Dual Canopy Mechanic Electrical Engineering Co., Ltd. is one of the leading manufacturers and suppliers of Primary Current Injector Tester in China. Please feel free to wholesale discount products for sale here and get quotation from our factory. Customized orders are welcome.
What is Primary Current Injector Tester?
The Primary Current Injector Tester is a specialized high-current, low-voltage test set designed to inject a controlled AC current directly into the primary side of electrical apparatus. Unlike secondary injection test sets that simulate signals to relays, the primary injection system tests the entire current path, including current transformers (CTs), wiring, connections, and the primary conductors of circuit breakers or busbars.
This system is essential for verifying the actual operating conditions of protection schemes. It confirms that CTs are correctly wired, have the correct ratio and polarity, and that the entire protection chain-from the primary conductor to the relay-functions as intended under realistic load or fault currents.
Our systems range from portable units (500A-1000A) for site maintenance to high-capacity station-class units (2000A-50000A) for substation commissioning and factory testing. They are indispensable tools for transformer commissioning, switchgear testing, and protective relay verification
What are the features of the product?
Input Voltage: Commonly available are AC 220V or 380V, though some larger devices can accommodate higher input voltages. Output current: The range is wide, from a few hundred amperes to tens of thousands of amperes. For example, the Hertz Power DDG series offers output currents in various specifications, including 500A, 1000A, 2000A, and even 15,000A.
Output voltage: Generally low, typically ranging from a few volts to tens of volts. For example, the DDG series typically has an open-circuit voltage of 6V.
Output waveform: Mostly a standard sine wave with a low ripple factor. For example, some products have a ripple factor of less than 0.3%, meeting relevant power system requirements.
Application Scenarios
Electrical Equipment Testing and Maintenance: Can be used for overload, temperature rise, and withstand voltage tests on electrical components such as circuit breakers, contactors, and relays, as well as current-carrying capacity and insulation performance testing of cables and busbars.
Material Research and Processing: Can be used to test the electrical conductivity of materials and can also achieve metal melting and welding through electrothermal heating.
Research and Teaching: Simulates actual operating conditions in research fields such as power electronics and electrical transmission. Can also be used for teaching demonstrations and experimental operations in electrical engineering programs in universities.
What points should be kept in mind during use?
1. Safety Warnings (Critical)
**Strict Prohibition Against Open-Circuiting the CT Secondary Side:** This is the most critical safety rule. When injecting current into the CT primary side, the CT secondary side *must* be reliably short-circuited or connected to a load. It is strictly forbidden to open the CT secondary circuit while energized; doing so will generate extremely high voltages (potentially thousands of volts), endangering both personnel safety and equipment insulation.
**Risk of High-Current Burns:** The output current is immense (ranging from hundreds to thousands of amperes), causing the test leads and the conductor under test to heat up significantly. Strictly avoid touching the test clamps, the conductor under test, or the wiring terminals to prevent severe burns.
**Strong Magnetic Field Interference:** High currents generate strong magnetic fields; the test site should be kept at a safe distance from precision instruments, magnetic storage media, and individuals wearing cardiac pacemakers.
2. Wiring and Operation
**Test Lead Selection:** You *must* use dedicated test leads with a sufficiently large cross-sectional area. Using leads with an insufficient diameter will result in excessive voltage drop across the line, preventing the device from outputting its rated current and potentially leading to cable burnout.
**Reliable Contact:** The test clamps *must* be securely fastened to the busbar or terminal under test. Poor contact leads to excessive contact resistance, generating severe heat and potentially causing the clamps to fuse (sinter).
**Circuit Impedance:** The impedance of the circuit under test is typically extremely low (e.g., a short-circuited busbar); consequently, the equipment must operate in a high-current, low-voltage mode. Ensure that the equipment's low-voltage, high-current output capability meets the specific requirements of the test.
**Grounding:** The equipment chassis *must* be reliably grounded.
3. Test Process Monitoring
**Temperature Monitoring:** During prolonged periods of high-current output, monitor the temperatures of the test leads and the contacts under test to prevent overheating.
**Instrument Observation:** Closely monitor the ammeter and voltmeter to ensure that the current remains stable at the set value and that the voltage does not exceed its limits.
4. Environmental Requirements
**Ventilation and Heat Dissipation:** The equipment generates a significant amount of heat during operation; therefore, adequate ventilation must be maintained.
**Site Enclosure:** The test area should be cordoned off with barriers and marked with warning signs to prevent unauthorized personnel from inadvertently entering the zone.
What should be done to ensure the device lasts for a long time?
1. Routine Maintenance
Test Lead Inspection: Before each use, inspect the high-current test leads to verify that the insulation is intact, the clamps are in good condition, and the contact surfaces show no signs of oxidation.
Contact Surface Cleaning: Keep the contact surfaces of the test clamps and the terminals under test clean; if necessary, polish them to minimize contact resistance.
Cooling System Cleaning: Periodically clean dust from the internal fans and ventilation vents within the chassis to ensure effective heat dissipation.
2. Periodic Maintenance
Annual Calibration: It is recommended to perform metrological calibration annually. Particular emphasis should be placed on calibrating the ratio error and phase angle error of the current transformers, as well as the accuracy of the ammeter.
Internal Inspection: Inspect internal high-current contacts, switches, and copper busbars for any signs of looseness or overheating.
Insulation Testing: Measure the insulation resistance between the power input and the chassis, as well as between the output terminals and the chassis.
Warranty Service: A free 12-month warranty covers the entire unit.
Spare Parts Supply: We provide a long-term supply of consumables and spare parts, such as high-current test leads, fixtures, and carbon brushes (where applicable).
Technical Support: We offer 24/7 technical consultation to assist in resolving any issues encountered during on-site testing.
On-site Installation and Commissioning: Engineers provide guidance on equipment installation, grounding, power connection, and high-current cable hookup.
Operational Training: Free training is provided, covering the following topics:
Safety protocols for high-current testing (with particular emphasis on safety regarding the CT secondary side).
Wiring methods for CT ratio and polarity testing.
Operation of primary-side trip testing.
Data recording and analysis.
Routine equipment maintenance and upkeep.
FAQ
Q1: Must the secondary side be short-circuited when testing a CT?
A: When measuring the transformation ratio or polarity, the secondary side is typically connected to a measuring instrument (acting as a load) and must not be short-circuited. However, when measuring volt-ampere characteristics (excitation characteristics) or performing energized inspections on the primary side-if no load is connected to the secondary side-the secondary side must be reliably short-circuited. Under no circumstances is it permissible for the secondary side to remain in an open-circuit state while current is flowing through the primary side.
Q2: Can the equipment output its maximum current for extended periods?
A: This depends on the equipment's duty cycle and the permissible temperature rise conditions of the on-site conductors; generally, continuous full-load output for indefinite periods is not recommended.
Q3: What should be done if the on-site power supply capacity is insufficient?
A: You may consider options such as stepped current boosting, selecting a model with a suitable duty cycle, optimizing wiring length and cross-sectional area to reduce impedance, or choosing a more appropriate power source and current-boosting solution.
Our address
Baoding Cloud Center, Hebei, China
Phone Number
+86 13483219412
Salesm@dualcanopy.com
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