35kV 200A Loadbreak BI & Elbow Connector
Design Test Report
Report Number: Test Start Date: Test Complete Date:
RN-R7509 2017 / 05 / 08 2019 / 06 / 10
Chardon Taiwan No. 37 Min-Chie Road Tung Lo Industrial Park Miao Li, Taiwan 366
1
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Table of Contents
1. Sequence A: Partial Discharge Test ...................................................... 2 2. Sequence A: AC withstand Voltage Test .............................................. 4 3. Sequence A: Impulse Withstand Test ................................................... 6 4. Sequence A: Test Point Test ................................................................. 8 5. Sequence B: Accelerated Sealing Life Test ........................................ 10 6. Sequence C: Switching and Fault-closure .......................................... 16 7. Individual Test: Short-time Current Test ............................................ 19 8. Individual Test: Accelerated Thermal Test ......................................... 21 9. Individual Test: Thermal Test with off-axis Operation ...................... 30 10. Individual Test: Cable Pull-out Test ................................................... 34 11. Individual Test: Operating Force Test ................................................ 36 12. Individual Test: Operating Eye Test ................................................... 38 13. Individual Test: Test Point Cap Test ................................................... 40 14. Individual Test: Shielding test ............................................................ 42 15. Individual Test: Operating Interface AC Withstand Test ................... 45
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
1. Sequence A: Partial Discharge Test
Object
To verify the connectors that the parts meet ANSI/IEEE Standard 386-2016 35kV partial
discharge requirement of 26kV/3pC.
Testing Samples
Bushing Insert CHARDON 35-LBI200 10 PCS
Elbow CHARDON 35-LE200 10 PCS
Mating Parts
Elbow Test Rod 35kV#C Testing Rod Φ31.5mm
Procedure and Testing Spec
The test voltage shall be raised to 20% above the corona voltage level of 26kV. If corona
exceeds 3pC, the test voltage shall be lowered the corona voltage level of 26kV and
maintained at this level for at least 3 seconds but not more than 60 seconds. Corona
readings taken during this period shall not exceed 3 pC.
Results
Sample number Corona voltage level
A-1 26.6 kV / 0.5 pC
A-2 26.6 kV / 0.5 pC
A-3 26.6 kV / 0.5 pC
A-4 26.6 kV / 0.5 pC
A-5 26.6 kV / 0.5 pC
A-6 26.6 kV / 0.5 pC
A-7 26.6 kV / 0.5 pC
A-8 26.6 kV / 0.5 pC
A-9 26.6 kV / 0.5 pC
A-10 26.6 kV / 0.5 pC
3
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Partial Discharge Test
Partial Discharge Testing in Progress
4
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2. Sequence A: AC withstand Voltage Test
Object
To verify the connectors that the parts meet ANSI/IEEE standard 386-2016 35kV AC
withstand requirement of 50kV/ 1 min.
Testing Samples
Bushing Insert CHARDON 35-LBI200 10 PCS
Elbow CHARDON 35-LE200 10 PCS
Mating Parts
Elbow Test Rod 35kV#C Testing Rod Φ31.5mm
Procedure and Testing Spec
The test voltage shall be raised to the value of 50kV in 30 seconds. The test sample shall
withstand the specified test voltage for 1 minute without flashover or puncture.
Results
Sample number 50kV/1min AC withstand voltage
A-1 PASS
A-2 PASS
A-3 PASS
A-4 PASS
A-5 PASS
A-6 PASS
A-7 PASS
A-8 PASS
A-9 PASS
A-10 PASS
5
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AC Withstand Voltage Test
AC Withstand Voltage Testing in Progress
6
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3. Sequence A: Impulse Withstand Test
Object
To verify the connectors that the parts meet ANSI/IEEE Standard 386-2016 35kV
impulse withstand testing requirements of 1.2×50μs ±150kV wave., 3 positive and 3
negative full-wave impulses.
Testing Samples
Bushing Insert CHARDON 35-LBI200 10 PCS
Elbow CHARDON 35-LE200 10 PCS
Mating Parts
Cable Conductor Type 35kV 1/0 AWG(Aluminum)
Procedure and Testing Spec
The test voltage shall be 1.2/50µs wave having the crest value (BIL) of 150kV. The
connector shall withstand 3 positive and 3 negative full-wave impulses without flashover
or puncture.
Results
Sample number 1.2×50μs±150kV Impulse withstand voltage
A-1 PASS
A-2 PASS
A-3 PASS
A-4 PASS
A-5 PASS
A-6 PASS
A-7 PASS
A-8 PASS
A-9 PASS
A-10 PASS
7
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Impulse Withstand – Positive Wave
Impulse Withstand Testing – Negative Wave
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Sequence A: Test Point Test
Object
To verify the elbow test point meeting the ANSI/IEEE Standard 386-2016 testing
requirement.
Testing Samples
Elbow CHARDON 35-LE200 10 PCS
Mating Parts
LCR Meter CHENHWA 1012F
Testing Fixture
Procedure and Testing Spec
The purpose of this test is to verify that the capacitance values of the test point meet the
requirements of 6.5.1. of IEEE 386.
The connector shall be installed on a cable of the type for which it is designed to operate,
and the shielding shall be grounded in the normal manner. The capacitances from test
point to cable and test point to ground shall be measured with suitable instruments and
proper shielding techniques. The measured values shall be within the tolerances specified
in 6.5.1. of IEEE 386.
Results
Sample number
Test point and the
conductor shall be at
least 1.0 pF.
Test point and shield to
the capacitance between
test point and conductor
shall not exceed 12.0
Result
A1 7.69 pF 2.68 PASS
A2 7.91 pF 2.17 PASS
A3 7.57 pF 2.92 PASS
A4 7.83 pF 2.29 PASS
A5 8.14 pF 2.14 PASS
A6 8.06 pF 2.76 PASS
A7 8.16 pF 2.26 PASS
A8 7.87 pF 2.73 PASS
A9 8.11 pF 2.57 PASS
A10 7.84 pF 2.61 PASS
9
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Test Point Test
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4. Sequence B: Accelerated Sealing Life Test
Object
To verify the connector can maintain a long-tern seal at all interfaces to prevent the
entrance of moisture.
Testing Samples
Bushing Insert CHARDON 35-LBI200 4 PCS
Elbow CHARDON 35-LE200 4 PCS
Mating Parts
Cable Conductor Type 1/0 AWG(Aluminum)
Cable Insulation Thickness 345 mil
Conductor 200A Bi-Metal Lug
Equalizers Aluminum Equalizers Size:106mm(L)20mm(OD)10.1mm(ID)
Bushing Bus 356mm(L), 102mm(W),10mm(T)
Procedure and Testing Spec
The four connector assemblies shall be placed in an oven having 121 °C temperature and
remain there for three weeks.
After the time has elapsed, the four samples shall be subjected to 50 cycles of the
following sequence of operations: The assemblies shall be heated in air using sufficient
current to raise the temperature of the connector of the control cable to 90 °C ± 5 °C for 1
hour.
The assemblies shall be de-energized and within 3 min, submerged in 25 °C ± 10 °C
conductive water (5000 Ω-cm maximum) to a depth of 30 cm (1 ft) for 1 hour.
After 50th cycle, the connector and cable assembly shall withstand a design impulse test
of IEEE 7.5.3(1.2*50µS impulse wave of 125kV, 3 positive and 3 negative) and test point
voltage test.( During the impulse test, the bushing well and bushing bus were soaked into
the silicone oil.)
11
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Results
Sample
#
PD Testing
Before Acc
Life Sealing
Test
AC Withstand
Testing Before
Acc Life
Sealing Test
Impulse
Testing Before
Acc Life
Sealing Test
PD Testing
After Acc Life
Sealing Test
Test Point
Voltage
Testing
B-1 26.6kV0.7pC 50kV/1m Pass ±150kV
3 Shots Each,
Pass
26.4kV0.6pC 16.2kV
B-2 26.5kV0.7pC 50kV/1m Pass 26.4kV0.6pC 15.7kV
B-3 26.5kV0.7pC 50kV/1m Pass 26.4kV0.6pC 15.3kV
B-4 26.5kV0.7pC 50kV/1m Pass 26.4kV0.6pC 15.9kV
Remark
Tested with Bushing Insert and Elbow Assembly
Cable Temp:90.3~92.7
Water Temp:26.8~28.7
Resistance of Water:3392 Ω-cm
Depth of Water:30 cm
Impulse Testing Waveform before Accelerated Sealing Life Test – Positive Wave
12
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Impulse Testing Waveform before Accelerated Sealing Life Test – Negative Wave
Test Setup Diagram
13
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Samples Assembly – Before Accelerated Sealing Life Testing
Samples in the Chamfer 121/21 days
14
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Samples in the Chamfer 121/21 days
15
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Impulse Testing after Accelerated Life Sealing Test
Test Point Testing after Accelerated Life Sealing Test
16
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5. Sequence C: Switching and Fault-closure
Description
The purpose of these tests is to verify that the Loadbreak Bushing Insert and Elbow are
capable of closing and interrupting the rated switching current of 200A rms. Additionally,
these tests will verify the parts are capable of closing on a 10,000A rms fault current for
0.17 sec.
Requirement
The Loadbreak Bushing Insert shall withstand 10 complete switching operations without
arcing to ground or impairing its ability to meet the spec of IEE Std 386-2016. The
Loadbreak Elbow shall also withstand 10 complete switching without arcing to ground or
impairing its ability to meet the spec of IEE Std 386-2006. Failures are permitted;
however, none of the failures are permitted in 10 consecutive samples of a maximum lot
size of 30.
Procedures
1. Assemble 30 Bushing Inserts and Elbows assemblies on cable.
2 Test all samples in accordance with IEEE Standard 386-2016 sections 7.7 “Switching
Test” under the conditions described in Tables 10 and 11, Figure 28(a) of the standard.
Each sample is subjected to 10 complete switching operations at 21.1/36.6 kV, 200A
using a mechanical fixture.
3. Test all samples that successfully passed 10 switching operations in accordance with
IEEE Standard 386-2016 sections 7.8 “Fault-closure Test” under the conditions described
in Table 11 and 12, Figure 29(a) of the standard. Each sample is subjected to 1 fault-close
operation.
4. The procedure above was repeated with elbow samples from Elastimold and Cooper
Industries, in compliance with IEEE 386-2016 standard section 6.4 “Interchangeability”.
Results
Switching passed; Fault-closure passed. Testing performed at Powertech Labs Inc, Surrey
BC Canada.
Chardon – Powertech Report PL-02179 REP1
Elastimold Interchangeability – Powertech Test Report PL-02525 REP1
17
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
18
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
19
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
6. Individual Test: Short-time Current Test
Object
To verify the connectors that the parts meet ANSI/IEEE Standard 386-2016 200A
short-time current test requirements.
Testing Samples
Bushing Insert CHARDON 35-LBI200 4 PCS
Elbow CHARDON 35-LE200 4 PCS
Mating Parts
Cable Conductor Type 35kV 1/0 AWG(Aluminum)
Procedure and Testing Spec
The rms value of the first major loop of a current wave shall be not less than the value
specified in Table 2 multiplied by 1.3 (X/R=6) for 200 A connectors The magnitude shall
be measured in accordance with ANSI/IEEE C37.09.
Connectors shall withstand the current without separation of interfaces or impairing
the ability to meet the other requirements of the standard.
Results
10kA/0.17sec
Sample
number
1st Cycle
Current
(peak)
1st Cycle
Current
(rms)
Current
(rms) Time Verification Result
I-1 & I-2 21.49 kA 15.20 kA 11.88 kA 0.275 sec Normal PASS
I-3 & I-4 21.86 kA 15.46 kA 11.91 kA 0.272 sec Normal PASS
3.5kA/3sec
Sample
number
1st Cycle
Current
(peak)
1st Cycle
Current
(rms)
Current
(rms) Time Verification Result
I-1 & I-2 8.15 kA 5.76 kA 4.61 kA 3.12 sec Normal PASS
I-3 & I-4 8.32 kA 5.88 kA 4.79 kA 3.09 sec Normal PASS
20
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Short-time Current Test Record for 10kA/0.17sec
Short-time Current Test Record for 3.5kA/3sec
21
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7. Individual Test: Accelerated Thermal Test
Object
The purpose of this accelerated test is to demonstrate that 200 A insulated connectors can
carry rated current under usual service conditions. Successful completion of the test shall
be considered as evidence that the connector meets its rating.
Testing Samples
Bushing Insert CHARDON 35-LBI200 4 PCS
Elbow CHARDON 35-LE200 4 PCS
Mating Parts
Cable Conductor Type 1/0 AWG(Aluminum)
Cable Insulation Thickness 345 mil
Conductor 200A Bi-Metal Lug
Equalizers Aluminum Equalizers Size:106mm(L)20mm(OD)10.1mm(ID)
Bushing Bus 356mm(L), 102mm(W),10mm(T)
Procedure and Testing Spec
7.10.1 Accelerated thermal test
A control cable, used for the purpose of obtaining conductor temperature, shall be
installed in the heat cycle loop between two equalizers. Its length shall be 183 cm (72 in).
The control cable shall be the same type and size as the cable used to join the connectors
under test.
Four connectors shall be assembled in series on AWG No 1/0 insulated aluminum
conductors having a length of 91 cm (36 in). The cable insulation thickness shall be
selected according to its voltage class (see Table 13 of IEEE 386).Equalizers used shall
be in accordance with ANSI C119.4.The bushing bus shall be a flat, rectangular, bus bar
356 mm (14 in) long, 102 mm (4 in) wide, and 10 mm (3/8 in) thick. The bushing wells
shall be mounted 31 cm (12 in) apart centered along the midline of the bus bar. The
bushing well studs shall be tightened to the bus bar using an installation torque of 9 N·m
± 1 N·m (80 lbf·in ± 10 lbf·in).
Unless otherwise specified by the manufacturers, the elbow male contact probe shall be
threaded into the elbow compression lug using an installation torque of 9 N·m ± 1 N·m
(80 lbf·in ± 10 lbf·in).
Current-cycling tests shall be conducted at an ambient temperature of 15 °C to 35 °C in a
space free of drafts.
22
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The current-cycle amperes shall be adjusted during the current-on period of the first five
cycles to result in a steady-state temperature rise of 100 °C to 105 °C on the control
conductor. This current shall then be used during the remainder of the test current-on
periods, regardless of the temperature of the control conductor.
The test shall consist of 50 current cycles, with the current on 4 h and off 2 h for each
cycle. At the end of each current-on cycle, the assembly shall be de-energized and within
3 min be submerged in water at 5 °C ± 5 °C for the remainder of the current-off cycle.
At the end of the 10th, 25th and 40th cycles (± 2 cycles), after the samples have returned
to room temperature, a short time ac current of 3500 A ± 300 A rms shall be applied to
each sample for a minimum of 3 s.
The temperature of at least the following current transfer points shall be measured at the
end of each cycle with the current on:
a) Probe to compression lug
b) Probe to female contact
c) Female contact structure to metallic housing (piston contact)
d) Between bushing insert and bushing well.
These temperatures shall not exceed the temperature of the control conductor.
The temperature differences between the control conductor and the connector shall show
a condition of stability from the fifth cycle to the end of the test. Stability is indicated
when the change in the individual differences is not more than 10 °C from the average of
the measured differences in this interval for this connector.
The dc resistance of the connector system shall be measured at the end of cycles 10, 20,
30, 40, and 50 (± 2 cycles). The dc resistance measurements shall be made between the
elbow cable equalizer and the bushing stud after the connector system has stabilized at
ambient temperature. Ambient temperature shall be measured by devices located within
61 cm (2 ft.) of the test loop but in a location that minimizes the effect of thermal
convection. The ambient temperature shall be recorded at the same time as each set of
resistance measurements, and the resistance shall be corrected to 20 °C. The dc resistance
shall be stable over the period of measurement. Stability is achieved when any resistance
measurement, including allowance for instrument accuracy, does not vary more than ±
5% from the average of all the measurements in this interval.
23
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Results
Unit
Cycle I-5 I-6 I-7 I-8
Cable Room Water
Temp a. b. c. d. a. b. c. d. a. b. c. d. a. b. c. d. Temp
6 72.3 61.4 58.9 58.4 74.1 62.2 58.6 59.1 75.4 63.6 58.9 59.7 72.5 60.3 58.4 57.9 126.8 26.4 7.2
7 72.6 61.8 59.3 58.7 74 62.6 58.7 59.1 75.4 63.6 58.9 59.7 73.1 61.3 58.2 57.7 127.6 26.8 7.4
8 72.8 62.1 59.4 58.9 74.2 62.5 58.9 59.3 75.5 63.6 59.1 59.9 73.2 61.6 59.7 57.6 127.3 26.6 7.5
9 72.6 62.1 59.3 59 74.3 62.6 59 59.4 75.6 63.5 59 59.8 73.2 62.4 60.5 59 127.6 26.5 7.7
10 73.4 63.1 59.6 59.3 75 63.4 59.3 59.7 76.1 64.3 59.6 60.4 74.2 63.5 61.6 61.1 128.0 27.1 8.0
11 73.6 63.2 59.8 59.4 75.1 63.4 59.7 60.1 76.1 64.4 59.7 60.5 74.4 63.4 61.5 61 128.5 27.2 7.8
12 74 63.5 60.1 59.7 75.2 63.9 60.1 60.5 76 64.3 59.6 59.8 74.6 63.8 61.9 61.4 128.2 27.4 7.4
13 74.4 63.7 60.4 59.9 75.6 64.4 60.5 60.9 76.4 64.7 60 59.9 75.2 64.3 62.4 61.9 128.7 27.8 7.6
14 74.4 63.7 60.7 60.2 75.1 63.9 60.2 60.6 76.6 65.1 60.4 60.1 75.1 64.3 62 61.9 128.0 27.5 7.9
15 74.7 64.1 61 60.4 75.3 64.3 60.4 60.8 76.9 65.1 60.4 60 75.4 64.3 62.5 61.9 128.7 27.7 7.7
16 74.9 64.1 61.1 60.6 75.5 64.6 60.7 61.2 76.9 65.3 60.6 60.6 75.3 64.3 62.2 61.9 128.2 27.6 7.4
17 75 64 61.1 60.7 75.9 64.7 60.9 61.4 77.2 65.5 61 61.8 75.5 64.6 62.2 62.2 128.4 27.6 7.2
18 75 64.1 61.2 60.9 75.6 64.7 61 61.5 77.3 65.4 60.9 61.7 75.4 64.6 62.5 62.2 127.6 27.3 7.5
19 75.5 64.3 61.3 61 76.2 65.3 61.3 61.8 78 66.9 62.5 63.3 76 64.8 62.5 62.4 128.4 27.8 7.8
20 75.6 64.4 61.2 61.1 76.3 65.1 61.4 61.9 78.6 67.4 62.7 63.5 76.4 65.2 62.8 62.8 129.1 28.2 7.7
21 75.7 64.5 61.6 61.1 76.5 65.4 61.6 62 78.5 67.5 62.8 63.6 76.3 65.2 63 62.8 128.7 27.9 7.6
22 76.1 64.8 61.7 61.4 76.8 65.4 61.7 62.1 78.8 68 63.3 64.1 76.7 65.5 63.6 63.1 128.6 28.1 7.4
23 76.1 64.8 61.9 61.5 76.8 65.6 61.9 62.3 78.8 68 63.3 61.8 76.5 65.1 63.2 62.7 128.5 27.8 7.5
24 76.5 65.2 62.2 61.6 77.3 65.8 61.9 62.3 79 68.2 63.5 63.4 76.9 65.6 63.7 63.2 129.6 28.4 7.8
25 76.7 65.3 62.4 61.7 77.4 65.9 62.1 62.5 79.5 68.5 63.8 63.6 77.1 65.8 63.9 63.4 129.1 28.2 8.1
26 76.8 65.5 62.6 61.9 77.6 65.9 62.3 62.7 79.8 68.9 64.2 63.7 77.5 65.9 64 63.5 129.6 28.3 7.9
27 76.7 65.3 62.7 62 77.6 65.8 62.5 62.9 79.4 68.3 63.6 64.4 77.4 65.9 64 63.5 129.5 27.9 7.6
28 77.3 65.8 63 62 78.2 66.3 62.6 63 79.9 69 64.3 65.1 77.6 66.3 64.4 63.9 129.4 28.4 7.2
29 77.6 66 63.4 62.3 78.5 66.3 62.7 63.2 80.5 69.4 64.9 65.7 78 66.7 64.8 64.3 129.4 28.5 7.5
30 77.7 66.2 63.6 62.6 78.6 66.5 62.9 63.4 80.7 69.5 65 65.8 78.4 66.9 65 63.6 129.6 28.5 7.4
31 77.9 66.5 63.9 62.8 78.8 66.6 62.9 63.3 80.8 69.6 65.1 65.9 78.5 67.1 64.9 64 129.9 28.4 7.5
32 77.7 66.4 64 63.3 79 66.8 63 63.4 80.6 69.8 65.4 66.2 78.5 67.1 65 64.2 129.9 28.1 7.9
33 77.9 66.6 64.1 63.5 79.2 67.2 63.2 63.6 80.6 69.8 65.4 66.2 79 67.7 65 64.5 129.4 28.3 8.1
34 77.8 66.5 64.3 63.6 78.8 66.7 63.2 63.6 80.6 70 65.3 66.1 78.6 67.2 65.6 65.1 128.5 27.9 8.0
35 77.6 66.3 64.4 63.8 79 66.9 63.1 63.5 80.6 69.7 65 65.8 78.8 67.3 65.4 64.6 128.5 27.6 7.7
24
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
36 77.8 66.6 64.4 64.1 79.3 67.2 63.4 63.8 81.3 70.1 65.4 66.2 79.1 67.6 65.7 64.7 128.5 27.8 7.5
37 78 66.8 64.8 64.2 79.6 67.1 63.5 63.9 81.7 70.4 65.7 66.5 79.3 67.6 65.7 65 128.5 28.0 7.6
38 77.7 66.7 65 64.5 79.2 67.4 63.7 64.1 81.8 70.4 65.7 66.5 79.3 67.6 65.7 64.9 129.0 27.7 7.4
39 77.9 66.8 65.2 64.6 79.3 67.2 63.9 64.3 82 70.7 66 66.4 79.1 67.5 65.6 65.1 128.4 27.6 7.8
40 78.1 67.4 65.6 64.7 80.4 67.6 64 64.4 82.4 71 66.3 66.3 79.2 67.6 65.7 65.2 130.3 28.2 7.5
41 78.5 67.7 65.7 64.9 80.2 67.9 64.1 64.5 82.7 71.4 66.7 66 79.6 67.9 66 65.5 130.8 28.3 7.7
42 78.4 67.5 65.9 65.1 80 68.2 64.3 64.7 83.1 71.6 66.9 66.4 80.2 68.3 66.4 65.9 130.1 28.4 7.8
43 78.1 67.2 65.5 65.3 79.8 67.8 64.1 64.5 82.8 71.3 66.6 66.7 79.8 67.7 65.8 65.3 129.7 28.4 8.0
44 77.7 67 65.6 65.3 79.6 67.3 63.8 64.2 82.8 71.4 66.7 66.7 79.6 67.4 65.5 65 129.2 28.1 7.6
45 77.9 67 65.6 65.2 79.3 67.4 64.1 64.5 83.2 71.8 67.1 67.2 79.8 67.7 65.9 65.3 129.8 28.2 7.5
46 77.4 66.6 65.4 65.5 78.9 66.9 63.9 64.3 82.8 71.3 66.9 67.6 79.3 67.4 65.6 65 129.6 27.8 7.7
47 78.2 67.2 65.7 65.4 79.5 67.6 64.2 64.6 82.8 71.4 67 67.8 79.8 67.6 65.3 65.2 129.2 28.3 7.6
48 78.5 67.6 65.9 65.3 79.7 67.9 64.5 65 82.7 71 66.5 67.5 79.4 67.2 65.5 64.8 129.4 28.4 7.9
49 78.2 67.4 65.8 65.5 79.5 67.6 64.6 65.1 83 71.4 66.9 67.6 79.7 68 65.1 65.6 129.3 28.5 7.7
50 78 67.2 65.6 65.2 79.2 67.4 64.5 65 82.1 70.8 66.3 67.5 79.2 67.4 65.9 65 128.6 27.9 7.8
Avg. 76.4 65.4 62.9 62.4 77.6 65.8 62.2 62.6 79.6 68.3 63.7 64.1 77.3 65.8 63.8 63.3 128.9 27.9 7.6
Max
2.1
(41
2.3
(41
3.0
(42
3.1
(46
2.8
(40
2.4
(42
2.4
(49
2.5
(49
3.6
(45
3.5
(45
3.4
(45
3.7
(47
2.9
(42
2.5
(42
2.6
(42
2.6
(42
126.8
~
130.8
26.4
~
28.5
7.2
~
8.1
Temp
Delta
(Cycle
Remark Temp difference does not vary more than 10 , meets the requirement of the standard.
Resistance Measurement Unit:mΩ
Date Week
#
Room
Temp
Equalizers-I1 /
Bushing Well-I1
Equalizers-I2 /
Bushing Well-I2
Equalizers-I3 /
Bushing Well-I3
Equalizers-I4 /
Bushing Well-I4
5/22 9 26.5 0.65 0.75% 0.69 0.06% 0.70 1.08% 0.68 0.93% 5/24 20 28.2 0.67 1.70% 0.68 2.15% 0.71 0.98% 0.69 0.14% 5/27 28 28.4 0.66 0.11% 0.70 0.65% 0.72 2.45% 0.69 0.22% 5/30 40 28.2 0.66 0.18% 0.71 2.16% 0.73 1.81% 0.70 1.31% 6/2 50 27.9 0.65 1.24% 0.69 0.60% 0.72 0.53% 0.69 0.02%
Average 0.658 0.694 0.716 0.690
25
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Short-time Current 3500A/3 sec
25kV200A Bushing Insert 2017-May-22 9th Cycle
3.5kA/3sec X/R 6
Sample
Number
1st Cycle
Current
(peak)
1st Cycle
Current
(rms)
Current
(rms) Time Verification Result
I-5 & I-6 6.25 kA 4.42 kA 4.21 kA 3.14 sec Normal PASS
I-7 & I-8 6.74 kA 4.76 kA 4.24 kA 3.09 sec Normal PASS
25kV200A Bushing Insert 2017-May-25 24rd Cycle
3.5kA/3sec X/R 6
Sample
Number
1st Cycle
Current
(peak)
1st Cycle
Current
(rms)
Current
(rms) Time Verification Result
I-5 & I-6 7.61 kA 5.38 kA 4.17 kA 3.11 sec Normal PASS
I-7 & I-8 7.42 kA 5.24 kA 4.26 kA 3.14 sec Normal PASS
25kV200A Bushing Insert 2017-May-30 40th Cycle
3.5kA/3sec X/R 6
Sample
Number
1st Cycle
Current
(peak)
1st Cycle
Current
(rms)
Current
(rms) Time Verification Result
I-5 & I-6 7.85 kA 5.55 kA 4.17 kA 3.08 sec Normal pass
I-7 & I-8 7.79 kA 5.51 kA 4.24 kA 3.07 sec Normal pass
26
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3.5kA/3sec Short-time Current Test Record for 2017-May-22 9th Cycle
3.5kA/3sec Short-time Current Test Record for 2017-May-25 24th Cycle
27
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3.5kA/3sec Short-time Current Test Record for 2017-May-25 24th Cycle
Test Setup Diagram
28
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Current Cycle Test in Progress
29
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Resistance Test
30
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8. Individual Test: Thermal Test with off-axis Operation
Object
The purpose of this accelerated test is to demonstrate that 200 A insulated connectors can
carry rated current after being subjected to an off-axis operating force. Successful
completion of these tests shall be considered as evidence that the connector meets its
rating.
Testing Samples
Bushing Insert CHARDON 35-LBI200 4 PCS
Elbow CHARDON 35-LE200 4 PCS
Mating Parts
Cable Conductor Type 1/0 AWG(Aluminum)
Cable Insulation Thickness 345 mil
Conductor 200A Bi-Metal Lug
Equalizers Aluminum Equalizers Size:106mm(L)20mm(OD)10.1mm(ID)
Bushing Bus 356mm(L), 102mm(W),10mm(T)
Procedure and Testing Spec
7.10.2 Thermal test with off-axis operation For this test, each connector shall be subjected to six cycles, each consisting of a
“mechanical operation” and “current cycling test”.
The elbow shall be assembled with a 12.7-mm (0.5-in) wide pulling band, as shown in
Figure 30, for application of an off-axis force.
Four connectors shall be assembled in series on AWG No 1/0 insulated aluminum
conductors having a length of 91 cm (36 in). The cable insulation thickness shall be
selected according to its voltage class (see Table 13 of IEEE 386).
Mechanical Operation
The elbow rotated about the probe axis of a minimum of 10° in both the clockwise and
counterclockwise directions. The connector shall be opened 5 times with the force
applied to pulling band and closed 5 times with the force applied to operating eye.
Current Cycling test A control cable, used for the purpose of obtaining conductor temperature, shall be
installed in the heat cycle loop between two equalizers. Its length shall be 183 cm (72 in).
The control cable shall be the same type and size as the cable used to join the connectors
under test.
31
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The current shall be adjusted so that the temperature on the control cable is 90°C±5°C.
The current shall be applied for 8 continuous cycles, each cycle consisting 3 hours on and
3 hours off.
Current cycling tests shall be conducted at an ambient temperature of 15°C to 35°Cin a
space free of external of forced drafts.
The temperature shall be measured by thermocouples located as follows:
(a) At the compression lug
(b) At the approximate midpoint of the bushing contact or as near thereto as practical
(c) On the conductor surface at the midpoint of the control cable
The temperature at location (a) and location (b) shall not exceed the temperature of the
conductor of the cable at location (c) when measured during the final cycle of each
6-cycle set.
32
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Results
Cycle I-9 I-10 I-11 I-12
Cable Room
a. b. a. b. a. b. a. b. Temp
Cycle-1
1 66.1 46.7 67.9 45.0 67.7 47.0 68.4 47.3 90.1 25.2
2 66.3 46.8 68.0 45.1 67.9 46.9 68.3 47.7 90.0 25.3
3 66.3 46.6 67.8 45.2 67.6 47.0 68.1 47.4 90.2 25.6
4 66.2 46.8 68.0 45.1 67.9 46.9 68.5 47.5 90.2 25.1
5 66.5 47.1 68.3 45.2 68.2 47.2 68.8 47.8 90.3 24.9
6 66.5 47.1 68.3 45.3 68.2 47.3 68.6 47.8 90.1 25.2
7 66.4 47.0 68.2 45.4 68.1 47.4 68.7 47.9 89.9 25.5
8 66.3 46.9 68.1 45.4 67.9 47.5 68.6 47.7 89.5 24.8
Cycle-2
1 66.6 47.1 68.3 45.3 68.1 47.1 68.6 47.9 89.8 25.0
2 66.7 47.2 68.4 45.3 68.2 47.1 68.7 48.0 88.7 25.3
3 66.8 47.1 68.3 45.5 68.2 47.5 68.8 48.0 89.3 25.1
4 67.0 47.6 68.8 45.4 68.7 47.4 69.3 48.3 89.9 24.7
5 66.8 47.4 68.6 45.6 68.5 47.6 68.9 48.1 90.0 24.9
6 66.6 47.2 68.3 45.9 68.2 47.9 68.8 47.8 90.2 24.6
7 66.9 47.5 68.6 45.8 68.5 47.8 69.1 48.1 89.8 25.0
8 67.0 47.6 68.7 45.6 68.6 47.7 69.0 48.4 90.1 24.9
Cycle-3
1 67.1 47.7 68.8 45.8 68.8 47.6 69.4 48.6 89.7 24.9
2 67.0 47.6 68.7 45.9 68.7 47.7 69.3 48.3 90.3 25.2
3 67.0 47.5 68.7 46.1 68.6 48.1 69.2 48.2 90.5 25.4
4 66.8 47.4 68.5 46.0 68.5 48.0 69.0 48.1 89.9 25.1
5 66.9 47.5 68.6 46.2 68.6 48.2 69.2 48.2 90.1 25.2
6 67.0 47.3 68.4 46.1 68.3 48.1 68.9 48.1 90.3 24.8
7 67.2 47.5 68.5 46.1 68.5 48.1 69.0 48.3 90.0 25.6
8 67.3 47.8 69.1 46.2 68.8 48.3 69.5 48.6 90.2 26.1
33
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Cycle-4
1 67.6 47.9 69.2 46.3 68.9 48.3 70.0 48.7 90.3 25.8
2 67.9 48.2 69.2 46.6 69.2 48.6 69.8 48.8 90.1 25.6
3 68.2 48.8 70.1 46.9 69.8 48.9 70.7 49.4 89.9 25.5
4 68.6 49.2 70.2 47.1 70.2 49.1 71.0 49.8 89.5 25.2
5 68.8 49.4 70.7 47.2 70.6 49.2 71.5 50.2 88.9 25.4
6 68.9 49.5 70.5 47.3 70.7 49.3 71.1 50.3 89.9 25.7
7 69.2 49.5 70.8 47.2 70.7 49.2 71.4 50.3 90.4 25.3
8 69.5 49.8 70.8 47.5 71.0 49.5 71.4 50.8 90.6 25.2
Cycle-5
1 50.0 50.3 71.6 47.8 71.5 49.9 72.2 51.3 89.7 25.4
2 70.2 50.5 71.8 48.1 71.7 50.2 72.3 51.5 89.5 25.3
3 70.3 50.9 71.9 48.2 72.2 50.2 72.4 52.0 88.9 25.7
4 70.6 51.2 72.5 48.4 72.4 50.4 73 52.0 89.6 26.2
5 71.0 51.6 72.6 48.6 72.8 50.6 73.1 52.4 90.3 26.1
6 71.3 51.9 72.9 49.0 73.2 50.8 73.4 52.8 89.9 25.8
7 71.5 52.1 73.1 49.2 73.4 51.0 73.6 53.2 90.4 25.9
8 71.7 52.0 73.3 49.5 73.3 51.6 73.8 53.1 90.2 26.0
Cycle-6
1 72.1 52.4 73.7 49.9 73.7 52.0 73.8 53.3 90.3 25.9
2 72.3 52.9 74.2 50.0 73.2 51.8 74.3 53.8 90.3 25.7
3 72.6 53.2 74.2 50.3 74.4 52.1 74.3 54.2 90.1 25.8
4 72.9 53.5 74.5 50.8 74.5 52.6 74.6 54.3 90.3 25.6
5 73.0 53.6 74.7 51.0 74.6 53.1 74.8 54.4 89.8 25.3
6 73.4 54.0 74.9 51.3 74.7 53.3 75.0 54.5 89.9 25.1
7 73.2 53.5 74.8 51.7 74.8 53.7 74.9 54.6 90.4 25.3
8 73.1 53.4 74.7 51.6 74.6 53.6 74.8 54.4 90.1 25.4
34
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
9. Individual Test: Cable Pull-out Test
Object
To verify the compression lug and cable assembly that the parts can meet ANSI/IEEE
Standard 386-2016 Cable Pull-Out Test requirements.
Testing Samples
Elbow Compression Lug
Chardon 200A
BiMetal Connector
1/0
4 PCS
Mating Parts
Cable 1/0 AWG Aluminum Cable
Procedure and Testing Spec
The purpose of this test is to determine if the connection between the cable conductor and
compression lug of the connector is capable of withstanding a tensile force of 890 N (200
lbf).
The compression lug shall be held in a manner that will not affect the strength of the
connection. The tensile force shall be applied to the cable conductor.
The connection shall withstand the applied force for 1 minute without impairing the
connector's ability to meet the other requirements of this standard.
Results
Sample number Measurement Result
I-9 211 lbf PASS
I-10 209 lbf PASS
I-11 210 lbf PASS
I-12 213 lbf PASS
35
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Cable Pull Out Test
Cable Pull Out Test in Progress
36
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10. Individual Test: Operating Force Test
Object
To verify the force of the elbow connector operating force when mating with bushing
insert that the force meets NSI/IEEE Standard 386-2016 operating force requirement.
Testing Samples
Bushing Insert CHARDON 35-LBI200 4 PCS
Elbow CHARDON 35-LE200 4 PCS
Mating Parts
Elbow Test Rod 35kV#C Testing Rod Φ31.5mm
Procedure and Testing Spec
The purpose of this test is to demonstrate that the force necessary to operate a connector
meets the requirements of 6.2.( 222 N - 890 N (50 lbf - 200 lbf) for connectors without
hold-down bails)
The elbow shall be assembled with a probe and compression lug and the connector
system shall be lubricated in accordance with the manufacturer's instructions.
Results
Sample number Open Close Result
Room
Temperature
27
I-13 104 lbf 96 lbf PASS
I-14 112 lbf 102 lbf PASS
I-15 108 lbf 98 lbf PASS
I-16 105 lbf 98 lbf PASS
-20
I-13 117 lbf 106 lbf PASS
I-14 124 lbf 112 lbf PASS
I-15 121 lbf 109 lbf PASS
I-16 120 lbf 111 lbf PASS
37
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No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
+65
I-13 93 lbf 87 lbf PASS
I-14 98 lbf 91 lbf PASS
I-15 95 lbf 90 lbf PASS
I-16 97 lbf 92 lbf PASS
Cable Pull Out Test
38
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
11. Individual Test: Operating Eye Test
Object
To verify the elbow operating eye that the part meet ANSI/IEEE Standard 386-2016
requirements.
Testing Samples
Elbow CHARDON 35-LE200 4 PCS
Mating Parts
Testing Fixture
Procedure and Testing Spec
The purpose of this test is to demonstrate that the operating eye meets the requirements of
6.2 at 25°C ±5°C.
A tensile force shall be gradually applied to the operating eye in the direction of normal
operation. The operating eye shall withstand the force for 1 minute.
A rotational force shall be applied with a suitable live-line tool to the operating eye in a
clockwise direction and in a counter-clockwise direction.
Some distortion of the operating eye is acceptable provided the connector is serviceable
after the test and meets the corona voltage-level requirement specified in Table 1 of IEEE
standard 386-2016.
Results
Sample number 500 lbf /min 120 lbf-in
rotational force PD Test
I-17 PASS PASS 26 kV / 0.8 pC
I-18 PASS PASS 26 kV / 0.8 pC
I-19 PASS PASS 26 kV / 0.8 pC
I-20 PASS PASS 26 kV / 0.8 pC
39
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Operating Eye Test
Operating Eye Test
40
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12. Individual Test: Test Point Cap Test
Object
To verify the test point cap of the elbow that the part meets ANSI/IEEE Standard
386-2016 requirement.
Testing Samples
Elbow CHARDON 35-LE200 4 PCS
Test Point Cap 4 PCS
Mating Parts
Testing Fixture
Procedure and Testing Spec
The purpose of this test is to demonstrate that the removal force of the test point cap
meets the requirements of 6.5.2 and the cap operating eye is capable of withstanding the
maximum operating force
Results
Sample number Pull Force
(8 lbf – 49 lbf) 100 lbf Pulling Result
Room
Temperature
27
I-21 38 lbf PASS PASS
I-22 36 lbf PASS PASS
I-23 42 lbf PASS PASS
I-24 41 lbf PASS PASS
-20
I-21 46 lbf PASS PASS
I-22 42 lbf PASS PASS
I-23 47 lbf PASS PASS
I-24 44 lbf PASS PASS
65
I-21 22 lbf PASS PASS
I-22 24 lbf PASS PASS
I-23 27 lbf PASS PASS
I-24 26 lbf PASS PASS
41
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Test Point Cap Test
42
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13. Individual Test: Shielding test
Object
To verify the outer conductive layer of the connector that the material meet ANSI/IEEE
Standard 386-2016 requirement of shielding test
Testing Samples
Elbow CHARDON 35-LE200 4 PCS
Procedure and Testing Spec
Shield Resistance. The shield resistance measured between the cable entrance and the
farthest extremity of the shield from the cable entrance shall be 5000Ω or less.
The purpose of this test is to demonstrate that the shielding meets the requirements of 6.3.
Thetest procedure shall be in accordance with IEEE Std 592.
Connectors shall have an electrically conductive shield and, where required, shall have
provision for connecting an external ground to the shield. Except for non-elastomeric
components, connectors shall meet the requirements of IEEE std 592.
Results
Shielding passed. Testing performed at Powertech Labs Inc, Surrey BC Canada.
Chardon – Powertech Report PL-26365
Temperature Sample number 5000Ω max Result
27
I-25 3290Ω PASS
I-26 3412Ω PASS
I-27 3256Ω PASS
I-28 3398Ω PASS
Temperature Sample number 5000Ω max Result
90
I-25 2045Ω PASS
I-26 2138Ω PASS
I-27 2396Ω PASS
I-28 2247Ω PASS
43
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Temperature Sample number 5000Ω max Result
27
(Air oven aged
for 504 h at 121
)
I-25 2842Ω PASS
I-26 2163Ω PASS
I-27 2655Ω PASS
I-28 2494Ω PASS
Temperature Sample number 5000Ω max Result
90
(Air oven aged
for 504 h at 121
)
I-25 1972Ω PASS
I-26 1880Ω PASS
I-27 2046Ω PASS
I-28 1938Ω PASS
Shielding Test
44
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45
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
14. Individual Test: Operating Interface AC Withstand Test Object
To verify the connectors that the parts meet ANSI/IEEE standard 386-2016 35kV
Operating interface AC withstand requirements.
Testing Samples
Bushing Insert CHARDON 35-LBI200 12 PCS
Elbow CHARDON 35-LE200 12 PCS
Mating Parts
Cable Conductor Type 35kV 1/0 AWG(Aluminum)
Procedure and Testing Spec
The purpose of this test is to demonstrate that loadbreak and livebreak separable
connectors or devices are capable of performing an opening operation under expected
field conditions without a flashover to ground. All separable connectors or devices,
designed to be operated while energized shall pass the requirements of this test. The
connector component designed to prevent partial vacuum flashovers shall also
demonstrate the ability to meet the requirements of this test when tested with mating
components from other manufacturers where applicable.
If necessary, operating interfaces under test can be cleaned with a laboratory grade of
isopropyl alcohol (2-pro-penal). After cleaning, the samples shall dry for a minimum of
15 min before assembly to allow the cleaning solvent to evaporate from the interface.
Further preparation of the samples shall follow Option A or Option B as follows:
Option A: The operating interfaces shall be free of any lubrication. Twelve separable
connectors or devices to be evaluated should have test cable installed where appropriate
and be assembled onto 12 mating connectors or components at an ambient temperature of
25 °C ±5 °C.
After Option A or Option B, chill the connector assemblies in a cold chamber at -20 °C to
-25 °C for a min-imum of 16 h. Remove one connector assembly at a time from the cold
chamber and mount the assembly to a grounded test stand. Attach ground leads to the
external shields of the connector. Adjacent grounds are not required. This conditioning
may be performed at -1 °C to +4 °C for any connector or device that is to be mated for
less than 24 h in any field applications, such as direct-test probes.
Separate the connector or device assembly from the bushing within 10 min after removal
from the cold cham-ber. The opening operation shall be performed with a positive
continuous motion applied manually or by a mechanical actuator with an average
operating speed during the initial 2.5 cm (1.0 in) of travel of 89 cm/s ±13 cm/s (35 in/s ±5
in/s). The force shall be applied to the operating eye of the connector using a suitable
live-line tool or equivalent device.
46
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Results
Sample No. Wave No. VL-G IF IGround Result
C01 0010014 37.144kV 1.028A 0A PASS
C02 0010015 37.055kV 1.023A 0A PASS
C03 0010016 40.487kV 1.042A 0A PASS
C04 0010017 37.343kV 1.053A 0A PASS
C05 0010018 36.931kV 1.085A 0A PASS
C06 0010019 37.322kV 1.091A 0A PASS
C07 0010020 37.275kV 1.081A 0A PASS
C08 0010021 37.486kV 1.079A 0A PASS
C09 0010022 37.123kV 1.075A 0A PASS
C10 0010023 36.779kV 1.077A 0A PASS
C11 0010024 37.059kV 1.068A 0A PASS
C12 0010025 36.830kV 1.062A 0A PASS
Note:
XS = 3.64kΩ, RS = 0.606kΩ, RG = 28.5kΩ
1. ZS = RS + XS = 4.246 kΩ
2. XS / RS = 6
3. ZS ≧ 0.10RG = 0.149 RG
4. IF = V / (ZS + RG) ≧ 1A
47
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Cold Chamber at -20 °C to -25 °C
OIACW Test
48
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Test Voltage (VL-G)
Test Current (IF)
49
Copyright © 2019, Chardon Group All rights reserved
No. 37, Min-Chie Road, Tung Lo Industrial Park, Miao Li, 366 Taiwan, R.O.C. Tel: +886-37-984385 | Fax: +886-37-984770 E-Mail: [email protected]
Face to Ground Current (IGround)
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