VLF HIGH VOLTAGE TESTER

EPVLF
USER’S GUIDE

EP HIPOT ELECTRIC CO., LTD.

[公司地址]
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Cautions

⚫ The following instructions are used by qualified person to avoid fire

accident and any electrical shock, do not perform any service beyond

operation instructions unless you are qualified to do so.

⚫ Before connecting or removing the cables, please make sure to power

off the tester, and cut off the power supply of whole testing units.

⚫ Please connecting the wire according the wiring diagram strictly, and

wire to the ground reliably. And please cordon off the test area to make

sure the safety and prevent unqualified person entrance, and avoid

accident occurred.

⚫ Don't operate this device in flammable, moist and high temperature

environment. Keep the surface clean and dry, ventilative area free from

corrosive gas.

⚫ Connect cables correctly. The order is to connect the device with ground

first and then to connect with other cables.

⚫ Test operator should keep safe distance from high voltage electrified

apparatus. Don't touch exposed contacts and apparatus when test item

electrified.

⚫ Don’t touch the metal of the test leads to avoid electric shock.
⚫ Please turn off the power after the testing is finished or the user left the

test area.
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⚫ Please make sure the equipment is upright before opening. Don't drop

equipment heavily avoid equipment movement damage.

⚫ Panel should be upright during storage. Elevate stored items to protect

from moisture.

⚫ Please confirm the replaced fuse is same type and rated as the old one.

Warranty

The warranty period for this series is one year from the date of shipment,

please refer to your invoice or shipping documents to determine appropriate

warranty dates. EP Hipot Electric warrants to the original purchaser that this

product will be free from defects in material and workmanship under normal

use. Throughout the warranty period, provide that such defects are not

determined by EP Hipot Electric to have been caused by abuse, misuse,

alteration, improper installation, neglect or adverse environmental condition,

EP Hipot Electric is limited solely to repair or replacement of this instrument

during the warranty period.

Packing List

No. Name Qty

1 Controller 1
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2 HV Booster 1

3 HV Cable 1

4 LV Cable 1

5 Power Cable 1

6 Discharge Rod 1

7 Grounding Wire 1

8 Capacitor 1

9 Fuse 4

10 Print Paper 2

11 User’s Manual 1

12 Test Reports 1

13 Warranty Cert 1

I. Overview

High voltage withstand test of electrical equipment is one of the most

important items specified in insulation preventive test.

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The withstand voltage test can be divided into AC withstand voltage test and

DC withstand voltage test. The AC withstand voltage test can be divided into
power frequency, frequency conversion and 0.1hz ultra-low frequency test

technology, of which 0.1hz ultra-low frequency technology is recommended

by the current international electrotechnical commission. EP Hipot Electric

Co., Ltd. EPVLF adopts 7-inch touch screen, the latest ARM7 single chip

microcomputer, high-speed ad acquisition circuit. It overcomes many

shortcomings of similar products (see table 1), and its cost performance is

much higher than that of similar products. It is especially suitable for

withstand voltage test of electrical equipment with large insulation equivalent

capacitance (such as power cable, power capacitor, large and medium-sized

generator and motor, etc.), which conforms to the national standard of electric

power industry, general technical conditions for ultra-low frequency and high

voltage generator (d) issued in DL/T849.4-2004.

Table 1 performance comparison between mechanical type and electronic

type of 0.1Hz voltage withstand test equipment

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II. Advantages of 0.1Hz ultra-low frequency withstand voltage
technology

The ultra-low frequency insulation withstand voltage test is an alternative to

the power frequency withstand voltage test. In the power frequency withstand

voltage test of large and medium-sized generators, motors, power cables and

other test objects, due to their large capacitance in the insulation layer, a

large capacity test transformer or resonance transformer is required. Some

of these huge equipment is not only heavy and expensive, but also

inconvenient to use. The method of reducing the test frequency and the
capacity of the test power supply is widely used in the world. Replacing power

frequency withstand voltage test with 0.1Hz ultra-low frequency withstand

voltage test can not only have the same equivalence, but also greatly reduce
the volume and weight of the equipment, theoretically, the capacity is about

one fifth of the power frequency, and the operation is simple.

Although the DC voltage withstand test equipment has the advantages of

small size, light weight and low cost, the DC voltage withstand test is also the

most destructive to the insulation of the tested object. Therefore, the latest

national regulations on preventive test of electrical equipment have expressly

stipulated that DC high voltage is no longer used for voltage withstand test of

electrical equipment, and AC voltage withstand test is recommended.

III. technical parameters of series products

1. Product name Description

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2. Technical parameters

1) Output rated voltage: see Table 2

2) Output frequency: 0.1Hz, 0.05Hz, 0.02hz

3) Load capacity:

0.1Hz, maximum 1.1 μ F

0.05Hz Max 2.2 μ F

0.02Hz 5.5 μ F max

4) Measurement accuracy: 3%

5) Voltage positive and negative peak error: ≤ 3%

6) Voltage waveform distortion: ≤ 5%

7) Service conditions: indoor and outdoor; temperature:

- 10 ℃ ~ + 40 ℃; humidity: ≤ 85% RH
8) Power fuse: see Table 2

9) Power supply: voltage 110V, 60Hz

Note: if the portable generator is used for power supply, the output

voltage and frequency of the generator shall be stable (generally the

power is more than 3KW, the frequency is 60Hz, and the voltage is 110V)
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10) The electrical capacity of the test object shall not exceed the maximum

value of the rated electrical capacity of the instrument. See Table 2 for

the value.

Table 2 Main technical parameters of series ultra-low frequency high

voltage generator.

Rated
Model Load capacity Fuse Weight
voltage

0.1Hz ≤1.1µF

EPVLF- 30kV Controller：4kg

0.05Hz ≤2.2µF 10A
30/1.1 （peak） Booster：25kg

0.02Hz ≤5.5µF

0.1Hz ≤1.1µF
EPVLF- 40kV controller：4kg
10A
0.05Hz ≤2.2µF
40/1.1 （peak) Booster：40kg

0.02Hz ≤5.5µF

0.1Hz ≤1.1µF
EPVLF- 50kV Controller：4kg
0.05Hz ≤2.2µF 20A
50/1.1 （peak） Booster：45kg
0.02Hz ≤5.5µF

EPVLF- 60kV 0.1Hz ≤1.1µF 20A Controller: 4 kg

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60/1.1 （peak） 0.05Hz ≤2.2µF Booster：50 kg

0.02Hz ≤5.5µF

0.1Hz ≤1.1µF
EPVLF- 80kV Controller: 4 kg
0.05Hz ≤2.2µF 20A
80/1.1 (Peak) Booster：50 kg
0.02Hz ≤5.5µF

11)Select products of appropriate specifications according to the test

subjects
When in use, the capacitance of the test object shall not exceed the rated

capacitance of the instrument. If the capacitance of the test object is too small,

the output waveform will be affected. If it is less than 0.05 μ F, the instrument
will not output normally. At this time, 0.05 μ f capacitor (provided by EP Hipot

Electric) can be connected in parallel for auxiliary output. See Table 4 and

table 5 for the estimation of capacitance of common electrical equipment.

Table 3 single phase earth capacity of different types of generators.

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Table 4 capacitance of XLPE insulated single core power cable (μ f / km)

12) Estimation method of test object current:

Calculation formula: I = 2 π FCU

IV. Product features

 Advanced technology: digital frequency conversion technology,

microcomputer control, pressure rise, pressure reduction, measurement,

protection, etc

 The test process is fully automated.

 Easy to operate: simple wiring, easy operation.

 Comprehensive protection: multiple protection (over-voltage protection,

over-current protection at high and low voltage sides), rapid action

(when acting)
 Room ≤ 10ms), the instrument is safe and reliable.

 Safety and reliability: the controller is connected with the low voltage of

the high voltage generator, with photoelectric control, safe and reliable

use.

 The high and low voltage closed-loop negative feedback control circuit

is adopted, and the output has no capacity rise effect.

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 Complete configuration: capacitive touch screen, LCD English display,

automatic storage, automatic printing.

 Large test range: 0.1Hz, 0.05Hz and 0.02hz multi frequency selection,

large test range.

 Small volume and light weight: it is very convenient for outdoor operation.

V. Structure and function description

The instrument consists of two parts: controller and booster. The structure

and function of the two parts are as follows:

1. The layout of each part of the controller panel is shown in Figure 1, and

the function description of each part is as follows:

Figure 1. Schematic diagram of the controller panel

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“ ” －Grounding terminal: it is connected with the earth when in use.

"Switch" - power switch: built-in indicator light, on when on, off when

"AC110V" - power input socket, built-in fuse.

“Printer” - print test reports.

"Capacitive touch screen" - display test data and output waveform, and can

be operated directly on the screen by hand.

"USB" - its function is used to communicate with the upper computer.

"Stop" - for emergency stop test.

2. Structure diagram of booster

Figure 2 Schematic diagram of booster structure

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VI. Operation instructions

1. 80kV Very Low frequency output wiring method

Figure 3 wiring diagram

Wiring instructions: connect the control output special line, high voltage

output special line and grounding wire equipped with the product according

to the method shown in Figure 3. The power cord of the power socket is

connected to the AC of 110V / 60Hz.

2. Operation procedure

(1) startup, shutdown and reset

After connecting all the lines according to the above method, the power

switch can be turned on. After the microcomputer is powered on or reset, the

instrument will automatically enter the interface as shown in Figure 4. When

connecting wires, removing wires, or temporarily not using the instrument,

turn off the power supply. The power socket is equipped with a safety tube. If
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there is no display on the start-up screen, check whether the fuse is broken

first, and the size of the fuse shall be replaced according to the data provided

in Table 3.

Figure 4 Schematic diagram of touch screen

(2) Set limited parameters

Figure 5 parameter setting interface

First, click the "setting" button on the screen of Figure 4 to display the setting

parameter interface shown in Figure 5. In Figure 5, the output frequency, test

time, test voltage, overcurrent protection value and overvoltage protection

value on the high voltage side can be set according to the needs of the test.
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The modification method is as follows:

★ There are three options for frequency: 0.1, 0.05 and 0.02 in Hz.

★ Timing modification range: 0-99 points. It specifies the duration of the

test, in minutes.

★ Set voltage: range from 0 to rated value, in kV. It sets the test voltage we

want to raise. When the instrument rises to this set voltage limit, it will no

longer boost voltage, and maintain constant amplitude sine wave output at

this peak value.

★ Set voltage limit: the setting range of voltage protection value is from 0 to

rated value, and in kV. It specifies the upper limit value of the voltage

passing the test object. When the voltage exceeds this setting, the

instrument will automatically cut off the output.

★ Setting current limit: the setting range of current protection value is from

0 to rated value, and in mA. It specifies the upper limit value of current

passing through the test object. When the current exceeds this setting, the

instrument will automatically cut off the output.

(Note: the above voltage, current and measurement data displayed by the

instrument are all peak values.)

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(3) Automatic boosting

After pressing the "start" key in Figure 4, the instrument will carry out the

boosting test under the control of the computer as follows:

Self-inspection → boosting → constant amplitude output → shutdown

The specific process is as follows:

1) Self inspection process

The controller automatically enters the load detection. If no load is detected,

the prompt message "load not connected" in the status bar of Figure 6

indicates that the booster or capacitive test sample is not connected.

Figure 6 the controller indicates that the load is not connected

2) Boosting process

After the self-test is successful, the instrument will automatically enter the

boosting state, as shown in Figure 7, and the prompt message in the status

bar is "boosting". At the same time, the timing began.

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Figure 7 the controller indicates that the voltage is boosting

3) Equal amplitude output

The controller will raise the voltage to the set value in several cycles, and

the instrument will output the equal amplitude, as shown in Figure 8. The

prompt message in the status bar is "equal amplitude output".

Figure 8 constant amplitude output of controller prompt

4) Downtime
When the timing reaches the set time, the instrument will stop automatically,

as shown in Figure 9, and the prompt message in the status bar is "stop the

test".
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Figure 9 controller prompts to stop the test

The instrument stops the high-voltage output and automatically discharges

the test object, as shown in Figure 10. The prompt message in the status bar

is "discharging".

Figure 10 the controller indicates that it is discharging

After the shutdown, as shown in Figure 11, the prompt message in the

status bar is "test passed" and the data history is saved.

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Note: during the test, if there is no abnormal voltage, no discharge or

overcurrent protection, the test can be considered as passed.

Figure 11 controller prompt test passed

This instrument provides two shutdown modes:

★ timed shutdown: when the timing reaches the set time, the instrument will

stop automatically.

★ manual shutdown: click the "shutdown" key to stop the machine.

The two shutdown modes are normal shutdown.

★ there are also two kinds of abnormal shutdown: over-voltage protection

shutdown and over-current protection shutdown.

★ overvoltage protection shutdown

In the process of test, when the output high pressure exceeds the set limit,

the instrument will automatically cut off the output after starting and shutting
down the command, and then execute the data history saving. After shutting

down, as shown in Figure 12, the prompt message in the status bar is "over

voltage protection" and execute the data history saving.

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Figure. 12 controller prompts overvoltage protection

★ overcurrent protection shutdown

In the process of test, when the output current exceeds the set limit, the

instrument will automatically cut off the output after starting and stopping the

command, and then execute the data history saving. After the shutdown, as

shown in Figure 13, the prompt message in the status bar: "overcurrent

protection" and execute the data history saving.

Figure. 13 over current protection prompted by controller

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(4) printing

Click the "print" key in Figure 3 to print the data on the display into a test

report.
Under the status of viewing historical data, click the "print" key to print the

historical data currently displayed on the screen.

(5) view historical data

Figure 14 historical data interface

All the data instruments that have been shut down by timing, clicking the
"stop" key, over-voltage protection and over-current protection will

automatically save them as historical data. It can save up to 64 times of

measured data, and the previous 64 times will be deleted automatically. Click
the "view" key in Figure 3 to open the interface in Figure 13 to view the

historical data of the latest 64 tests.

(6) clock setting

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Figure 15 date and time setting interface

Click the "clock" button in Figure 3 to open the setting interface in Figure

15, which is used to set the date and time of the system.

VII. Power cable withstand voltage test method

1. Disconnect all electrical equipment connected to the tested cable.

2. Use a megger to test the insulation parameters of each phase of the cable,
and carry out the ultra-low frequency withstand voltage test only after the test

is qualified.

3. Set the test voltage value: Umax = 3uo, where uo is the rated phase

voltage of the cable.

Example 1: cable parameter: the rated line voltage is 10kV, and the rated

phase voltage uo = 6kV, so the test voltage setting value is:

Umax = 3uo = 18kV

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See Table 4 for the setting value of 0.1Hz ultra-low frequency test voltage

Rated Handover test Preventive experiment

voltage Test Test

multi Test time multi Test time
U0/US voltage voltage
ple （mins） ple （mins）
(kV) （kV） （kV）

1.8/3 3U0 5 60 3U0 5 15

3.6/6 3U0 11 60 3U0 11 15

6/6 3U0 18 60 3U0 18 15

6/10 3U0 18 60 3U0 18 15

8.7/10 3U0 26 60 3U0 26 15

12/20 3U0 36 60 3U0 36 15

21/35 3U0 63 60 3U0 63 15

26/35 3U0 78 60 3U0 78 15

of various rubber and plastic insulated power cables.

Table 4 0.1Hz ultra-low frequency test voltage and time of various

rubber plastic insulated power cables.

Note: UN is the rated voltage of the cable, and uo is the phase voltage of

the cable.
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4. Test time: 60 minutes for handover test and 15 minutes for preventive test.

5. Setting current value of overcurrent protection:

Estimation method of capacitive current (or leakage current) of ultra-low

frequency withstand voltage test article:

Io=2πfCU=2×3.14×0.1CU(mA)………………… (formula 1)

C is the electric capacity of the cable to the ground, unit: UF; u is the effective

value of the test voltage, unit: kV.

Example 2: a 10KV (UN = 10kV, uo = 8.7kv) cable is 4km long, with a single

phase to ground capacitance of 0.21uf/km and 0.1Hz super

If the low frequency test voltage is 26kv (peak value), the leakage current is
approximately:

Io=2πfCU=2×3.14×0.1CU=0.628×0.21×4×26/ 2 =9.69（mA）

Setting current value of overcurrent protection:

I=kIo………………… (formula 2)

K is the reliability coefficient of overcurrent protection, obviously k > 1

If K is 1.5, the setting current value of overcurrent protection can be taken as

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14.5mA.

6. Test wiring: connect the test equipment and test cable with the special
connection attached with the machine according to the method shown in

Figure 13. Close the power supply after carefully checking the correct wiring,

set the test frequency, time and voltage again, as well as the over-current
protection value and over-voltage protection value on the high-voltage side,

and then start the boosting test.

During the boosting process, the high-voltage circuit shall be closely

monitored to see if there is any abnormal sound in the test cable. When the

test voltage is raised, the instrument will automatically record the test time

and display the test voltage value.

Figure 8 single phase cable withstand voltage test wiring diagram

7. When the test time is up, the instrument will stop automatically. If no
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destructive discharge occurs in the test, it is considered to pass the withstand

voltage test.

8. In the process of boosting and withstand voltage, if it is found that the

output waveform is abnormally distorted, the current is abnormally increased,

the voltage is unstable, and the test cable has peculiar smell, smoke,

abnormal sound or flashing, etc., stop boosting immediately, and find out the
cause after shutdown. If these phenomena are caused by the weak insulation

part of the tested cable, the voltage withstand test is unqualified. If it is

determined that the test cable is polluted due to air humidity or surface dirt,

clean and dry the test cable before test.

9. During the test, if the insulation defect of non-test cable causes over-

current protection of the instrument, the voltage withstand test shall be

carried out again after the cause is found out.

VIII. Withstand voltage test method of synchronous motor

The operation method of ultra-low frequency withstand voltage test for

synchronous motor is similar to the operation method of cable above. The

following is a supplementary explanation of different places.

1. This test can be carried out during handover, overhaul, local replacement
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of winding and routine test. Using 0.1Hz ultra-low frequency to carry out the

voltage withstand test on the motor, the defects of the end insulation of the

generator are more effective than the power frequency voltage withstand test.
The reason is that under the power frequency voltage, the capacitance

current flowing from the wire rod causes a large voltage drop when it flows

through the semiconductor corona proof layer outside the insulation, so that
the voltage on the wire rod insulation at the end is reduced; while under the

ultra-low frequency condition, the capacitance current is greatly reduced, and

the voltage drop on the semiconductor corona proof layer is also greatly

reduced, so the voltage on the end insulation is high, which is convenient.

Defects found.

2. Wiring method: conduct the test in phases, pressurize the tested phase,

and short-circuit the non-tested phase. The test wiring is shown in Figure 14.
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3. According to the regulations, the peak value of test voltage can be

determined according to the following formula 3:

Umax= 2βKUo……………………………… .. (formula 3)

Umax: peak value of 0.1Hz test voltage (kV)

β: the equivalent coefficient of 0.1Hz and 60Hz voltage, according to the

requirements of China's regulations, β is 1.2;

K: setting coefficient, usually 1.3-1.5, generally 1.5

Uo: rated voltage of stator winding of synchronous motor (kV)

For example: for the synchronous motor with rated voltage of 10.5kv, the

peak value calculation method of ultra-low frequency test voltage is as

follows:

Umax= 2 ×1.2×1.5×10.5≈26（kV）

4. Test time setting: the same as the test time of power frequency withstand

voltage, generally 1min.

5. Setting value of overcurrent protection action current: the setting method

is the same as that of cable.

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6. In the process of withstand voltage, if there is no abnormal sound, smell,

smoke and unstable data display, it can be considered that the insulation has
withstood the test. In order to better understand the insulation situation, it is

necessary to monitor the surface state of the insulation, especially the air-

cooled unit. Experience shows that the appearance monitoring can find the
abnormal insulation phenomena of synchronous motor which cannot be

reflected by the instrument, such as surface corona and discharge.

Note: compared with synchronous motor, asynchronous motor has no rotor

winding, and its test wiring is like synchronous motor.

IX. Precautions

1. During the test, please strictly abide by the safety specifications of the high-
pressure test, and operate by professional personnel.

2. In case of any failure of the instrument, do not dismantle and repair it by

yourself, and contact EP Hipot company immediately.

3. After shutdown, discharge the test object fully with discharge rod. After the

discharge is confirmed, remove the wire!

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X. Transportation and preservation

(1) Transportation
The product must be packed during transportation. Cartons can be packed

in cartons or wooden boxes, and foam proof layer should be placed in the

packing box. The packed products shall be able to be transported by road,

railway and air. It shall not be placed in the open truck during transportation.

The warehouse shall be protected from rain, dust and mechanical damage.

(2) Storage

When the instrument is not used at ordinary times, it should be stored in a

room with ambient humidity of - 20 ℃ ~ + 60 ℃, relative humidity of no more

than 85%, ventilation and no corrosive gas. Storage should not be close to

the floor and walls.

(3) Moisture proof

In humid areas or wet seasons, if the instrument is not used for a long time,

it is required to turn on and power on once a month (about two hours) to make
the moisture emission and protect the components.

(4) Anti exposure

When the instrument is used outdoors, direct sunlight exposure shall be

avoided or reduced as much as possible. When the instrument is used

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outdoors, direct sunlight exposure shall be avoided or reduced as much as

possible.

XI. Paper change method of printer

The operation of replacing the paper roll printer is very simple. It does not
need to take out the whole printer. Just press the open button to open the

front cover. Open the front cover as shown in Figure A and take out the

remaining paper core. Then install the new paper roll as shown in Figure B

and close the front cover as shown in Figure C.

Note: when closing the front cover, make the printing paper stretch out from

the paper outlet, put it in the middle position, and let the rubber shaft fully

press the printing paper, otherwise it can't be printed. When the thermal

printer is loading paper, it must be confirmed that the thermal coating of the
thermal paper is on it, and then put the thermal paper into the printer paper

bin. If the thermal coating is not on the correct side, no writing will be printed.

If the printing paper deviates, you can open the front cover again and adjust
the position of the printing paper.
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A How to open the front cover

B Printer in roll

C Close the front cover of the printer

EP Hipot Electric Co. Ltd.

Address: Building 4, No. 888 Hanhuang Road, Daijiashan Science and

Technology Venture City, Jiangan District, Wuhan, P. R. CHINA 430000.

Tel: 0086-185 0719 5668/182 7198 9586

Email: [email protected], [email protected]

Website：www.ephipot.com