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TEST LABS

Surge Generator in Reactor Coils

Ensure the quality of your coils before they reach the field. HVEX’s Coil Surge Generator is the complete solution for turn-to-turn testing of reactors, combining high-voltage oscillatory pulse generation, precision measurement, and analysis software that automatically generates diagnostic reports. As the only domestic manufacturer of medium- and high-voltage laboratory equipment, HVEX delivers a system at a competitive price, with responsive technical support and full customization—from sizing to installation and staff training. An investment that reduces rework, prevents field failures, and certifies the quality of your production.

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Technical Information

Power Supply
.220 V phase-to-phase, three-phase, 60 Hz power supply .Maximum current of 180 A .The supply voltage must never exceed 220 V .Recommended 4 mm² wiring for the connection between the control panel and the step-up power supply
Computers and Software
Computer with HVEX LIAS software installed. Communication via IP network with the panel components
Environmental conditions
Operating temperature: 10 °C to 40 °C. Relative humidity: ≤ 95%, non-condensing. Altitude: up to 1,000 m
Laboratory Infrastructure
A proper grounding system to which all modules are connected. Space for positioning and moving the modules (mounted on bases with casters).
Staff and Commissioning
Because this equipment operates at voltages of up to 200,000 V, installation, testing, and calibration must be performed exclusively by trained and qualified professionals. The equipment is delivered calibrated during commissioning, along with staff training.
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Introduction

Unlike conventional atmospheric pulse generators, which use multiple stages (Marx circuit), this equipment operates using a single-stage capacitive discharge. A capacitor bank is charged with direct current by a step-up power supply (Hipot) connected to a high-voltage rectifier diode; upon reaching the set breakdown distance between the copper caps of the spark gap, the energy is injected directly into the reactor terminals. The generated waveform is a damped oscillatory pulse (sinusoidal with exponential decay), with a steep rise time to maximize dielectric stress in the first few turns. To verify the robustness of the insulation, the reactor is subjected to no fewer than 7,200 overvoltages at the required magnitude. The product consists of a power panel, a Hipot step-up power supply, a diode module, series resistors, a capacitor bank, a spark gap drive module, a grounding system, and the LIAS control and analysis software.

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Benefits and Usability

  • HVEX | Benefits and Uses
    Benefits and Uses

    The key advantage lies in the reliability of the diagnosis combined with ease of operation. The system detects millimeter-scale faults in copper because the reactor under test itself becomes part of the resonant circuit: any change in the insulation between turns alters the oscillation frequency and the wave damping, making the fault immediately visible. Key benefits include high precision and traceability of results, fast and safe test execution, and automated analysis of oscillograms—the software superimposes the full-voltage discharge onto the reference waveform and calculates regulatory parameters (such as front time) without the need for manual calculations. In practice, the operator sets the test voltage, triggers the discharge, and monitors the result on the screen, with all system statuses displayed in green before starting. The equipment is modular, mounted on bases with casters for easy movement within the laboratory, and integrated into the grounding system for safe operation.

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