It goes without saying that the diagnostic testing of substation assets during commissioning and on-going maintenance is essential to ensure their reliable and safe operation. Considerable time and resources are invested to conduct all the necessary tests on assets, such as power and instrument transformers, grounding systems, circuit breakers, switchgear, rotating machines and cables.

Reducing the number of testing devices
The effort and expense of conducting the complete array of tests on these various assets is compounded by the fact that it has been common practice to use separate instruments for each type of test. This often results in the complicated and costly transport of several individual testing instruments to onsite locations. Most significantly, having to connect and configure a variety of instruments for each type of test also increases the time in which assets are not in productive operation.

A multi-functional test device designed to conduct most of the standard electrical tests can make commissioning and maintenance testing more efficient and cost effective.

Selecting the best solution
In selecting a multi-functional testing device, key considerations need to be made. For example, the system should be compact and lightweight for easy transport and handling. It should feature an expandable modular design that enables users to easily add accessories to meet both present and future test application requirements.

Ideally, the multi-functional testing device should be able to generate high currents and voltages on site for various off-line measurements. A high level of interference suppression should also be possible to ensure accurate readings in substations where high levels of electrical noise are present. Most importantly, despite its versatility, the multi-functional testing device should remain easy to use for on-site commissioning and maintenance testing based on IEC and IEEE standards.
 

Figure 1: Multi-functional CPC 100 for substation testing
 

The first of its kind
All of these considerations are what inspired OMICRON over 15 years ago to develop and launch its patented CPC 100 primary injection test system. It was then the first multi-functional testing solution of its kind and its continued popularity has made the CPC 100 the reference point in the industry for multi-functional substation asset testing.

Already more than 5,000 CPC 100 primary injection test systems are in use at utilities and industrial plants around the world for asset commissioning and maintenance. Current customers can attest to the fact that the CPC 100 dramatically reduces the costs for transport and training, and it greatly minimizes testing time.

All-in-one solution
Several standard and advanced diagnostic tests can be performed with the CPC 100 on various electrical assets, including power transformers, current and voltage transformers, circuit breakers and switchgear, rotating machines, grounding systems, as well as cables and transmission lines.
 

Figure 2: CPC 100 application areas
 

The CPC 100 provides users with up to 800 A or 2 kV (2 kA or 12 kV with boosters) with up to 5 kVA over a frequency range of 15 Hz to 400 Hz or 400 A DC.

Add-on devices allow the CPC 100 to further expand its testing capabilities to perform specialized tests, such as power/dissipation factor, line and ground impedance measurements as well GIS testing. In addition, the CPC 100 also enables sampled values and merging unit testing in accordance with the IEC 61850-9-2 standard.

Compact and lightweight
The CPC 100 weighs only 29 kilograms (64 lbs.) and it comes with a wheeled transport case. This makes it easy for one person to carry and handle the equipment during on-site testing. Thanks to its compact and lightweight design, it can be easily transported in a vehicle or economically shipped in advance to measurement locations.

Portable HV source
In addition to the diverse variety of electrical tests it performs, the CPC 100 can also be used as a convenient HV source to energize assets for off-line diagnostic testing, as for example during induced voltage testing for voltage withstand and partial discharge measurements. Thanks to its design, the CPC 100 can be easily transported and used in testing areas that are hard to access or have limited space. By comparison, traditional types of external HV sources used for off-line testing are often very large, cumbersome and expensive to transport.

Variable test frequencies
To operate the CPC 100, users simply plug it into a standard electrical outlet, open up the front panel and turn on the power. The energy coming out of the power socket is converted electronically so that it is at a stable frequency. Variable test frequencies from 15 Hz to 400 Hz can be selected to ensure the effective suppression of mains-related interference. This enables users to obtain accurate measurement results even in noisy environments.

High level of safety
To protect users and their electrical assets during high-voltage diagnostic testing, the CPC 100 is equipped with various safety mechanisms, including an automatic ground connection check, overload detection, multiple isolated outputs, a safety lock key, an acoustic signal to indicate measurements in progress, as well as an emergency switch-off button. These features ensure a safe testing environment, helping to prevent both personal injury and equipment damage.

Flexible operation
The CPC 100 provides users with various ways to conduct on-site tests on substation assets, whether manually, directly from the instrument panel, or with a laptop PC or tablet using OMICRON's Primary Test Manager^TM (PTM) software. This powerful software tool enables users to have extended on-site testing capability at their fingertips, including guided test workflows, data management and automatic real-time assessment.

Easy data handling and reporting
All results are displayed as diagrams and tables in real time, and the PTM software also shows the progress of the measurements as well as the remaining tasks. An overview of the test results is given during the measurement and an instant "pass/fail" assessment of the test results is displayed based on specified limit values, such as those conforming to international standards. The software automatically generates reports that include pre-selected information about the asset and the tests that have been performed.
 

Figure 3: The CPC 100 can be easily controlled from a laptop or tablet
 

Designed for future testing requirements
The modular and expandable CPC 100 is designed to meet expectations for substation commissioning and maintenance testing for years to come. New add-on components and software features are being continuously developed to cover present and future asset testing requirements.