Instrument Transformer Testing

System

Manufactured by:ZERA Electric GmbH

Hauptstrasse 392
D 53639 Knigswinter
Germany
Tel no. +49 2223 704 0
Fax no. +49 2223 70470

c)

ZERA GmbH

Instrument Transformer Testing system

Contents

1
2
3

4
5
6

7
8

Introduction:- ........................................................................................................................3
Principle of accuracy testing of CT/PT................................................................................3
Component for instrument transformer testing system ......................................................4
3.1 Voltage regulating unit (Variable transformer)..................................................................4
3.1.1 Electronic voltage regulating unit EVRU xx (EVRU 20 max. 20 kVA) .....................4
3.1.2 Voltage regulating transformer VRT xx (VRT 20 max. 20 kVA) .............................5
3.2 Standard Current Module SCM........................................................................................5
3.3 Standard Voltage Module SVM 60-120.............................................................................7
3.3.1 Voltage generating transformer ................................................................................7
3.3.2 Standard voltage transformer ...................................................................................7
3.4 Current- and voltage measuring unit WM 303 U/I............................................................8
3.5 Standard current burden ..................................................................................................9
3.6 Standard voltage burden ................................................................................................10
3.7 Measuring cabinets ........................................................................................................11
3.7.1 Measuring cabinet...................................................................................................11
3.7.2 Measuring cabinet...................................................................................................12
3.8 PC and software ............................................................................................................12
3.8.1 PC system ..............................................................................................................13
3.8.2 Software package ZERA Checkcon .......................................................................13
3.9 Peak voltage measuring unit..........................................................................................14
3.10 Connecting cables......................................................................................................15
3.11 Accessories................................................................................................................15
Installation ..........................................................................................................................15
Project................................................................................................................................16
How to select appropriate system:-...................................................................................16
6.1 Who wants to test CT/PT combined (automatic testing system).................................16
6.2 Who wants to test only CT, automatic testing system ..................................................17
6.3 Who wants only CT testing system manually/semi auomatically .................................17
6.4 Who wants only PT testing system manually/semi automatically ................................17
6.5 Manually testing system for CT economic version........................................................18
Delivery period ...................................................................................................................18
Enclosure...........................................................................................................................18

ZERA GmbH

Instrument Transformer Testing system

Introduction:ZERA Electric manufactures components and complete testing system for

testing laboratories, to test instrument transformers, with an experience of more than
20 years. We are supplier of world-wide customers, manufactures of instrument
transformers as well as electricity boards.
The system details is described in the following clauses as a standard items to
provide basic information. But nevertheless It is possible to develop or adapt the
system as per customers requirements

Principle of accuracy testing of CT/PT

Standard Current module

Variable Transformer

Current Generating
Transformer

Standard Current
Transformer

CT under test

Standard
Current
Burden
X

Measuring
Shunt
20 bit ADC

20 bit ADC

Microprocessor

PC
WM303I

Figure 1:- Accuracy Testing of CT

Printer

ZERA GmbH

Instrument Transformer Testing system

Standard Voltage module

Standard
Voltage
Burden

Variable Transformer

Voltage Generating
Transformer

Standard Voltage
Transformer

PT under test

Measuring
Shunt
20 bit ADC

20 bit ADC

Microprocessor

PC

Printer

WM303U

Figure 2:- Accuracy Testing of PT

Basic principle of accuracy testing is comparison of unknown CT/PT with standard
CT/PT which accuracy is 20 times better than CT/PT under test and known. This
comparison is done with most precision microprocessor based comparator which
20bit dual ADCs allows the precise detection of signal of standards CT/PT and
CT/PT under test

Component for instrument transformer testing system

Components required for instrument transformer test are described below

3.1

Voltage regulating unit (Variable transformer)

This is suitable for supply of variable voltage to high voltage and current generating
transformers. This is available in two module

3.1.1

Electronic voltage regulating unit EVRU xx (EVRU 20 max. 20 kVA)

This feed variable voltage to high voltage and/or current generating transformers in
automatic testing of CT/PT system, or where power frequency withstand test has to
be conducted.
Mains voltage:

3 x 230/400V, +10% / -15%, 50 / 60 Hz

Output voltage:

0...200V

Output frequency:

40...70 / 400 Hz

ZERA GmbH

Instrument Transformer Testing system

Output power: minimal 8 kVA increasing in steps of 4 kVA (based on the power
requirement for high voltage and current generating unit)
The source is equipped with remote control via PC control by V24 (RS232) interface
or for manual mode by push buttons.
Design of the cabinet as 19-single or double cabinet (depending the output power).
ALTERNATIVE

3.1.2

Voltage regulating transformer VRT xx (VRT 20 max. 20 kVA)

This feed variable voltage to the high voltage or high current generating transformers
manual / semi automatic testing of CT/PT.
Mains voltage:

400 V, 50 or 60 Hz

Output voltage:

selectable to 0...200V or 0...400V

Output power:

max. 10 up to 60 kVA (based on the power requirement for high

voltage and current generating unit)

The output voltage is adjusted manually or through motor controlled from pushbutton
available at control desk.

3.2

Standard Current Module SCM

built into one housing with
- test current generating transformer
- standard current transformer.

This compact design was developed by ZERA to offer a very preferment component
in terms of technology and budget.
The current generating transformer is designed for the connection to the output
voltage 0...200V or 0...400V of the voltage regulating unit of see section 3.1. The
output power of the SCM is the determining requirement for the EVRU and VRT. So
select the SCM and then EVRU and VRT

This combination is available in different module to meet the requirement of various

customers world wide.
Frequency 50 or 60 Hz

ZERA GmbH

Instrument Transformer Testing system

Examples:

Module

Current range

SCM 1000200

1000-800-750-600500 - 400-300-250200 -150 125- 100

- 80- 75-60 -50- 4030- 25- 20- 15- 105A
2000 1600- 1250 1200 A additional to
SCM 1000-200
3000-2500-20001600 1250- 1200
additional to
SCM1000-200
2000 1600- 1250 1200 A additional to
SCM 1000-200
3000-2500-20001600 1250- 1200
additional to
SCM1000-200

SCM 2000120
SCM 3000120

SCM 2000200
SCM 3000200

In sec

Load
range
1 A and 1...200%
5A

Max.
Current
2000A

o/p
power
10kVA

1 A and 1....120%
5A

2400A

10kVA

1 A and 1....120%
5A

3600A

15kVA

1 A and 1....200%
5A

4000A

20kVA

1 A and 1....200%
5A

6000A

30kVA

The max. secondary burden of the standard current transformer is tuned to the
connection cables and the input of the measuring unit.

Accuracy of the standard transformer in the above mentioned measuring ranges

F 0,02 % (higher accuracy on request)
1 min.

Simultaneous connection of the ranges for the test current and the standard current
transformer by links and selector.
In a full automatic test equipment the ranges will be switched over automatically,
controlled by a PLC.
Note:- The required maximum current should be specified by the customer at the
time of inquiry.

The current transformers under test are connected to the output of the current
combination by links at one side of the unit.

ZERA GmbH

Instrument Transformer Testing system

Separate standard current transformer can be delivered, if the user has its own set
of current generating unit. Also the current generating transformer can be delivered
separately.

The standard current transformer can be delivered optionally with a PTB test
certificate.

3.3

Standard Voltage Module SVM 60-120

consisting of

3.3.1

Voltage generating transformer

for generation of the test voltage during the accuracy tests,
Also the test voltage with 150 or 300 Hz to test the insulation of the primary winding
can be generated with this transformer.
primary voltage:

200 V or 400V, 50 / 60 Hz

secondary voltage: 10 / 20 / 40 / 75 kV
output power:

2,5 / 5 / 10 / 15 kVA

impedance voltage: UK 6 %
Other tapings or required voltage ranges can also supplied. The customer has to
specify this data at the time of inquiry.
IMPORTANT !
The insulation test with 150 or 300 Hz frequency tests are carried out by manual
adjustment of the load point.
Also a peak voltmeter for high voltage up to 70 kV must be available. This test is
possible only with EVRU and available as option.

3.3.2

Standard voltage transformer

with the voltage ranges
Unpr
Unsec

= 6/3 - 10/3 - 15/3 - 20/3 - 30/3 - 60/3 kV

= 100/3 - 110/3 V, 50 Hz

for single pole isolated transformers.

For double pole isolated transformers the ranges are
Upr

= 6 - 10 - 15 - 20 - 30 60 kV

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Instrument Transformer Testing system

Unsec = 100V and 110V

Max. operating voltage Um = 72 kV.
load range 40...120 % Un
secondary burden: 6 VA, cos = 1
accuracy over the range 40...120 % Un
F 0,02 %
1.
The max. secondary burden of the standard voltage transformer is tuned to the
connection cables and the input of the measuring unit.
Other tapings or required voltage ranges can also supplied. The customer has to
specify this data at the time of inquiry.
The standard voltage transformer can optionally be delivered with a PTB test certificate.

3.4

Current- and voltage measuring unit WM 303 U/I

for the testing of voltage and current transformers. The transformer measuring unit
consists of the voltage unit WM 303-U and the current unit WM 303-I.

The technical features are:

inputs with measuring resistances
direct A/D conversion of the measuring values by 20 Bit A/D converter
internal divider to match transformer ratios deviating from those of the standard
transformers
controlling and measuring value indication via PC.

The technical specifications are:

voltage transformer measuring unit WM 303-U with 2 measuring voltage
inputs 2...480 V
current transformer measuring unit WM 303-I with 2 measuring current inputs
50 mA... 10,5 A
automatic or manual range selection
frequency range 40 Hz...70 Hz
accuracy for ratio E 0,01% of the reading,
phase displacement 0,5 min
resolution ratio 10-6 , phase displacement 10-3 grd

ZERA GmbH

Instrument Transformer Testing system

programmable divider for ratios out of the range of the standard transformer
= 0,5...2

supply voltage 185 V...265 V, 47...65 Hz.

Display of load point, phase angle error and ratio error and other relevant information
available on PC

Design of the transformer measuring unit WM 303

A PC indicates the measuring values and controls the manual, semiautomatic and
automatic test modes.
The WM 303 can be delivered with test certificate of the PTB Braunschweig.
The additional cost is quoted optionally.

3.5

Standard current burden

for measuring current transformers according to IEC 185,
designed for (data of SCB60-NB-S for example)
-

Isec = 1A and 5A, 50 Hz

load range 1...200 % In or 1...120 % In

burden steps:

cos = 1 :

1 - 1,25 - 1,5 - 2 - 2,5 - 3,75 VA

cos = 0,8 :

5 - 6,25 - 7,5 - 10 - 11,25 - 15 - 20 - 25 - 30 - 45 - 60 VA

accuracy within the load range 3 %

Selection of the burden steps manually (or via PLC for PC control, in case of
automatic test system).

ZERA GmbH

Instrument Transformer Testing system

10

Following different burden modules with 1 , 2 or 3 secondary current ranges are

available:

SCB30-NB-S (with burden step up to 30VA)

SCB60-NB-S (with burden step up to 60VA)
SCB90-NB-S (with burden step up to 90VA)
SCB200-1B-S (ANSI, with burden step up to 200VA only 5 A range)
Design of the standard current burden as 19-unit as shown on page 9 of the
enclosed leaflet WPE/97/1 DESP.

3.6

Standard voltage burden

for the testing of voltage transformers according to IEC 186, ( data of SCB238-NB-S
for example)
designed for
Un = 100/3 - 110/3 - 100 - 110 V, 50 Hz

Burden steps can be selected in the groups A, B, C, D

A : 0 - 1,25 - 2,5 - 3,75VA, cos = 0,8
+
B:
0 - 5 - 10 - 15 VA, cos = 0,8
+
C:
0 - 20 - 40 - 60 VA, cos = 0,8
+
D:
0 - 80 - 160
VA, cos = 0,8
___________________________________
max. burden

238,75

VA

So each burden step can be selected over the range 0...238,75 VA in steps of 1,25 VA.
Load range 80...120 % UN.
Accuracy in the load range 3 %.
Selection of the burden steps manually (or as option via PLC during PC control).
Different standard voltage burden module is available

SVB78-NB-S (with burden steps up to 78.75VA)

SVB98-NB-S (with burden steps up to 98,75VA)
SVB138-NB-S (with burden steps up to 138.75VA)
SVB158-NB-S (with burden steps up to 158.75VA)
SVB238-NB-S (with burden steps up to 238.75VA)

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Instrument Transformer Testing system

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SVB318-NB-S (with burden steps up to 318.75VA)

Standard burden for PTs with other specification can be made on the request
Design of the standard voltage burden as 19-housing.

3.7

Measuring cabinets

3.7.1

Measuring cabinet
(for automatic test procedures using EVRU)
It is possible to deliver the cabinet as a 19 cabinet or as a test table. Please find
relevant drawings,
for the incorporation of:
- measuring unit WM 303 U/I
- standard current burden
- standard voltage burden
- peak voltmeter
- PC for automatic test procedures.

The instrument housing of the cabinet is equipped with:

1 analogue voltmeter CL.1, indication 0...120%,(voltage transformer test equipment)
connected to the secondary side of the standard voltage transformer,
1 analogue ammeter CL.1, indication 0...200%,(current transformer test equipment)
connected to the secondary side of the standard current transformer,
1 analogue voltmeter CL.1, indicates the output voltage of the amplifier.

On the cabinet-front(or table top) are mounted all operating elements for the manual
operation.
For the automatic test procedure this elements indicate the adjusted load point.

Via relays inside the measuring cabinet the different transformers are connected to
the output voltage of the source to item 2.1:
- voltage transformer 10/20/40/75 kV
- current transformer.

After closing the safety circuit the high voltage transformer can be switched on.
Main switch, emergency-stop-switch and all operating elements are built into the
measuring cabinet.

ZERA GmbH

3.7.2

Instrument Transformer Testing system

12

Measuring cabinet
(for semiautomatic test procedures using VRT)
in accordance to the enclosed drawing no. 09733200,
for the incorporation of:
- measuring unit WM 303 U/I
- standard current burden
- standard voltage burden
- peak voltmeter (option)
- PC for semiautomatic test modes.

The instrument housing of the cabinet is equipped with:

1 analogue voltmeter CL. 1, indication 0...120%,
connected to the secondary side of the standard voltage transformer,
1 analogue ammeter CL. 1, indication 0...120%,
connected to the secondary side of the standard current transformer.

On the table top are mounted all operating elements for the manual operation:
- main switch,
- emergency-stop-switch,
- push buttons for
control circuit ON/OFF,
test circuit ON/OFF,
switching on for the generating transformers,
control of the regulating transformer to item 2.1.
- safety circuit,
- selector for IN and UN,
- balance burden for Usec and Isec circuits.
The PC, the measuring unit WM 303 and the printer are mounted on the table top.

3.8

PC and software
For the control of the test procedures, indication of the measuring values the scope
of delivery includes:

ZERA GmbH

3.8.1

Instrument Transformer Testing system

13

PC system
processor Pentium 1000 MHz,
128 MB RAM, hard disk > 40 GB,
floppy disk 3,5, 1.44 MB,
2 RS232C interfaces,
1 Centronics interface
1 CD ROM Drive 32"
2 RS232C interfaces,
15 TFT Monitor
MF2 keyboard, mouse
operating system Windows NT or Windows 2000
ink jet printer A4
modem for trouble shooting.
* Please mark this as a technical alteration. Because of fast improving
computer technology

3.8.2

Software package ZERA Checkcon

with the functions for semiautomatic/automatic test mode:
- manual test
- semiautomatic/automatic test (along with EVRU ).

Software allows operator to:

Enter the details of CT or PT under test (type table)
Enter the error class table
Prepare the test sequence table including load points, burden acceptance criteria
etc.
Conduct the testing in automatic/manual way
Evaluate the results of CT or PT under test
Compensation of error of Standard CT or PT
Printout of the test reports
Possibility to connect a label printer
Possibility to connect a barcode scanner
Possibility to transfer the test results to a host computer

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Instrument Transformer Testing system

14

In manual mode the operator set the load points and perform the measurement. The
results are not stored or printed out.
In automatic mode the PC controls all tests and stores the results. The menu
Software is in English (as an option any other language )

The operator must enter the transformer ratios in the type table, transformers with a
ratio which is not the same as the standard transformer can be tested.
A separate divider is not required anymore to adapt transformers to test, having
transformer ratios deviating from the standard transformers.

For the semiautomatic or automatic test procedure the operator has to enter once:
- type table (technical specification of the transformer under test),
- sequence table (sequence of load points for the transformer under test),
- table for the standard burden,
- table for the standard transformers.

Then the automatic test can be started. For all load points mentioned in the
sequence table the errors of the transformer will be measured automatically.
After the measurement of all load points the PC carries out:
- evaluation of the transformer under test,
- print-out of the test report,
- store the test results in an access database.

The difference between an automatic and a semiautomatic test is, during the
automatic test the hole testing procedure will run automatically and during the
semiautomatic test the operator is guided through the test procedures by the PC
and has to set the range, burden, transformer to test and load points manually.

3.9

Peak voltage measuring unit

for the peak measurement of the high voltage during the insulation tests,
consisting of:
1 measuring capacitor, 100 pF, 100 kV for PT testing or
1 measuring capacitor 0.5 nF, 35 KV

for CT interturn insulation test calibrated

together with the peak voltmeter,

1 peak voltmeter with digital indication for the measurements

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Instrument Transformer Testing system

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- peak value or peak value . 2 for both polarities,

- arithmetic mean value (average),
- RMS-value,
- ripple amplitude.
In case of a disruptive discharge the measuring value is stored.
After a reset or test voltage switch in again the new measuring value is indicated.

Accuracy for
- peak or average values F 0,5 %
- RMS value

F1%

1 coaxial cable 5 m, calibrated with the peak voltmeter

3.10

Connecting cables
For the CT/PT testing , it is necessary to have calibrated cable. So we can deliver
the appropriate cables used for:
- connecting cables between the measuring cabinet and the secondary sides of the
voltage and current transformer and the transformers under test,
- connecting cables between the measuring cabinet and the primary sides of the
generating transformers for test voltage and test current.
The high voltage and high current cables are to connect the transformer under test.

3.11

Accessories
Desk to suspend or install the transformer under test
Motor driven selector for the automatic testing of CT
High voltage rail with grounding switch
Peak voltmeter with measurement capacitor
CT demagnetisation mechanism

Installation
We do installation, commissioning at the customer premises and trained to
customer to take maximum advantage out of the system for a long life. Depending
on the system some of the work has to do by the customer before installing the
system, like mains supply, grounding system, safety system

ZERA GmbH

Instrument Transformer Testing system

16

Project
We also undertake complete project to set-up complete testing laboratory as shown
on page no.11 of the leaflet.

If manufacturer of CT/PT wants automatic testing including movement of CT /PT that

also we undertake as a special project

All such projects are dealt by well experienced and responsible engineer in ZERA,
who are pleased to share their experiences with the customer to make him
advantageous

If a customer likes to carry out the system integration himself we are also pleased to
deliver the required component.

How to select appropriate system:Selection of system and component depend on the various aspects, and objectives

6.1

Who wants to test CT/PT combined (automatic testing system)

Then select following component
EVRU (depending on the o/p power requirement)
SCM (depending on the maximum Current requirement)
SVM (depending on the voltage requirement
WM303U and WM303I
SCB (depending on the burden requirement)
SVB (depending on the burden requirement)
Measuring cabinet or table
PC system and Software
Peak voltage measuring unit
Suspension desk (if required)
High voltage rail with grounding

ZERA GmbH

6.2

Instrument Transformer Testing system

Who wants to test only CT, automatic testing system

Then select following component
EVRU
SCM (depending on the maximum Current requirement)
WM303I
SCB (depending on the burden requirement)
Measuring cabinet
PC system and Software
Suspension desk (if required)

6.3

Who wants only CT testing system manually/semi auomatically

Then select following component
VRT
SCM (depending on the maximum Current requirement)
WM303I
SCB (depending on the burden requirement)
Measuring cabinet
PC system and Software
Suspension desk (if required)

6.4

Who wants only PT testing system manually/semi automatically

Then select following component
VRT
SVM (depending on the maximum voltage requirement)
WM303U
SVB (depending on the burden requirement)
Measuring cabinet
PC system and Software
Suspension desk (if required)
High voltage rail
Safety system grounding switch

17

ZERA GmbH
6.5

Instrument Transformer Testing system

18

Manually testing system for CT economic version

Current generating system (from primary injection test kit )

Standard CT
WM 303I
SCB
PC system and software
Measuring cabinet

Important :- There may be some other alternative depending on the requirement.

Above mentioned are just for example and help you.

More information can be taken from our leaflet WPE/97/1 DESP

Delivery period
This vary from 5 months to 7 months, depending on the system ordered. If complete
system has to be certify by the PTB then additional 4 week is required.

Enclosure
a) drawing no. 09733200
b) Specification format

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19

Instrument Transformer Testing system

Specification sheet to specify your requirements

S.NO.

Requirement

Remarks

Suitable for Testing of

CT only
PT only
CT/PT both

Control of testing

Automatic
Semi automatic
manual

Primary current of CTs which you want Specify Imax and Nominal current and
to test from this system

ranges required
dynamic range e.g. 1..120% of In or
1..200% of In.

Secondary of CT

1A only
5A only
1A and 5A both
other ranges: ......A ,.......A ,........A

Class of CT under test

Type of CT
Core type
window/ring

Required secondary burden of CT under

test

Reference standard for testing

IEC or ANSI ( CT )

10

Do you want to conduct test other then specify

the

test

name,

accuracy test from the system ( CT )

magnitude etc

Primary voltage of PT under test

specify max. to min in detail

standards,

also specify single pole type, double pole

type
11

Secondary voltage of PT under test

12

Required secondary burden of PT under

test

13

Do you want to conduct test other then specify

accuracy test from the system ( PT )

the

magnitude etc

test

name,

standards,

ZERA GmbH
14

Instrument Transformer Testing system

Reference standard for testing

IEC or ANSI ( PT )

15

Do you have any required component at Specify the detail of existing system
present or you want complete system

16

What accessories you will need

e.g. Peak voltmeter
suspension desk
HV rails
CT demagnetisation

17

Software language

English or
German or
Other ..............

18

Do you want that system should be

certify by the PTB. It is also possible that
only standard CT/PT and comparator
and burden can be certify by the PTB

20