USER’S MANUAL

AC DIELECTRIC TEST SET

600 SERIES

Model Number 6CP100/50-10

VERSION 3.2

Phenix Technologies, Inc.

75 Speicher Drive
Accident, Maryland 21520

Copyright © Phenix Technologies, Inc.

Rev 5/1/2019 SHB

Rev 8/15/2019 (format) nab

6CP100/50-10
 TABLE OF CONTENTS

DESCRIPTION SECTION NUMBER

DANGER / GENERAL SAFETY PRECAUTIONS

TECHNICAL SPECIFICATIONS 1

UNCRATING PROCEDURE 2

CONTROLS AND INDICATORS 3

INITIAL SET-UP—MECHANICAL / ELECTRICAL 4

OPERATIONAL VERIFICATION / GENERAL TEST 5

CALIBRATION 6

TROUBLESHOOTING 7

MECHANICAL MAINTENANCE 8

CHECKING OIL PURITY / SPECIFICATIONS 9

TRANSPORTING/STORAGE OF EQUIPMENT 10

CIRCUIT DIAGRAM SYMBOLS 11

ELECTRICAL DIAGRAMS 12

PARTS ORDERING INFORMATION 13

RECOMMENDED SPARE PARTS 14

PARTS LIST 15

RETURNED MATERIAL 16

CUSTOMER COMMENTS / SUGGESTIONS 17

ATTACHMENTS
` TAD1U Timer Manual

6CP100/50-10
 DANGER / WARNINGS

WARNING !!

DANGER

Grounding of this unit is necessary for the safe

operation of this equipment. Disconnect inputs before
ungrounding this equipment

6CP100/50-10
 GENERAL SAFETY PRECAUTIONS

This equipment can produce POTENTIALLY LETHAL VOLTAGES!

Improper operation or test practices may result in injury or death to the operator or
surrounding personnel.

The operation of High Voltage test equipment should only be performed by personnel
familiar with HIGH VOLTAGE testing and safety procedures. The operator of this
equipment must be aware of all hazards associated with High Voltage testing. The
operator is responsible for himself and others in close proximity of the testing area.

Some General Safety Practices for working with High Voltage Test Equipment have
been listed below for your reference.

• Become familiar with your instrument before performing an actual test

• Know your work area, check that all circuits are de-energized and locked out.
• Never work alone; always work with another qualified worker.
• Mark off entire work area with barriers and warning tape.
• Make all personnel aware of your testing activities.
• Be aware of dangerous conditions that may arise from energizing a test
specimen.
• Never modify test equipment, modifications to equipment could introduce an
unknown hazard or hinder a designed-in safety feature.
• DO NOT operate damaged equipment. Remove power, and do not use the
equipment until safe operation can be verified by service-trained personnel.

Phenix Technologies, Inc. assumes no liability for unsafe or improper use of test equipment.

6CP100/50-10
 1-1
SECTION 1: TECHNICAL SPECIFICATIONS

Input

220 - 240 volts, single phase, 50/60 Hz, 30 amperes

Output Rating

0 - 50 kilovolts, 200 milliamperes

0 - 100 kilovolts, 100 milliamperes

Duty Cycle – Capacitive Loading

5 minutes ON /15 minutes OFF @ 10 kVA

15 minutes ON / 1 hour OFF @ 7.5 kVA
1 hour ON / 1 hour OFF @ 5 kVA

Type of Cooling

ONAN (Oil Natural / Air Natural Convection)

Operating Ambient Temperature

10 – 40 degrees C

Output Termination

2” Polished Ball – 50 kV
3” x 12” High Voltage Spinning – 100 kV

Metering - Digital

Output Voltmeter: 3 ½ Digit LCD, Accuracy ±(0.8% of reading + 0.2% of range)

Output Currentmeter: 3 ½ Digit LCD, Accuracy ±(0.8% of reading + 0.2% of range)

4 Ranges: 0-200µA, 2mA, 20mA, 200mA

Sizes and Weights

Control/Regulator Section: 21.25” (540mm) W x 16.75" (426mm) D x 13.75" (350mm) H;

63 lbs. (29 kg)

High Voltage Section: 19” (483mm) W x 19” (483mm) D x 29” (734mm) H;

280 lbs. (127 kg)

Additional Equipment

Cart: 22.5” (572mm) W x 29.25” (743mm) D x 50” (1270mm) H;

70 lbs. (32 kg)

Cables: 30 lbs. (14 kg)

6CP100/50-10
 2-1
SECTION 2: UNCRATING PROCEDURE

1. Exercise care in removing shipping materials so as not to damage unit.

2. Perform visual inspection to determine if unit was damaged during shipment. If there are any
signs of physical damage (such as dents, scratches, oil leaks), contact the Service Department at Phenix
Technologies before proceeding.

6CP100/50-10
 3-1
SECTION 3: CONTROLS AND INDICATORS
Control Panel

Figure 3-1

 

  
       

 

PHENIX
TECHNOLOGIES

 
 





 
!

  




   
   

 
 
  
 



!

  



 

The following descriptions are keyed to Figure 3-1:

1. Main Power Indicator.

Illuminates to indicate input power is supplied to unit.

2. Main Power Circuit Breaker

Turns main power of unit on and off and provides input overload protection.

3. F1, F2
Control Power Fuse.

4. Transformer Power Circuit Breaker.

Turns main power to HV tank on and off.

5. Measurement Divider Switch

Selects proper overload and voltmeter circuitry for the H.V. output terminal being used. Match switch
setting to output being used on HV transformer.

6CP100/50-10
 CONTROLS AND INDICATORS
Control Panel (Cont’d)

6. Overload Trip
Use for presetting desired Overcurrent trip setting. Range approximately 10-110% of rated current.3-2

7. Reset
Will light when Overcurrent trip setting is exceeded. Push to reset. Lamp must be extinguished for
H.V. ON.

8. Emergency Off
Push down to stop test immediately. Button must be pulled up to activate High Voltage Output.

9. High Voltage On Switch and Indicator Lamp

Turns on H.V. when Ready indicator is illuminated.

10. High Voltage Off Switch and Indicator Lamp

Turns H.V. off, indicator shows when all conditions are met to turn H.V. ON. (External Interlock closed,
Reset Lamp off, Emergency Off Button pulled up, Voltage Control at Zero).

11. Voltage Control

Adjusts Output Voltage and must be set at zero to turn High Voltage on.

12. Currentmeter Range Selector

Turn to select the desired current measurement range.

13. Output Currentmeter

14. Output Voltmeter

15. Ext. Intlk. – SX1/WX1. Provides for user connection of external interlock or auxiliary safety control
device such as emergency off switch, gate switch, foot switch, dead man switch, etc. Included plug
has shorting jumper installed to complete circuit. Jumper must be removed, and cable connected to
user supplied device by user if desired to use this provision. Only non-energized switch or dry relay
contact devices may be used. This is a series 120VAC circuit that must remain closed for high voltage
to be activated. An optional warning light accessory is also available to plug into this connector and
also make use of the security circuit via a passthrough connector.

16. Output to Transformer

High Voltage Transformer power connection.

17. Main Input

Main input power cable connects here.

18. Ground Terminal

19. TX1
Signal/ Metering cable between H.V. Unit and controls connects here.

20. Timer
Press START/RESET to start the timer after test voltage has been reached. Press START/RESET
again to reset timer to the original setting. Press HV OFF BYPASS to allow high voltage to remain on
after the timer has expired. Test time can be set using the buttons on the face of the timer.

6CP100/50-10
 3-3
CONTROLS AND INDICATORS
High Voltage Transformer
Figure 3-2

The following descriptions are keyed to Figure 3--2:

1. Power Connector
Connect the Power Cable from ‘Output to Transformer’ connector on control box at this point.

2. High Voltage Unit Ground Point

A Ground cable from facility ground or earth ground must be connected here.

3. Guard Binding Post (GRD)

Currents associated with this connection bypass the current meter (meter bypass connection). See
Section 5 for more information on these connections.

4. Ground Binding Post with Jumper Clip (GND) - This binding post is connected to ground. See
Section 5 for more information on these connections.

NOTE: The Jumper Clip must always be connected from Ground to either Return or Guard.

6CP100/50-10
 3-4
CONTROLS AND INDICATORS

High Voltage Transformer (cont’d)

5. Return Binding Post (RTN)

Low potential side of test specimen connects here. This connection routes current through the Current
Meter circuit (metered connection point).

6. TX1 Connector
Signal / Metering cable connects from here to TX1 on control box.

7. 50 kV TAP
For 0 – 50 kV output at 0 – 200 mA – the Measurement Divider switch on the control panel must be
set to 50 kV/200 mA position.

8. 100 kV Tap
For 0 – 100 kV output at 0 – 100 mA - the Measurement Divider switch on the control panel must be
set to 100 kV / 10 mA.

6CP100/50-10
 4-1
SECTION 4: INITIAL SET-UP / MECHANICAL

1. Set up object under test.

2. The area to be used for the test must provide sufficient mechanical and electrical clearances. The
approximate weight of each section is available from the nameplates or the Specification Page.

3. If the unit is to be operated indoors, be sure the floor will be strong enough to support the unit.
If outdoor operation is to be used, the site for the base must be capable of supporting the unit
without any settling that would tilt the assembly.

4. Position the High Voltage Transformer Tank and Control Unit as necessary for operation.

5. Clean entire High Voltage Unit using nothing stronger than ordinary household cleaner to remove all traces
of any surface contamination. This cleaning should also include the High Voltage Electrodes.

6CP100/50-10
 4-2
INITIAL SET-UP / ELECTRICAL

WARNING !

DO NOT OPERATE THE TEST SET

WITHOUT REMOVING HIGH-VOLTAGE
TRANSFORMER FROM THE CART.

THE HIGH-VOLTAGE TRANSFORMER

MUST BE POSITIONED A SAFE DISTANCE
FROM PERSONNEL AND OTHER OBJECTS.

WARNING:
Ground the output of the High Voltage Transformer until set-up is complete! Be sure the Main
Power Circuit Breaker is in the OFF position before proceeding. This equipment should only be
operated by personnel familiar with High Voltage testing and safety procedures.

1. Grounding Connections:

- Tie ground post on control case to ground stud on high voltage cylinder base using copper braid
or jacketed cable with current capacity equal to or greater than the input current.
- Tie ground stud on the high voltage cylinder base to facility ground using copper braid or jacketed
cable with current capacity equal to or greater than the input current.

2. Select the Standard or Guard current metering configuration (see following pages for explanation).
6CP100/50-10
 4-3
INITIAL SET-UP / ELECTRICAL

3. If the external interlock function is to be used, remove the jumper on the male cable end of the
SX1/WX1 connector and connect the external security circuit at these points.

NOTE: The external interlock circuit must consist of a closed loop of dead contacts; an open circuit
prevents the high voltage output from being energized. When the control power is on, the external
circuit will be energized with 120 volts AC.

4. Connect signal / metering cable between High Voltage Transformer TX1 connector and TX1 connector
on the controls.

5. Connect the power cable from the High Voltage Transformer to the ‘Output to Transformer’ connection
on the control box.

6. Connect the test object to the output termination of the high voltage transformer using supplied output
cable. Ensure that the ground connection is applicable for test level and type of test and that the
connection has sufficient safety clearances for the voltage rating. Two high voltage output
connections are possible:

50kV, 200mA: The 50kV tap is located on the side of the high voltage cylinder. Set the Measurement
Divider switch (See Section 4) to the 50 kV/200mA position when using this output.
This sets the metering and overload properly for the output being used.

100kV, 100mA: The 100kV tap is located on the top of the high voltage cylinder. Set the Measurement
Divider switch (See Section 4) to the 100 kV/100mA position when using this output.

A wire can be used to make this connection; however, for best results (less corona leakage current),
route a wire down the center of a one-inch diameter pipe (aluminum or copper) and solidly connect the
ends of the wire to the output tap and the test specimen. The pipe should also be solidly connected at
each end.

7. Connect the input main power cable to the Main Input connection at the control box and then to the
facility power source.

6CP100/50-10
 4-4
INITIAL SET-UP / ELECTRICAL

CURRENT METER GUARD CIRCUIT

There are three terminals on the base of the high voltage transformer; white GRD (Guard), green GND
(Ground), and a red RTN (Return). There is a metal jumper that must always be connected between either the
GND and GRD terminals or the GND and RTN terminals.

Refer to Figure 4-1 on the next page:

Standard Mode

In this configuration the current meter measures all leakage current from the high voltage electrode.
Measured current includes specimen leakage and stray leakage.

Guarded Mode

In this configuration only the leakage current from the high voltage electrode through the test
specimen to the RTN terminal is measured by the current meter. Any stray leakage current to ground
is guarded out (bypasses the meter) and is not measured. Stray leakage current to ground can be
from several sources. The high voltage transformer has some capacitive leakage to ground. The high
voltage connection might have some leakage due to partial discharge (corona). The test specimen
might have some leakage current to ground and your application requires that this “stray” leakage not
be measured.

Electrical Setup

In either configuration, the high voltage transformer’s ground stud must always be connected to earth
ground. The GND terminal referred in the following two paragraphs is internally connected to the
ground stud.

For standard current measurement, connect the jumper between the GND and RTN terminals.
Connect the test specimen return (low voltage side) to the RTN terminal.

For guarded current measurement connect the jumper between the GND and GRD terminals.
Connect the test specimen return (low voltage side) to the RTN terminal. Do not connect the
specimen return to ground. The test specimen must be totally isolated from ground.

6CP100/50-10
 4-5
INITIAL SET-UP / ELECTRICAL

CURRENTMETER GUARD CIRCUIT

Figure 4-1

6CP100/50-10
 5-1
SECTION 5: OPERATIONAL VERIFICATION PROCEDURE

WARNING:
This equipment should be used only by personnel familiar with High Voltage testing and safety
procedures.

1. Make sure that Main Power Circuit Breaker on the Control Panel is in OFF position.

2. Make sure that all electrical connections have been properly made between the Controls and High
Voltage Unit, including grounds. Remove Ground from HV Transformer output if it is grounded. There
is to be no connection to the high voltage outputs at this time. There must be adequate clearance
from the High Voltage Unit to allow voltage to be raised safely.

3. Place currentmeter in RTN mode. (Connect jumper of RTN/GND/GRD binding posts between RTN
and GND.)

4. Connect Main Input Power Cable to Controls and to Power Source. Switch the Main Power Circuit
Breaker on the Control Panel to On position. Main Power indicator lamp should illuminate. Check that
the Transformer Power Breaker is on, Emergency Off button is pulled up, Voltage Control is at Zero,
Reset Lamp is Off, and EXT INTLK CKT is complete or has shorting jumper in place. HV Off lamp
should be illuminated.

5. Press HV On switch. Indicator lamp should illuminate. Press the HV Off switch. HV On indicator
lamp should extinguish and HV Off / Ready lamp should illuminate.

NOTE: The following conditions must be met before High Voltage will engage: External Interlock
loop must be closed, Emergency Off switch must be closed (mushroom button up), Overload Reset
Lamp must be off, Voltage Control at Zero Start, and Transformer Power Circuit Breaker on.

6. Set Measurement Divider Switch to 100 kV / 100 mA

7. Press the HV On switch.

8. Manually raise the Voltage Control dial on the Control Panel to approximately 50 (50%). Voltmeter
should indicate voltage change and show approximately 45 to 55 kV.

9. Select 50 kV / 200 mA on Measurement Divider Selector Switch. At 50 on Voltage Control Dial,

voltmeter should read approximately 22 to 28 kV.

10. Return Voltage Control to Zero. Press HV Off switch.

11. Turn Main Power Circuit Breaker off and connect a short between the 50kV High Voltage Output and
Ground. Measurement Divider Switch is to be set at 50 kV / 200 mA.

12. Set Overcurrent Trip to low (1) setting.

6CP100/50-10
 5-2
OPERATIONAL VERIFICATION PROCEDURE

13. Turn Main Power Circuit Breaker on. Press HV On switch and slowly raise voltage with the dial on the
Control Panel. Output Current Meter will indicate changed value, and at approximately 10% of output
current rating, the High Voltage will trip off and the Overcurrent Indicator Lamp will illuminate. With the
front panel Overload Selector Switch set at 50 kV/200 mA, the trip point should be at approximately 20
mA. Return Voltage Control to zero and turn off Main Power Circuit breaker.

14. Move short from 50 kV output to 100 kV output and ground. Repeat step 13. Unit should trip off at
approximately 10 mA.

NOTE: Do not attempt to check 110% level of current trip under shorted output conditions. Rated output
currents are only available through a capacitive load of sufficient value. Shorted current values should
never exceed 50% of rated currents for the High Voltage Tap being used. If desired to test at 110% of
current rating, the 50kV/200mA tap must be connected to a High Voltage Capacitor of approximately 6.5
nanofarads rated at 50 kVAC or higher (for 50 Hz).

15. Turn Off Main Power Circuit Breaker on Control Panel.

END OF OPERATIONAL VERIFICATION TEST!

6CP100/50-10
 5-3
GENERAL TEST PROCEDURE

1. Make sure that Main Power Circuit Breaker on the Control Panel is in the Off position.

2. Make sure that all electrical connections have been properly and securely made, and that the test
specimen is properly connected to the High Voltage Transformer (refer to Initial Set-up Procedures).
Make sure the Guard / Ground / Return Jumper Clip is set properly for test being performed. Make
sure all personnel are clear of danger and test area is clearly marked.

3. Connect Input Cable to Controls and to Power Source. Switch the Main Power Circuit Breaker on the
Control Panel to the On position.

4. Set Measurement Divider switch to the position that matches the High Voltage output being used.

5. Set Overload Trip dial to desired trip-out level.

NOTE: In setting this device, it is important to consider the capacitive current that the sample under
test will require. Set the dial to a high enough value to preclude false failure indications. If this value
is not known, it is recommended that the dial be left in a higher setting.)

6. Press the HV On switch.

NOTE: The following conditions must be met before High Voltage will engage: Security Circuit Loop
must be closed, Emergency Off Switch must be closed (mushroom button up), Overload Reset Lamp
must be off, Voltage Control at Zero Start, Transformer Power Circuit Breaker on, and Ready lamp
illuminated.)

7. Raise the manual Voltage Control knob on the Control Panel until desired test voltage level is
reached. Keep voltage at desired level for required duration. Record data if desired.

8. After completion of the test, manually return the Output Voltage to zero or its lowest level via the
Voltage Control knob.

9. Press HV Off momentary switch.

10. If during the test a failure should occur or if the Overcurrent Trip setting is exceeded, the High Voltage
will automatically shut off. In order to regain High Voltage, the Reset pushbutton must be pressed,
and Voltage Control knob returned to Zero.

6CP100/50-10
 6-1
SECTION 6: CALIBRATION

WARNING:
Calibration should only be done by persons familiar with High Voltage testing and safety
procedures.

All calibrations have been done at the factory. Periodic calibration of the output voltmeter and output
currentmeter should be done annually.

NOTE: Refer to Electrical Diagram Section for schematics pertaining to the model number of your test set.

Locating the Calibration Adjustments

The calibration points are shown in the following diagram.

R19 R17 R113 R84 R82 R80 R78 R77 R87 R72 R69
100 kV 50 kV VOLT 200mA 20mA 2mA 200µA CURRENT RANGE 110% 10%
VM VM OFFSET CM CM CM CM OFFSET OVLD OVLD OVLD

1. Output Voltmeter

Connect a precision high voltage voltmeter across the output to ground on 50 kV output, with
Measurement Divider switch set to 50 kV. Raise the output to approximately 80% of the output rating.
Adjust the reading on the panel meter (M2) by means of potentiometer R17 to a corresponding reading.
Repeat procedure with precision high voltage voltmeter connected between the 100 kV output and
ground with the Measurement Divider switch set to 100 kV. Adjust R19 to match precision voltmeter at
80% of output rating.

2. Output Currentmeter

It is necessary to connect adequately rated High Voltage loads (isolated from ground) to the high voltage
unit that will allow each full range current to be drawn at approximately 15% or higher output voltage.
This allows sufficient resolution to adjust current levels. All ranges can be calibrated from 50 kV output.

Place Binding Post Configuration in GUARD MODE. (Jumper clip is installed between “GRD” and
“GND” posts.)

Connect a precision ammeter between the low potential side of the appropriate high voltage load and
the “RTN” post. Select the 200 uA meter range. Raise the output to approximately 80% of the range
rating. Adjust the reading on the panel meter (M1) by means of potentiometer R78 to a corresponding
reading. Repeat for 2 mA, 20 mA and 200 mA ranges adjusting R80, R82 and R84, respectively. (High
Voltage load will need to change when changing range).

NOTE: An optional method is to use current injection between RTN and GND (Guard Mode).
Do not turn High Voltage on for this method!
6CP100/50-10
 6-2
CALIBRATION

3. Overcurrent

This calibration should not need adjustment (factory adjusted). If the Overcurrent Circuit is out of
calibration, perform the following steps. To recalibrate the Overcurrent Circuit with the High Voltage Unit it
will be necessary to connect an 8 nanofarad capacitor rated at 50 kVAC or higher to the 50 kV / 150 mA
output of the High Voltage Unit. If the capacitor is isolated from ground at the low potential end, the low
potential end can be connected to the RTN post. The Guard Post Jumper may be connected to GRD
(Guard Mode). If the low potential end of the capacitor is grounded, the Ground Post Jumper must be
connected to RTN post.

a. Set front panel Measurement Divider switch to 50 kV/150mA. When current trip dial is set to
minimum (1) current trip level should be approx. 15mA. When dial is set to maximum (11) trip
level should be approx. 165mA.

b. Set the Overload Trip potentiometer (R15) on the front panel to "1" and the Current Range
switch to 200 mA.

c. Turn on HV On and adjust the output current slowly until 10% of rated current
is displayed on the current meter (15 mA).

d. Adjust potentiometer R69 until the Reset lamp illuminates and

high voltage is shut off.

e. Set the Overcurrent Trip potentiometer (R15) on the front panel to "11."

f. Turn on HV On and adjust the output current slowly until 110% of rated current is
displayed on meter (165 mA).

g. Adjust potentiometer R72 until the Reset Lamp illuminates and

high voltage is shut off.

h. Repeat steps "b" through "g" if necessary, until both settings are calibrated.

4. Range Overcurrent:
R87 sets an overcurrent for the ranges and should be set to trip at approximately 112% of full range
current on medium range setting with current trip potentiometer set at “11.”

5. Voltage offset adjustment (R113):

The voltage offset should be done with the voltage output lead connected to board ground. This typically
can be done by connecting the output to the guard terminal. Once connected, the offset should be
adjusted until the output meter reads nearest to zero. This offset adjustment should be done before
adjustments to the voltage ranges are made. Test point T10 may also be used to make this adjustment.

6. Current offset adjustment (R77):

The current offset should be done with the current input connected to board ground. This typically can be
done by placing a jumper from the guard to the return terminal. Once jumped, the offset should be
adjusted until the output meter reads nearest to zero. This offset adjustment should be done before
adjustments to the current ranges are made. Test point T37 may also be used to make this adjustment.

6CP100/50-10
 7-1
SECTION 7. TROUBLESHOOTING

General

If the controls do not operate properly after having been used according to the instructions, the following
process may help.

Check main facility input power to the test set.

Check all control and switch settings.

Check indicating lamps. (Spare lamps are available through Phenix Technologies.)

Check Fuse F1 and F2

Check operation of main power circuit breaker (CB1). Main Power lamp should be on.

Check Transformer Power circuit breaker.

Check all plug connections, internal and external, on the test set.

Specific Problems

1. High voltage cannot be turned on?

▪ Emergency OFF has been pressed – pull switch button up.

▪ External interlock is open (SX1/WX1).
▪ Voltage Control dial is not in zero start position.
▪ Protection circuit (Overload Trip) is not Reset.
▪ Transformer Power circuit breaker is off or faulty.
▪ Faulty HV On or Off switch.
▪ Faulty relay contacts.

2. Voltage control inoperable?

▪ Transformer Power circuit breaker faulty.

▪ Problem with power cable between Controls and High Voltage Unit.
▪ High voltage is not on (K8 or K3 not energized or see number 1 above).
▪ Faulty regulator T1.
▪ Faulty step-up transformer in high voltage unit. (T301).

3. Overload Trip inoperable?

▪ Improper sensitivity (adjust Current Trip (R15) on front panel).

▪ Defective U13.
▪ Check the +15 volts DC and -15 volts DC regulator (U16, U17).
▪ Check LP4 (RESET) and relay K7 on PCB 1387.

6CP100/50-10
 7-2
TROUBLESHOOTING

Specific Problems (cont’d)

4. Currentmeter inoperable?

▪ Binding post jumper clip installed between ground and guard with a grounded test object.
▪ Connection between currentmeter and high voltage test specimen return connected improperly.
▪ Meter damaged
▪ Faulty TX1 interconnect cable.
▪ Damaged or inoperative range switch or wiring.
▪ Faulty Circuit on PCB1387.

5. Voltmeter inoperable?

▪ Faulty TX1 interconnect cable.

▪ Meter damaged.
▪ No high voltage present at transformer output.
▪ Damaged or inoperative Measurement Divider Switch.
▪ Faulty circuit on PCB1387.

6. No output voltage from high voltage section?

▪ No input to voltage regulator section, possible problems with K8 or K3, regulator (T1), or with
Transformer Power circuit breaker.
▪ Internal connection broken.
▪ High voltage winding of T2 short circuited.
▪ Refer also to 1 and 2 above.

6CP100/50-10
 8-1
SECTION 8: MECHANICAL MAINTENANCE

General

CAUTION: When cleaning, always have unit disconnected from power source.
No solution or chemical stronger than an ordinary household cleaner should be applied to the cabinet area of
this unit. Care must be used when cleaning the meter faces and console panel. Abrasives may remove
printing and descriptive titles and scratch meter faces. When cleaning, always have unit disconnected from
power source. Never attempt to clean inside the unit as the cleaning solution may cause damage to the
electronic components.

High Voltage Transformer

Surface

All surfaces are finished with heavy duty paints and will provide adequate protection against the elements in
normal use. It is recommended that the finish be wiped down for longer life and also for proper electrical
operation of the unit. Also inspect all fabrication joints for oil leakage. If a leak is found, consult factory.

Control Box / Regulator Section

At least once every year, the control assembly should be removed for inspection of the regulator assembly and
other parts. If dust and dirt are present, cleaning with a dry brush and air hose should be sufficient. Inspect
the voltage regulator contact surfaces for any signs of burning or wear. The brushes are the carbon type and
are constructed to provide a 1/8" wide contact point. If they are worn down to be nearing (approximately) 1/32"
at the wider part of the brush, they should be replaced.

The only other mechanical maintenance needed on the control box is that it be kept clean.

Transformer Oil Maintenance

At time intervals ranging from six months to one year, the oil purity (see next page) should be checked in the
high voltage transformer to verify its reliability. If the transformer is subject to adverse weather conditions or
an oil leak develops, the oil purity should be checked regularly.

6CP100/50-10
 9-1
SECTION 9: CHECKING OIL PURITY

NOTE: Typical test data for the oil used by Phenix Technologies are provided at the end of this section.

1. The most reliable means of determining the purity of the oil in the field is to test the dielectric strength. Test
sets for this purpose available on the market differ in design, particularly in the shape of the electrodes and the
test container. Tests on samples from the same oil carried out with electrodes of different types give different
breakdown values for the same distance between the electrodes. Oil test values should therefore always be
accompanied by information about the type of test gap used. The most common types of test gaps are:

a. Cylinder gap.

b. Spheres, 12.5 m in diameter.

c. Flat discs, 25 mm in diameter.

d. Segments of spheres, 35 mm in diameter, radius of sphere 25 mm.

Phenix employs for field testing Gap C, flat discs, which is per ASTM specification D-877.

2. Regardless of which type of test gap is used, it is important that container and electrodes be well cleaned
and dried before oil filling. Cleaning should be done per the instructions with the oil testing equipment.

3. Sample the oil both at the top and the bottom of the transformer, if possible. In general, with small
(portable) transformers, it may not be practical to sample the bottom oil. Phenix recommends a minimum test
level of 30 kV when using the ASTM D-877 test procedure. If the oil tests lower than this, consult Phenix
Technologies’ Service Department for recommendations. Generally, for small (portable) transformers with
small oil volumes, draining and refilling with new or repurified oil will be recommended. If filtering is
recommended, proceed as follows:

a. Perform the purification of contaminated oil in a transformer by circulating the oil between the
transformer and the purification plant, drawing off the oil at the base and returning it at the top of the
transformer. If the oil is heated in the purification plant, a stratification of heated and unheated oil will take
place in the transformer. As the different oil layers mix very little, the circulation of the oil quantity will be more
effective, thus reducing the time needed for treatment of the oil. Circulation of the oil is carried on until oil tests
indicate that the desired oil quality is obtained. After circulation, the oil level is adjusted in accordance with the
instruction plate on the transformer to the correct level at the prevailing oil temperature.

b. When making or changing connections, always fill the feed hose completely with oil before opening
the bottom valve on the transformer. If this precaution is not taken, the air in the hose, which may have
considerable volume, will be forced into the transformer with the oil stream.

NOTE: If air has been injected into the oil, it is recommended that a period of two days be allowed after
completion of oil filling until energizing to allow the oil to absorb any occluded air or gas in the insulation.

4. Oil Specifications

Transformer oil is a high-quality insulating oil specially refined and formulated to meet the exacting
requirements of major electrical equipment manufacturers and users. It also meets Federal Specification VV-I-
530a.

High quality mineral-based transformer oil is recommended as the insulating and cooling medium for oil-
immersed transformers. It is also recommended for arc-forming apparatus such as switches, circuit breakers,
tap changers, reclosers, and fuses. General Characteristics of transformer oil include:

6CP100/50-10
 9-2
CHECKING OIL PURITY
a. High Dielectric Strength:

Transformer Oil has high electrical insulating values as shown by their dielectric strengths of over 30,000 volts.

b. Excellent Oxidation Stability:

Excellent oxidation stability and high resistance to sludging provide protection, particularly where high
temperatures are likely to be encountered. These products are specially refined to ensure long time service
with a minimum of maintenance.

c. Freedom From Contaminants:

Absence of organic acids, corrosive sulfur, and other foreign materials, which might affect metals or insulation,
ensures long life for the oil as well as the electrical units.

d. High Interfacial Tension:

High interfacial tension shows the absence of soluble polar contaminants. Refinery sealed containers assure
maintenance of purity in transit.

e. Good Heat Transfer Properties:

Good circulation and rapid transfer of heat from the coils to the cooling fins are assured by low viscosities at all
operating temperatures.

Typical Test Data for Transformer Oil

TEST METHOD UNITS SPECIFICATION

Moisture ASTM D1533 Mg/kg 35 max
Color ASTM D1500 ASTM 0.5 max
DDF (Power Factor) @100ºC ASTM D924 0.3 max 0.3 max
Breakdown voltage (2mm gap) ASTM D1816 kV 35 min
Inhibitor Content ASTM D2668 %w/w 0.30 max
Interfacial tension ASTM D971 dynes/cm 40 min
Density @15ºC ASTM D1298 g/ml 0.91 max
Viscosity @ 100ºC ASTM D445 cSt 3.0 max
Viscosity @ 40ºC ASTM D445 cSt 12.0 max
Viscosity @ 0ºC ASTM D445 cSt 76.0 max
Refractive Index ASTM 1218 Units
Carbon N% ASTM D2140 %
Carbon A% ASTM D2140 %
Carbon P% ASTM D2140 %
Corrosive Sulfur ASTM D1275B Noncorrosive
PCBs – Detection Unit 1 mg/kg ASTM D4059 mg/kg Not Detected
Flash Point ASTM D92 0ºC 145 min

6CP100/50-10
 10-1
SECTION 10: TRANSPORTING / STORAGE OF EQUIPMENT

In some instances, there is a requirement for transporting the equipment from one location to another for on-
site field testing. If such conditions prevail, the following precautions should be adhered to.

1. Control Box / Regulator Section

Anchor sufficiently to prevent movement during shipment and cover with a canvas or other protective
covering to prevent damage during transport.

2. Interconnect Cables

The connectors, both male and female ends, should be covered to prevent foreign matter from entering.

3. High Voltage Transformer

Anchor sufficiently to prevent movement during transport and cover with a canvas or other protective
covering to prevent damages during transport. Prior to operation, all insulating materials and bushings
should be cleaned. Protective caps should be in place on connectors.

STORAGE OF EQUIPMENT

If the equipment will be stored for a prolonged period, the following precautions are recommended.

1. The equipment should be covered and kept in a warm, dry environment (95% maximum humidity, 5 to 50
degrees C).

2. If the high voltage transformer is to be stored outdoors, it should be completely covered to prevent
damage from environmental conditions.

3. In no case should the control box be stored outdoors, unless previously specified in the original purchase
agreement.

4. Prior to placing the equipment back into operation, all aspects of the maintenance schedule should be
strictly adhered to.

6CP100/50-10
 11-1
SECTION 11: CIRCUIT DIAGRAM SYMBOLS
CIRCUIT DIAGRAM SYMBOLS
SYMBOLES POUR SCHEMA DE CIRCUIT
SYMBOLE ZU SCHEMA

REF SYMBOL DESCRIPTION DESCRIPTION BEMENKUNG

A Amplifier Unite d'amplificateur Verstarker

ARSR Surge Arrestor Parafoudre Ueberspannungsableiter

C Capacitor Condensateur Kondensator

BSHG Bushing Tranversee Durchfuehoung

C Electrolytic Capacitor Condensateur electrol Eleckrolytik kondensator

F Fuse Fusible Sicherung

CT Current Transfomer Transformateur de Stromtransformer
Courant
CB Circuit Breaker Interupteur Unterbrecher

K Relay, Contactor Relais, Contacteur Relais, Schutz

L Inductor Self Drossel, Spule

MOT Motor Moteur Motor

MOV Movistor Parafoudre Movistor

NE Neon Parafoudre Ueberspannungsableiter

LP Lamp, Indicator Lampe Meldeleuchte

R Resistor Resistance Widerstand

R Variable Resisitor Resistance Variable Widerstand

T Transformer Transformateur Transformer

TB Terminal Block Borne Losbare Klemme

X Connector Prise de Courant Steckverbindung

Relay Contact Contact Normalement Schlierskontakt

K Normally Open Ouvert

K Relay Contact Contact Normalement Oeffnungskontakt

Normally Closed Ferme

K Changeover Contact Contact de Umschaltkontakt

Changement
Shielded Wire Cable blinde Abgeschirmetes Kabel

TR Transistor Transisteur Transistor

M Analog Meter Insrument Analogue Analog Meter

D Diode Diode Diode

Z Zener Diode Zener Zener

SCR Thyristor Thyristor Thyristor

SW Normally Open Interrupteur Normalement Schrittschalter

Maintained Switch Maintenu Ouvert (Schliesser)

SW Normally Closed Interrupteur Normalement Schrittshalter

Maintained Switch Maintenu Ferme (Oeffner)

SW Normally Closed Interrupteur Normalement Druckschalter

Momentary Switch Ferme Momentanement (Oeffner)

SW Normally Open Interrupteur Normalement Druckschalter

Momentary Switch Ouvert Momentanement (Schliesser)

DP Current Overload Dispositif De Sur UeberstromschutzEinheit

Device Intensite

6CP100/50-10
 12-1
SECTION 12: ELECTRICAL DIAGRAMS

Drawing Number Description

9602020 6CP100/50-10 (220V, 50/60 Hz) System Diagram

6CP100/50-10
6CP100/50-10
 13-1
SECTION 13: PARTS ORDERING INFORMATION

Replacement parts are available from Phenix Technologies, Inc.

Changes to Phenix Technologies' products are sometimes made to accommodate improved components as
they become available, and to give you the benefit of the latest technical improvements developed in our
Engineering Department. It is, therefore, important when ordering parts to include the serial number of the unit
as well as the part number of the replacement part.

When your purchase order is received at our office, a representative of Phenix Technologies will contact you
to confirm the current price of the part being ordered. If a part you order has been replaced with a new or
improved part, an Applications Engineer will contact you concerning any
change in part number.

Your order for replacement parts should be sent to:

Service Department
Phenix Technologies, Inc.
75 Speicher Drive
Accident, Maryland 21520

PH: 1 (301) 746-8118

Fax: 1 (301) 895-5570
E-mail: info@phenixtech.com

6CP100/50-10
 14-1
SECTION 14: RECOMMENDED SPARE PARTS

Phenix Technologies recommends that the customer purchase and stock the following parts for normal
maintenance of the unit. The recommended quantity should be sufficient to support the unit during normal
operation.

If the unit will be operated at an isolated site for an extended period or will be subjected to unusual stresses, a
larger quantity of parts should be stocked as spares. In such a case, contact your Phenix Technologies' sales
representative for a recommendation.

Current prices may be obtained by contacting the Service Department at Phenix Technologies.

Computer Recommended
Part Name Number Quantity
LCD Meter, KNS 3 ½ Digit DMO-66T 1506400 1

Limit Switch, 2HBA190-1 (SW7) 1866005 1

Switch, Mom., 1 Pole, 31-121.025 EAO 1860120 1

(HV on, HV off, Reset)

Fuse, 0.5 A, 3AG (F1-2) 1603599 2

Rotary Switch –4P, 2-6 Pos. 1863042 1

Relay (K3) 1705460 1

Input Power Cable (220V) 30110028 1

Interconnect Power Cable (220V) 30110007 1

Interconnect Signal / Metering cable 30160001 1

Led 24V White 1420163 3

Led 24V Red 1420162 1

Led 24V Green 1420161 1

6CP100/50-10
 15-1

SECTION 15: 6CP100/50-10 PARTS LIST

Item Part Number Description Quantity

CONTROL SECTION

CB1,2 1601332 30A, 2P CIRCUIT BREAKER 2

CON1 1151183 MALE CONTACT PINS, GOLD 10-8 AWG 3
CON1 1151178 HIGH CURRENT 3 PIN RECPT. 1
CON2 3150167 MS 22-2 F CONNECTOR ASSEMBLY 1
CON2 1151185 FEMALE CONTACT PINS, GOLD, 10-8 AWG 2
D1-D5 1780025 DIODE 1N4007 5
F1-2 1603599 FUSE, AGC-0.5 2
F1-2 1603920 FUSEHOLDER 3AG 2
GND CBL 30080018 20’ GROUND CABLE 1
K3 1705465 FUR.#42BF35AF 30A/3P 1
LP1 1423300 LAMP SOCKET 1
LP1,4,SW10 1420163 LED 24VDC WHITE 3
LP1,SW10,SW11 1422153 LENS, CLEAR 3
LP2 1420162 LED 24VDC RED 1
LP2 1422150 LENS, RED 1
LP3 1420161 LED 24VDC GREEN 1
LP3 1422151 LENS, GREEN 1
LP4 1422148 LENS, BLUE 1
M1,M2 31138800 PCB1388 METER PROTECTION BD 2
M1,M2 1506400 DIGITAL METER, ½ DIGIT LCD 2
M1,M2 1152152 RIBBON CONNECTOR 2
M1,M2 1079909 RIBBON CABLE 6FT
MOV1 1606110 MOVISTOR, V275LA40A 1
PCB1387 31138714 CONTROL/METERING BD 1
R15 1761098 RESISTOR, 10kΩ,2W LINEAR 1
R15 -CAP 1355102 PEAKED CAP 1
R15 KNOB 1355101 POTENTIOMETER KNOB 1
R15-DIAL 1355910 POTENTIOMETER DIAL 1
R15-KNOB 1355905 STATOR BLACK 1
R16A-C 1720201 RESISTOR, 180 Ω, ½ W 3
RTN CBL 30080010 20’ RETURN CABLE 1
SW10 1860265 SWITCH, LATCH 2 POLE 1
SW11 1860260 SWITCH, LATCH 1 POLE 1
SW2-4 1860120 SWITCH, MOM 1 POLE 3
SW5 1863042 ROTARY SWITCH, 4P 2-6POS-S. 1
SW5, SW9 1355310 PEAKED CAP 2
SW7 1866005 ROLLER LIMIT SWITCH 1
SW8 1860900 LATCHING MUSHROOM PB W / KEY 1
SW8 1862905 SIEMENS#3SB3400-OC,NC 1
SW9 1863048 ROTARY SW, 4P, 2-3 POS, SHORTING 1
SX1/WX1 1151147 AMP RECPT. 7 FEMALE PIN, SIZE 13 1
SX1/WX1 1151174 CONTACT PINS, 24-20 AWG FEMALE 6
SX1/WX1 50100018 SX1/WX1 7 PIN PLUG 1
T1 1890239 VARIABLE TRANSFORMER, GE #9T92A40 1
T2 1896017 CONTROL POWER TRANSFORMER, 50VA 1
TMR1 9602133 PANEL MOUNT PROGRAMMABLE TIMER 1
TX1 1151158 MS 18-01S F CHASSIS CONNECTOR 1
TX1 CBL 30160001 METERING INTERCONNECT CABLE 1

6CP100/50-10
 15-2

PARTS LIST
Item Part Number Description Quantity

HIGH VOLTAGE CYLINDER AND BASE

MOV301-303 1606110 V275LA40A MOVISTOR 3

T301 38342713 HIGH VOLTAGE TRANSFORMER, GO1-2713 1
R301A-C 1748351 RESISTOR, 150MΩ,1%,12W, SSX103 3
R302A-B 1748310 RESISTOR, 100MΩ,1%,12W, SSX103 2
SPG301-304 1605110 CG90L SPARKGAP 4
BP-GROUND 1351103 BINDING POST 459 GREEN 1
BP-GUARD 1351104 BINDING POST 459 WHITE 1
BP-RETURN 1351102 BINDING POST 459 RED 1
BP-SHORT BAR 1351110 SHORTING BAR 1
CON3 1151178 HIGH CURRENT RECPT. 3M PIN 1
CON3 1151183 MALE CONTACT PINS, GOLD 10-8AWG 2
D301-4 1780066 TRANZORB, 10V 4
R302A,B 1748310 12W, 100MΩ, 1% 2
R303-304 1724400 RESISTOR, 200kΩ, 1% 2
R305A-C 1720201 RESISTOR, 180Ω, 1%, 0.5W 3
R306-309 1112232 PCB 1223 RESISTOR BOARD 1
R306 1740185 10W, 30, 1% 1
R307 1720600 0.5W, 300 , 1% 1
R308 1722087 0.25W, 3.0K, 1% 1
R309 1722570 0.25W, 30K, 1% 1
SPG301-304 1605110 90V SPARKGAP 4
TX1 1151158 AMP RECPT. 16M PIN SIZE 17 1
TX1 1151170 CONTACT PINS, 24-20 AWG, MALE 10
GNDCBL 30080018 20’ GROUND CABLE 1
RTNCBL 30080010 20’ RETURN CABLE 1

6CP100/50-10
 16-1
SECTION 16: RETURNED MATERIAL

If for any reason it should become necessary to return this equipment to the factory, the Service Department of
Phenix Technologies, Inc. must be given the following information:

Name Plate Information

Model Number
Serial Number
Reason for Return
Cause of Defect

If Phenix Technologies, Inc. deems return of the part appropriate; it will then issue an "Authorization for
Return."

If return is not deemed advisable, other inspection arrangements will be made.

NOTE: Material received at this plant without the proper authorization shall be held as
"Customer's Property" with no service until such time as the proper steps have been taken.

Your cooperation is requested in order to ensure prompt service.

6CP100/50-10
 17-1
SECTION 17: CUSTOMER COMMENTS/SUGGESTIONS

Phenix Technologies made significant efforts to ensure that the materials in this Operator’s
Manual are correct. If there are concerns or comments as you have used this information,
Phenix Technologies appreciates any feedback.

Unit Serial Number:

Sect Page(s) Comment

Please return to Phenix Technologies, Engineering Department, 75 Speicher Drive,

Accident, MD 21520 USA.

Phone: 1 (301) 746-8118, Fax: 1 (301) 895-5570 or Email: info@phenixtech.com

6CP100/50-10