High Voltage

Laboratory
Supplementary
Connections Manual
Contents
Contents 3
About this manual 5
1. Safety Regulations for High Voltage Experiments 7
1.1 Introduction 7
1.2 Fencing 7
1.3 Safety locking 7
1.4 Earthing 8
1.5 Circuit and test setup 8
1.6 Conducting the experiments 8
1.7 Explosion and fire risk, radiation protection 9
1.8 Accident insurance 9
1.9 Conduct during accidents 9
2. High voltage AC circuits 11
2.1 Measurement and instrumentation 11
2.2 Component layout 12
2.3 Location 14
2.4 Cascade mounting 14
2.5 Cascade connections 15
2.6 Capacitive currents 16
2.7 Connecting test objects 16
3. High voltage DC circuits 19
3.1 Measurement and instrumentation 19
3.2 2-Stage DC voltage test setup (280kV) 20
3.2.1 Principle diagram 20
3.2.2 Component layout 20
3.3 3-Stage DC voltage test setup (420kV) 21
3.3.1 Principle diagram 21
3.3.2 Component layout 22
4. High voltage Impulse circuits 23
4.1 Measurement and instrumentation 23
4.2 2-Stage Impulse voltage test setup (280kV) 25
4.2.1 Principle diagram 25
4.2.2 Component layout 26
4.3 3-Stage Impulse voltage test setup (420kV) 29
4.3.1 Principle diagram 29
4.3.2 Component layout 30
The High Voltage Experiments manual series 33
4
About this manual
This manual has been developed to provide information on additional High Voltage
laboratory circuits.

It is recommended that users are familiar with the high voltage components and single-stage
AC, DC and Impulse setups before attempting to experiment with the setups included in this
manual.

If the user is not confident with the aforementioned components and setups, it is highly
recommended that the user works through the Introduction to High Voltage Experiments
Manual.

Focus
Focus is put on schematic and pictorial examples of additional high voltage circuits.

Stockholm/Sweden Stuart Sunkel

January 2012
September 2012 (Rev I)

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6
1. Safety Regulations for High Voltage Experiments
1.1 Introduction
Experiments with high-voltages could become particularly hazardous for the participants
should safety precautions be inadequate. To give an idea of the required safety measures,
an example the safety regulations followed in several High Voltage Laboratories attached to
the Technical University of Braunschweig shall be described below. These supplement the
appropriate safety regulations and as far as possible prevent risks to persons. Strict
observance is therefore the duty of everyone working in the laboratory. Here, any voltage
greater than 250 V to earth potential is understood to be a high voltage (VDE 0100).

Fundamental Rule:
Before entering a high-voltage setup area, participants must first ensure that all conductors
which can assume high potential and lye in the contact zone are earthed and that all main
leads are interrupted.

1.2 Fencing
All high-voltage setups must be protected against unintentional entry to the danger zone.
This is appropriately done with the aid of metallic fences. When setting up the fences for
voltages up to 1 MV the following minimum clearances to the components at high voltage
should not be exceeded:

Alternating and direct voltages 50 cm for every 100 kV

Impulse voltages 20 cm for every 100 kV

A minimum clearance of 50 cm shall always be observed, independent of the value and type
of voltage. For voltages over 1 MV, in particular for switching impulse voltages, the values
quoted could be inadequate; special protective measures must then be introduced.

The fences should be reliably connected conductively, earthed and provided with warning
boards inscribed: “High Voltage! Caution! Highly Dangerous!”. It is forbidden to introduce
conductive objects through the fence while the setup is in use.

1.3 Safety locking

In high-voltage setups each door must be provided with safety switches; these allow the door
to be opened only when all main leads to the setup are interrupted. Instead of direct
interruption, the safety switches may also operate the no-voltage relay of a power circuit
breaker, which on opening the door, interrupts all the main leads to the setup.

These power circuit breakers may also be switched on again when the door is closed. For
direct supply from a high-voltage network (e.g. 10 kV city network), the main leads must be
interrupted visibly before entry to the setup by an additional open isolating switch. The
switched condition of a setup must be indicated by a red lamp “Setup switched on” and by a
green lamp “Setup switched off”.

If the fence is interrupted for assembly and dismantling operations on the setup, or during
large-scale modifications, all the prescribed precautions for entry to the setup shall be
observed. Here, particular attention must be paid to the reliable interruption of the main
leads. On isolating switches or other disconnecting points and on the control desk of the
setup concerned, warning boards inscribed “Do not switch on! Danger!” must be displayed.

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1.4 Earthing
A high-voltage setup may be entered only when all the parts which can assume high-voltage
in the contact zone are earthed. Earthing may only be effected by a conductor earthed inside
the fence. Fixing the earthing leads onto the parts to be earthed should be done with the aid
of insulating rods. Earthing switches with a clearly visible operating position are also
permissible. In high-power setups with direct supply from the high-voltage network, earthing
is achieved by earthing isolators. Earthing may only follow after switching the current source
off and may be removed only when there is no longer anyone present within the fence or if
the setup is vacated after removal of the earth. All metallic parts of the setup which do not
carry potential during normal service must be earthed reliably and with adequate cross-
section of at least 1.5 mn2 Cu. In test setups with direct supply from the high-voltage network,
the earth connections must be made with particular considerations of the dynamic forces
which can arise.

1.5 Circuit and test setup

In the case that the setup is not supplied from ready wired desks, clearly marked isolating
switches must be provided in all leads to the low-voltage circuits of high-voltage transformers
and arranged at an easily identifiable position outside the fence. These must be opened
before earthing and before entering the setup.

All leads must be laid so that there are no loosely hanging ends. Low-voltage leads which
can assume high potentials during breakdown or flashovers and lead out of the fenced area,
e.g. measuring cables, control cables and/or supply cables must be laid inside the setup in
earthed sleeves. All components of the setup must be either rigidly fixed or suspended so
that they cannot topple during operation or be pulled down by the leads. For all setups
intended for research purposes, a circuit diagram shall be fixed outside the fence in a clearly
visible position. A test setup may be put into operation only after the circuit has been
checked and permission to begin work given by an authorized person.

1.6 Conducting the experiments

Everyone carrying out experiments in the laboratory is personally responsible for the setup
placed at his disposal and for the experiments performed with it. For experiments during
working hours one should try, in the interest of personal safety, to make sure that a second
person is present in the testing room. If this is not possible, then at least the times of the
beginning and ending of an experiment should be communicated to a second person. When
working with high-voltages beyond working hours, a second person familiar with the
experimental setups must be present in the same room.

If several persons are working with the same setup, they must all know who is to perform the
switching operations for a particular experiment. Before switching on high-voltage setups,
warning should be given either by short horn signals or by the call “Attention! Switching-on!”.
This is especially important during loud experiments, so that people standing-by may cover
their ears. If necessary, switching off can be announced after completion either by a single
long tone or by the call: “Swtiched off”.

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1.7 Explosion and fire risk, radiation protection
In experiments with oil and other highly flammable materials, special care is necessary owing
to the danger of explosion and fire. In each room where work is carried out with these
materials, suitable fire extinguishers must be close to hand and ready for use. Highly
flammable waste products, e.g. paper or used cotton waste, should always be disposed off
immediately in metal bins. Special regulations must be observed when radioactive sources
are used.

1.8 Accident insurance

Everyone working in the Institute must be insured against accidents.

1.9 Conduct during accidents

Mode of action in case of an electrical accident:

1. Switch off the setup on all poles. So long as this has not been done, the victim of the
accident should not be touched under any circumstances.

2. If the victim is unconscious, notify the emergency service at once.

Telephone Number: ………..........................................................

3. Make immediate attempts to restore respiration by artificial respiration or chest

massage!

4. These measures must be continued, if necessary, up to the beginning of an

operation. (Only 6 to 8 minutes time before direct heart massage!).

5. Even during accidents with no unconsciousness, it is recommended that the victim

lies quietly and a doctor’s advice is sought.

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10
2. High voltage AC circuits
For test objects requiring even higher voltages, the HV9105 test transformer can be cascade
connected to provide 200kV (2-stage), or 300kV (3-stage).The required number of test
transformers are stacked on top of one another.

2.1 Measurement and instrumentation

All high voltage measurement, albeit AC voltage, DC voltage or Impulse voltage is carried
out by voltage division. In the case of AC voltage measurement, this voltage division is done
over a capacitance. When 2 or 3-stage AC is in operation, a Low Voltage Divider is also
required.

Low Voltage Divider

The HV9143 Measuring Capacitor is to be connected via the HV9130 Low Voltage Divider.
This is screwed in at the bottom of the measuring capacitor to provide a stand output ratio for
the HV9150 AC Peak Voltmeter.

Fig. 2.1 Low Voltage Divider

Note! Failure to connect via the low voltage divider will result in damage to the Peak Voltmeter.

HV9150 AC Peak Voltmeter

The HV9150 AC Peak Voltmeter is usually mounted in the HV9103 Control Unit, which is
positioned outside the HV cage.
The connection from the HV9130 Low Voltage Divider is made via a BNC cable, which is
connected to the HV9150 connector, found on the rear panel of the control unit.

Fig. 2.2 HV9150 AC Peak Voltmeter

When using the 2 or 3-stage cascade system, the range switch should be in the ‘1000’
position as shown in figure 1.12. Otherwise the range switch should be in the ‘100’ position.

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2.2 Component layout
The basic circuit for a 3-stage setup is shown below.

HV9106

HV 9109
HV9140

3 x Cascaded HV 9105
HV 9143

From Control Desk

Regulated Voltage Output HV 9110

To Control Desk
AC measurement Input

Fig. 2.3 HV AC 3-stage test setup including 3 x test transformers, top electrodes and the HV9143 measuring capacitor.

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 Test object
(Not supplied)

To HV9150 AC Peak
Voltmeter

Fig. 2.4 3-Stage AC setup: 3 test transformers and the HV9143 measuring capacitor.

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2.3 Location
This setup should be constructed in the middle of the HV cage, as far away from walls and
fences as possible. Consideration should always be given to the increased possibility of
flashovers to unexpected objects during experimentation.

2.4 Cascade mounting

Note! Each transformer weighs in excess of 200kg. Please use suitable lifting equipment for
stacking the transformers in order to prevent damage to the equipment and injury to
participants.

Always keep the transformer upright.

Always lift the transformer from underneath as shown below, never from the top as
this will damage the unit.

Fig. 2.5 Correct lifting procedure

The bottom transformer should be mounted on the strengthened mobile base (provided) and
not on the standard single-transformer castors.

Fig. 2.6 Strengthened mobile base

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Replace the castors on the underside of the second and third stage transformers with the
mounting brackets provided.

Fig. 2.7 Mounting bracket on second stage transformer

After carefully lowering the transformer onto the previous, secure it by tightening the bolts on
each foot of the mounting bracket.

2.5 Cascade connections

To connect between stages, the following connections should be made between the
transformers using the jumpers provided.

Fig. 2.8 Cascaded transformer diagram Fig. 2.9 Cascade connection jumpers

Note: Common laboratory cables can be used to connect the first and second stage
transformers for even quicker changeover between 3-stage and Single-Stage setups, leaving
the second and third stage transformers in place.

Finally, place the HV9140 electrode atop the topmost transformer.

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2.6 Capacitive currents
Large currents can be observed, even during no-load conditions. This
is mainly due to the large capacitive currents from the HV9140 top
electrode to the surrounding environment. This is known as the
Ferranti Effect and is normal for this setup.
Compensating reactors can be introduced into the setup between
each transformer to reduce these effects.

Fig. 2.10 Compensating reactor

Test Output of the Transformer in Cascade Connection

Without compensation for transformer TEO 100/10 With compensating reactor for transformer TEO 100/10

Cascade Continuous Short-time Continuous Short-time No. of reactors

1-Stage 5 kVA 10kVA - - -
2-Stage 5 kVA 10kVA 10kVA 20kVA 1
3-Stage 5 kVA 10kVA 15kVA 30kVA 2

2.7 Connecting test objects

Due to the limitless types of different test object and their varying connections, no
standardized test object connector is provided. Therefore, in the absence of said connector,
the following connection suggestions are offered.

Connecting cup with 2 flexi-cables

Fig. 2.11 Top electrode connector, to test transformer, left, and to test object, right.

Note: this does not solve the actual connection to the test object, which must be customized.

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Shoed cable with single flexi-cable
To connect your chosen test object, use a suitable cable with an appropriately crimped end
as shown.
Pass the bolt through the cable ring before connecting to the measuring capacitor top
electrode.

HV9106
Flexi HV connector

(To HV9105 test

transformer)

Suitable cable to test object

(not supplied)

HV9143
Top electrode

Fig. 2.12 Flexi-cable to test transformer, top; shoed cable to test object, right.

Note: This does not solve the actual connection to the test object, which must be customized.

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Notes

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3. High voltage DC circuits
For conducting experiments where 140kV is not adequate, up to 280kV DC can be obtained
with the 2-stage setup or 420kV with the 3-stage setup.

3.1 Measurement and instrumentation

DC voltage measurement is carried out by voltage division using the HV9113 measuring
resistor.

Fig. 3.1 HV9113 Measuring resistor. BNC output can be seen bottom left of the component

The connection from the HV9113 is made via a BNC cable, which is connected to the
HV9151 input on the rear panel of the control unit.

Fig. 3.2 HV9151 DC Voltmeter set to2-stage respective 3-stage measurement

For more information please, refer to the HV9151 DC voltmeter manual.

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3.2 2-Stage DC voltage test setup (280kV)
3.2.1 Principle diagram

Fig. 3.3 Simplified 2-Stage DC circuit without measurement components

3.2.2 Component layout

The diagram below shows a suggested connection setup to achieve the circuit shown above.

HV9105

HV9114

To HV9151 DC
Voltmeter
Points to be earthed manually with the
earthing rod on entry.

HV9113 Measuring resistor HV9108 Connecting rod Electrodes

HV9121 Charging resistor HV9124 Isolator

HV9112 Smoothing capacitor HV9119 Spacer tube

HV9111 Rectifier HV9110 Floor pedestal

HV9108 Connecting cup

Fig. 3.4 Layout of 2-stage DC components

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Fig. 3.5 2-stage impulse setup assembled. (280kV) Note: AC measuring cap is seen in place of the HV transformer(left)

In the picture above, the AC measuring capacitor is also in place in the circuit (leftmost
component). The flexi-connector then continues to the HV9105 HV transformer (out of
picture). This setup enables simultaneous AC and DC measurement.

3.3 3-Stage DC voltage test setup (420kV)

For conducting experiments where 280kV DC is not adequate, up to 420kV DC can be
obtained following the same principle as with the previous 2-stage circuit.

3.3.1 Principle diagram

Fig. 3.6 Simplified 3-Stage DC circuit without measurement components

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3.3.2 Component layout

HV9105

HV9114

To HV9151 DC
Points to be earthed manually with the Voltmeter
earthing rod on entry.

HV9113 Measuring resistor HV9108 Connecting rod Electrodes

HV9121 Charging resistor HV9124 Isolator

HV9112 Smoothing capacitor HV9119 Spacer tube

HV9111 Rectifier HV9110 Floor pedestal

HV9108 Connecting cup

Fig. 3.7 Layout of 3-stage DC components

Notes

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4. High voltage Impulse circuits
4.1 Measurement and instrumentation
All high voltage measurement, albeit AC voltage, DC voltage or Impulse voltage is carried
out by voltage division.
In the case of Impulse voltage measurement, this voltage division is done over a
load/measuring capacitor (HV9120). For Impulse voltage measurement a Low Voltage
Divider should always be connected.

HV9130 Low Voltage Divider

The HV9143 Measuring Capacitor is to be connected via the HV9130 Low Voltage Divider.
This is screwed in at the bottom of the measuring capacitor to provide a stand output ratio for
the HV9150 AC Peak Voltmeter.

Fig. 4.4 Low Voltage Divider Fig. 4.5 HV9120 Measuring capacitor with HV9130divider mounted.

Note! Failure to connect via the low voltage divider will result in damage to the Impulse Voltmeter.
For 2-stage impulse, the appropriate 2-stage voltage divider should be used (refer to the rating
stamped on the unit).

HV9152 Impulse Voltmeter

The HV9152 Impulse Voltmeter is usually mounted in the HV9103 Control Unit, which is
positioned outside the HV cage. The connection from the HV9130 Low Voltage Divider is
made via a BNC cable, which is connected to the HV9152 input on the rear panel of the
control unit.

Fig. 4.6 HV9152 set to 2-stage respective 3-stage measurement.

The stage selector on the HV9152 impulse voltmeter should be set according to the setup.
Positive or negative measurements can be selected by the selector knob, right.
For more information about this unit, please see the separate HV9152 Impulse voltmeter
manual.

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24
4.2 2-Stage Impulse voltage test setup (280kV)
The 2 and 3 stage impulse voltage setup works on the same principle as a Marx generator.
The impulse capacitors are connected in parallel during the charging stage.
At the point of breakdown (correctly on the lowest sphere gap), the capacitors become series
connected through the path made over the sphere gaps, allowing them to discharge the
stored energy.

4.2.1 Principle diagram

The following diagram shows the principle schematic behind the 2-stage impulse setup.
The +/- seen at the lower left of the diagram denotes a rectified voltage entering the circuit.
This rectified voltage comes from two HV9111 rectifiers, connected in turn to the HV9105
test transformer.

HV9122
350 Ω*

HV9120
HV9125
1200pF
HV9123
2400 Ω*
HV9112

25000pF
HV9122
350 Ω*
HV9121
10M Ω HV9120
HV9125
1200pF
HV9123
2400 Ω*
HV9121 HV9112
+ HV9130
10M Ω 25000pF

Low
voltage
divider
240kV
-

HV9152
Impulse voltmeter
* Values for lightning impulse waveform

Fig. 4.1 2-stage impulse diagram (280kV)

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4.2.2 Component layout

HV9122
HV9120
HV9123

HV9105
HV9122

HV9123 HV9120

HV9114 HV9130

HV9126
To HV9152 Impulse
Control unit Control unit Voltmeter
HV9114 input HV9125 input
To HV9151 DC
Voltmeter

HV9113 Measuring resistor HV9108 Connecting rod

HV9121 Charging resistor HV9124 Isolator

HV9112 Smoothing capacitor HV9119 Spacer tube

HV9111 Rectifier

Fig. 4.2 2-stage impulse layout (280kV)

Fig. 4.4 2-stage impulse setup assembled. (280kV) Second rectifier not connected in photo. 2 rectifiers must be used.

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27
Notes

28
4.3 3-Stage Impulse voltage test setup (420kV)
4.3.1 Principle diagram
The 3-stage impulse voltage generator simply builds on the 2 stage generator.

HV9122
350 Ω*

HV9120
HV9125 1200pF
HV9123
2400 Ω*

HV9112

25000pF
HV9122
350 Ω*

HV9121
10M Ω HV9125 HV9120

HV9123 1200pF
2400 Ω*
HV9112

25000pF
HV9122
350 Ω*
HV9121
HV9120
10M Ω
HV9125 1200pF
HV9123
2400 Ω*
HV9121 HV9112
+ HV9130
10M Ω 25000pF

Low
voltage
divider
420kV
-

HV9152
* Values for lightning impulse waveform Impulse voltmeter

Fig. 5.1 3-stage impulse diagram (420kV)

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4.3.2 Component layout

HV9122 HV9123

HV9112
HV9120

HV9123 HV9122

HV9120 HV9112

HV9122 HV9123

HV9120

HV9112

HV9130

HV9105

To HV9151 DC
Voltmeter
To HV9151 DC
Voltmeter
To HV9152 To HV9151 DC
Impulse Voltmeter
Voltmeter

HV9113 Measuring resistor HV9108 Connecting rod HV9125 Sphere gap

HV9121 Charging resistor HV9124 Isolator HV9109 Connecting cup

HV9119 Spacer tube

HV9111 Rectifier

Fig. 5.2 3-stage impulse layout (420kV)

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Fig. 5.3 3-stage impulse setup assembled (420kV) Note! AC measurement not connected in circuit above.

31
Notes

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The High Voltage Experiments manual series

Introduction to High Voltage Experiments manual

The Introduction to High Voltage Experiments manual includes procedural instructions for
building the fundamental single-stage HV circuits and controlling experiments via the
HV9103 Control Desk. These circuits include:

 HVAC generation and measurement

 HVDC generation and measurement
 HV Impulse generation and measurement

After working through this manual, the user should feel confident working with the equipment
and have an understanding of the HV generation and measurement methods incorporated in
the Terco HV Laboratory as well as safety features and routines.

HV Lab Supplementary Connections manual

This manual includes information for the construction of advanced HV circuits. These circuits
are an extension of those investigated in this manual and require additional components.
Setups covered in the Supplementary Connections manual include:

 Multiple stage AC (cascaded transformers)

 2 stage DC setup
 3 Stage DC setup
 2 stage Impulse setup
 3 stage Impulse setup

It is highly recommended that the user should work through the Introduction to High Voltage
Experiments manual before attempting any of these setups. Failure to do so could result in
damage to the equipment.

High Voltage Experiments manual.

The High Voltage Experiments manual introduces some common high voltage experiments
which can be performed with the help of the Terco HV Laboratory.
Note: Some experiments may require external equipment such as measuring circuits,
instruments, test objects and connectors not supplied with the Terco HV Laboratory.

In order to fully understand the concepts introduced in this manual, it is highly recommended
that the user has a good understanding of the fundamentals of HV. The user should also be
familiar with all components and correct experimentation techniques before working through
this manual.

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