control system possesses the following control functions: By employing PLC technology and using dual-core optical fibers to transmit control commands and feedback device status, electromagnetic interference is avoided, thereby enhancing the security of both the control system and the computer. The control functions include manual, fully automatic, and program-controlled modes, with each level operating independently to ensure system reliability. It employs a thyristor-based voltage regulation method and features a charging voltage feedback measurement system. The ignition gap and cutting gap distances can be adjusted manually or automatically, with the adjustments displayed on the LCD panel. It features an adjustable delay cut-off trigger pulse and a feedback system activated by the generator ignition. By employing a function-controlled constant-current charging method, the stability of the charging voltage can reach 0.5%. The LCD panel displays the charging voltage and charging process of the impact generator with an accuracy of 1%. The charging voltage and duration can be directly input via the LCD panel. Equipped with abnormal charging protection functionality, capable of automatically or manually generating trigger ignition pulses. An indication of the shock generator's operating status, such as spontaneous combustion, untriggered, abnormal charging, or stable charging. Grounding and grounding release control for the main unit and charging section of the device. The charging voltage polarity can be automatically switched using the button on the controller. A charging process that allows automatic or manual control of the charging voltage The alarm can be activated automatically or manually. Automatic protection against overcurrent and overvoltage
4.2.4.3 Synchronous Ball Gap: The first stage employs a three-electrode ball gap trigger with a trigger range exceeding 20%.
- An electromagnetic automatic grounding mechanism connects the first-stage capacitor of the generator to ground via a grounding resistor.
- Grounding operations and charging control are equipped with interlocking protection to ensure safe and proper operation.
| Parameter | Value 1 | Value 2 |
|---|---|---|
| Model | HG-LGR-100/100 | HG-LGR-100/100 |
| Rated voltage | Un = 100 kV DC (positive or negative polarity) | Un = 100 kV DC (positive or negative polarity) |
| Rated current | In = 100 mA (at rated voltage) | In = 100 mA (at rated voltage) |
| Voltage Control | Silicon-controlled rectifier module for voltage regulation, with a range of 0% to 100%. | Silicon-controlled rectifier module for voltage regulation, with a range of 0% to 100%. |
| Polarity Conversion | Manual adjustment of the direction of the high-voltage silicon stack | Manual adjustment of the direction of the high-voltage silicon stack |
| Input voltage | 220V single-phase voltage | 220V single-phase voltage |
| Power frequency | 50/60 Hz | 50/60 Hz |
| Power consumption | Approximately 5 kVA | Approximately 5 kVA |
| Parameter | Value 1 | Value 2 |
|---|---|---|
| Model | HG-CR600kV/600pF | HG-CR600kV/600pF |
| Rated voltage | 600 kV | 600 kV |
| Rated capacitance | 600 pF | 600 pF |
| Number of capacitor cells | 2 cells | 2 cells |
| Capacitance per unit | 1200 pF (MWF400-1200 pulse capacitor) | 1200 pF (MWF400-1200 pulse capacitor) |
| Square wave response | Partial response time less than 100 ns, overshoot less than 10% | Partial response time less than 100 ns, overshoot less than 10% |
| Pressure division ratio | Approximately 500 | Approximately 500 |
| Uncertainty of voltage division ratio | less than 1% | less than 1% |
| Parameter | Value 1 | Value 2 |
|---|---|---|
| Model | HG-MC600kV | HG-MC600kV |
| Rated voltage | 600 kV | 600 kV |
| Spherical gap configuration | 300 mm diameter hemispherical gap | 300 mm diameter hemispherical gap |
| Trigger method | Three-electrode discharge triggering | Three-electrode discharge triggering |
| (A high-performance pulse amplifier delivers a 15 kV output with a 100 ns trigger pulse) | (A high-performance pulse amplifier delivers a 15 kV output with a 100 ns trigger pulse) | |
| Delay method | An adjustable electronic delay circuit with a delay range of 2–6 μs provides a wave-cutting trigger pulse. | An adjustable electronic delay circuit with a delay range of 2–6 μs provides a wave-cutting trigger pulse. |
| (When used with the HGCS2008 control system, the potentiometer allows fine-tuning of the signal cutoff delay time.) | (When used with the HGCS2008 control system, the potentiometer allows fine-tuning of the signal cutoff delay time.) | |
| Wave-cut dispersion | The standard deviation of wave-cut time is less than 0.1 μs | The standard deviation of wave-cut time is less than 0.1 μs |
| Parameter | Value 1 | Value 2 |
|---|---|---|
| Model | DIMS-3000 Digital Impact Measurement System | DIMS-3000 Digital Impact Measurement System |
| Amplitude measurement | HG (IPM) 23 impact peak voltage meter | HG (IPM) 23 impact peak voltage meter |
| Input range | 150V to 1600V (impulse voltage) | 150V to 1600V (impulse voltage) |
| Measurement uncertainty | less than 1% | less than 1% |
| Waveform measurement | TDS3012C digital oscilloscope | TDS3012C digital oscilloscope |
| Maximum sampling rate | 1.25 GS/s, bandwidth greater than 100 MHz, resolution: 9 bits | 1.25 GS/s, bandwidth greater than 100 MHz, resolution: 9 bits |
| The record length is 10 KB (sufficient for impact test requirements) with 2 channels. | The record length is 10 KB (sufficient for impact test requirements) with 2 channels. | |
| Waveform Analysis | 19-inch industrial control computer workstation (equipped with a 15-inch LCD display) | 19-inch industrial control computer workstation (equipped with a 15-inch LCD display) |
| Specialized software package for impact measurement: Calculation and Display of Shock Wave Shape Parameters Waveform Comparison Function Amplification, reduction, and translation of waveforms Storage and Retrieval of Waveform Data Waveform plotting and report preparation | Specialized software package for impact measurement: Calculation and Display of Shock Wave Shape Parameters Waveform Comparison Function Amplification, reduction, and translation of waveforms Storage and Retrieval of Waveform Data Waveform plotting and report preparation | |
| Appendix | Two high-performance 100x dedicated attenuators | Two high-performance 100x dedicated attenuators |
| 1 A4 format inkjet printer | 1 A4 format inkjet printer | |
| Isolation, filtering, and shielding design | Isolation, filtering, and shielding design |
The main components of the HGCS-2008 fully automatic control system are listed in the table below.
| Part Name | function declaration | installation site |
|---|---|---|
| control cabinet | Provide various control commands | installed on the base of the generator itself |
| Pulse Amplifier 1 | Generator body spherical gap triggering | installed on the base of the generator itself |
| block capacitor | High-voltage DC current that isolates the trigger pulse | Installed near the first ball gap of the generator |
| Ignition feedback voltage divider | Detect the triggering condition of the generator gap | installed on the base of the generator itself |
| DC voltage divider | Measurement generator charging voltage | installed on the base of the generator itself |
| Pulse Amplifier 2 | Wave-cutting sphere gap triggering | installed on the wave-cutting base |
| From the operation unit ( option ) | Input of various control commands and parameters, as well as status display | installed on the control cabinet |
| Main Operating Unit | Input of various control commands and parameters, as well as status display | installed on the control panel in the control room. |
| 2-core multimode optical fiber | Connect the control cabinet to the main operating unit. | Connect the control cabinet to the main operating unit. |
It supports manual control, fully automatic control, and program-controlled operation. The main measurement and control functions are as follows:
- DC charging voltage
- Primary current of the transformer
- The distance between the spherical gaps of the generator body
- Truncated gap sphere distance
- The closing status of the main power supply contactor
- The switching status of the grounding device
- Trigger state of the generator ball gap
- Polarity state of the generator charging voltage
The control functions include manual, fully automatic, and program-controlled modes, with each level operating relatively independently. It employs a thyristor-based voltage regulation method and features a charging voltage feedback measurement system. The ignition gap and cutting gap distances can be adjusted manually or automatically, with the adjustments displayed on the LCD panel. It features an adjustable delay cut-off trigger pulse and a feedback system activated by the generator ignition. By employing a function-controlled constant-current charging method, the stability of the charging voltage can reach 0.5%. The LCD panel displays the charging voltage and charging process of the impact generator with an accuracy of 1%. The charging voltage and duration can be directly input via the LCD panel. Equipped with abnormal charging protection functionality, capable of automatically or manually generating trigger ignition pulses. An indication of the shock generator's operating status, such as spontaneous combustion, untriggered, abnormal charging, or stable charging. Grounding and grounding release control for the main unit and charging section of the device. The charging voltage polarity can be automatically switched using the button on the controller. A charging process that allows automatic or manual control of the charging voltage The alarm can be activated automatically or manually. Automatic protection against overcurrent and overvoltage
- overcurrent protection
- excess voltage protection
- Abnormal Charging Protection
- Door interlock system
- Grounding System Interlock
- Polarity conversion linkage
The system features a dedicated program interface with various operational guidance screens. In case of system failures, errors, or improper operations, corresponding prompt dialog boxes will automatically appear. This facilitates comprehensive wave and partial-wave testing of electrical equipment and transformer products, significantly simplifying the operational procedures for technicians and effectively preventing human errors.
Operation interface of the waveform measurement, recording, and analysis software: Impact Control Panel
3D CAD Design and Final Assembly Diagram of the HGCJ-100～500kV Impact Voltage Generator Body
HGCS-2008 Fully Automatic Control System and DIMS-3000 Digital Impact Measurement System
- The optimal voltage for the SGS generator used in this solution is 100 kV, aligning with current domestic and international development trends. Its main structure adopts the design from the world-renowned company HAEFELY, making it the most compact generator available domestically, featuring low inherent inductance and convenient waveform adjustment.
- The control measurement system employed in this solution represents a domestically advanced technological product, with its core component being the FX series programmable controller from Mitsubishi Corporation of Japan. Nearly all control functions are implemented through software programming, resulting in a simple system architecture, minimal peripheral circuit boards, and exceptionally high reliability.
- The integrated design of the measurement and control structure features a peak voltage meter, an LCD display, and an industrial computer, enabling fully automated control, measurement, and analysis. The system operates via an LCD touchscreen with multiple status indicator screens, facilitating intelligent human-machine interaction. By eliminating multi-core control cables in favor of fiber optic communication lines, the system eliminates the need for cable trenches, simplifying and streamlining the control room layout.
- The fiber-optic control and transmission system adopted in this solution is a pioneering innovation among domestic high-voltage test equipment. It establishes fiber-optic connections between control and measurement devices and the main high-voltage equipment, effectively mitigating the adverse effects of elevated ground potential on the measurement and control system during high-voltage testing, eliminating electromagnetic interference caused by control leads, and significantly enhancing system reliability—particularly ensuring superior safety during wave-cutting and steep-wave impact tests.
- The electronic delay circuit employed in the scheme for adjusting the wave-cutting delay enables convenient attainment of a wave-cutting trigger delay ranging from 2 to 6 μs, offering greater simplicity compared to the delay cable approach. A pulse amplifier capable of generating a 15 kV pulse with a 100 ns rise time is used to trigger the wave-cutting interval, ensuring a cutoff time dispersion of less than 0.1 μs.
- The operational interface of the HGCS2008 control and measurement system adopted in the solution fully accounts for the operational characteristics of high-voltage testing, featuring a simple and intuitive design that facilitates operator use. The system incorporates dedicated program operation interfaces, enabling efficient execution of both full-wave and partial-wave transformer tests, significantly simplifying operational procedures and effectively minimizing human error. For the impact testing of transformer-type inductive specimens, the system incorporates various voltage application sequences—including full-wave and truncated-wave modes, as well as 100% and 50% voltage levels. It features dedicated program operation buttons, significantly simplifying operator procedures and effectively minimizing human error.
- This set of impulse voltage generator testing system employs the most advanced technology, refined manufacturing processes, and high-quality raw materials, ensuring long-term reliability with an operational lifespan exceeding 20 years. The daily operating costs are also remarkably low.
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