Controls on keypad: Power ON/OFF switch, set kV potentiometer, Test, Fault Reset & Buzzer Reset Key
Output contact: 1 no. of 230 VAC /24VDC, 2A changeover relay potential free contact on the backside of the control unit
Modes of operation:
AUTO mode: Continuous kV/momentary off
Manual mode: Removes kV on fault till manual Reset.
Standards referred: IS 10810-(Part 44)-1984 Appendix-A / UL – 1581 (Part 900)
High voltage “ON” Indication
Flasher & Hooter for Fault
Type of Electrode: Ball chain Electrode
Safety interlock: Microswitch interlock for protective cover of HV chamber.
Cable Fault conditions: Pin holes, Bare patches. (Fault current 600 microamp)
Dimensions for all models
Length (in Inches)
Width (in Inches)
Height (in Inches)
Weight (in KGs)
Wire Harness Application
Functionality of Spark Tester
KAT Controls make Spark Testers are designed for testing the insulation quality for Extruder, coiling machine & cutting cum stripping machine for harness manufacturer. The unit is capable of performing non-destructive integrity testing on all types of insulated cables for detecting pin-holes, cuts, slits, bare patches etc.in cable insulation.
The spark tester consists of a High Voltage electrode unit with High Voltage transformer and an electronic control unit which has a highly reliable solid-state structure and requires minimal maintenance.
Ball chain assembly used in High voltage / Frequency Electrode unit which is in contact with the cable under test and complete periphery of the cable is covered by corona which ensures effective contact zone around the cable insulation.
This unique feature ensures that the actual voltage displayed on the meter is applied accurately and consistently to the cable surface even if the bead chains do not touch the cable form all sides. A pre-adjusted and extremely sensitive fault detection circuit detects all the faults. As compared to water immersion test this is nondestructive test.
KAT Controls has been working & supplying EDI Rectifier panels for Water treatment plant manufactures locally & globally. We have been serving this Industry from the last 15 years with repetitive customers assuring us of our quality and the confidence of our Customers.
Electrodeionization (EDI) is a water treatment technology that utilizes electricity, ion exchange membranes and resin to deionize water and separate dissolved ions (impurities) from water. It differs from other water purification technologies wherein it is done without the use of chemical treatments and is usually a polishing treatment to reverse osmosis (RO). There are also EDI units that are often referred to as continuous electrodeionization (CEDI) since the electric current regenerates the resin mass continuously. CEDI technique can achieve very high purity, with conductivity below 0.1 μS/cm.
Systems for water treatment, demineralization and desalting .Electrolytic technology uses pressure and electrical current to separate soluble ions from water through a semi permeable material which includes both cationic and anionic membranes. Each cell incorporates specific ion exchange resin between the two types of membranes allowing negative and positive ions to only pass through one of the membranes. DC voltage transfers ions from one solution to another through selective ion exchange membranes.
An electrode in an electrochemical cell is referred to as either an anode or a cathode, terms that were coined by Michael Faraday. The anode is defined as the electrode at which electrons leave the cell and oxidation occurs, and the cathode as the electrode at which electrons enter the cell and reduction occurs. Each electrode may become either the anode or the cathode depending on the voltage applied to the cell. A bipolar electrode is an electrode that functions as the anode of one cell and the cathode of another cell. Each cell consists of an electrode and an electrolyte with ions that undergo either oxidation or reduction. An electrolyte is a substance containing free ions that behaves as an electrically conductive medium. Because they generally consist of ions in solution, electrolytes are also known as ionic solutions, but molten electrolytes and solid electrolytes are also possible. They are sometimes referred to in abbreviated jargon as lytes. Water is passed between an anode (positive electrode) and a cathode (negative electrode). Ion-selective membranes allow the positive ions to separate from the water toward the negative electrode and the negative ions toward the positive electrode. High purity deionized water results.
SPECIFICATIONS, PROTECTIONS AND SAFETY INSTRUCTIONS FOR EDI RECTIFIER
INPUT AND OUTPUT RATINGS:
Input 415V/380/V480V±10%,3 phase, 50/60 Hz. Total current rating will be as per no. of stack requirement.
Output 1(for upper stage): 3.5A at 100-500V/550V DC
Output 2(for lower stage): 2.5A at 100-500V/550V DC
Output current: Adjustable from 10 to 100%
Current tripping 110%
Output ripple < 3%
Efficiency min 92%
Model to be specified by supplier
Output short circuit protection
Fast acting DC fuse/DC MCB of proper grade and rating to be provided for each stack.
Main enclosure should be indoor ventilated floor mountable IP20/IP55
Size and weight will be provided
Color normally RAL7035 Gray, otherwise customer specified
Provision to move the equipment with fork lift
Cable terminals-on lugs for incoming power supply, DC supply and control signals
Cable entry top/bottom. Cable glands will be provided on request
Rectifier will be forced air cooled to be operated at room temperature 45ºC max
Cool air enters from bottom of the enclosure and warm air exits from top. If cooling system failed and abnormal temp. Occurred, the equipment wills ‘CUT OFF’ by thermostat provided on heatsink
Maximum altitude 1000m above sea level
Continuous 100%, 24 hours a day,7 days a week
SCR 6 Pulse, Three phase full wave full controller system
Regulation ±1% for voltage and current
Proper thermostat on heatsink for abnormal temp.
SCR PIV 1600V to protect equipment from input high voltage surges
Adequate heatsink to operate SCR Bridge within specified tolerance. Junction temp. Band specified by SCR manufacturers
One main input AC circuit breaker MCB/MCCB to protect the equipment from overload and short circuit
One main AC contactor at Transformer secondary to Cut-off output voltage totally and to switch off the output in case of any fault (over current/over temp.)
SCR heatsink over temperature
Main isolation transformer winding over temperature separate thermostat to be provided for each winding
Semiconductor grade fuse for input to protect the DC unit from short circuit/overload
Surge suppression arrangement for SCR to protect from input voltage surges
DC fuse or DC MCB for each stack to avoid damages because of internal/external short circuit
For any sudden rise of current, the SCR firing shall be removed by enable/disable electronic circuit, to protect the equipment from heavy current surge if any.
Single phasing cum wrong phase sequence with under /over voltage protection to be provided. This will protect the equipment from over/under voltage at input side
MAIN ISOLATION TRANSFORMER
Splice free copper windings
Low flux density of core
180ºC class F insulation to protect the winding in case of abnormal temp
High temp thermostat to be provided to protect the winding in case of abnormal temp.
Core strip to be earthed to avoid leakage current of transformer
BIL of 2.5kV min
Transformer cooling fan will be provided if transformer is placed in separate enclosure. Protection class will be IP20
Digital meters to be provided for incoming AC voltage, DC voltage and DC current at front of the panel
Start/stop push button
Voltage and current limit adjustment pot to be provided separately
External operating provision (PLC Operation) like Start/Stop, set voltage/current can be provided on request.
Selector switch to check individual EDI current can be provided on request
Isolator for output voltage and output current can be provided on request
To protect the equipment from earth fault, supplier shall provide earth fault relay at input side on request only
‘Negative’ terminal of the DC output voltage should be earthed properly at panel end
Instruction manual set with all safety instruction bill of material, recommended spares, operating instruction, electrical diagram single line diagram, specifications etc.
Test report of DC source, panel and isolation transformer
Stickers for safety symbols/instructions/warning to be pasted on equipment to increase the awareness.
High Voltage & extra High Voltage Switchgear
manufacturing companies needs High Voltage Current Transformers and High Voltage
– Voltage Transformers test set-up for
in-process testing & final testing.
KAT Controls has been working &
supplying this test set-up for HV switchgear manufacturing companies, locally
and globally, for the last 25 years.
KAT Controls has complete Technical know-how
& experience of the test requirement as per International quality standard
IEC 61869 – part 1 & 5 & Indian standard IS-16227.
All required test as per International/
National quality standard on HVCT, ranging from 72.5kV – 800 kV, Primary – Up
to 10000 A & secondary- 1A/5A (with 1/5 A burden selection), can be
Polarity test, Accuracy test using
High current source at 50 & 60 Hz with different burdens ( Ratio error
& Phase error with AITTS), Interturn overvoltage test at 400 Hz, Power
frequency withstanding test at 5kV for 1 minute, Measurement of Knee point
voltage & excitation current for special protection core, Measurement of
Instrument security Factor ( ISF) for metering core, Measurement of Composite
error for protection core, Temperature rise test at different location of HVCT.
Polarity tester, Pretesting panel, 400
Hz testing panel with 400 Hz M-G set, 50/60 Hz Accuracy testing panel with 60
Hz M-G set, High current source & dimmer.