Liquid dielectric breakdown voltage tester

TOR-80А

Operating Manual
Data Sheet

Kharkov 2022
Preface

Dear Client!

We thank you for choosing our product.

TOR-80А breakdown voltage testing unit is a modern high tech device for testing
of transformer oil and other liquid dielectrics. It meets the highest technical
standards relevant for modern equipment of this intended purpose. It includes
the latest electronic, design, and software solutions. The unit is reliable, practical
and convenient, as you will see during operation.

The unit and its components are tested for compliance with all technical
requirements and stated specifications. The unit was tested in the test laboratory
of our company.

Subject to following the operation instructions and performing timely

maintenance, the unit will have a long and trouble-free service life.

If you have any questions during operation and servicing of the equipment, please
contact the product supplier.

This manual contains all the necessary rules and requirements to commissioning
and further operation of the unit.

Failure to follow the requirements and rules contained herein and/or tampering
with the design of supplied components, assemblies, and parts without approval
by the manufacturer and developer serves as grounds to discontinue warranty
and makes warranty claims impossible.
Contents

PREFACE
1. Intellectual property rights
2. Safety
3. General information
3.1. Warranty
3.2. Icons and explanations
3.3. General requirements to operation
4. Application
5. Description and operation
5.1. Specifications
5.2. Scope of supply
5.3. Description of unit and component operation
5.4. Operating the unit
5.4.1. Preparation
5.4.2. Measuring cell setup
5.4.3. Operating procedure
5.4.4. User interface
5.4.5. The measuring process
5.4.6. Emergency stop and interlocks
6. Maintenance
6.1. General instructions
6.2. Types of maintenance
6.3. Testing the unit
6.4. Metrology control and calibration
6.5. Printer maintenance
7. Troubleshooting
8. Transportation and storage
9. Service and storage life
10. Warranty
11. Packaging certificate
12. Acceptance certificate

Special notes
 1. Intellectual property rights

The supplied equipment, the principle of its operation, as well as documentation

and any other materials are the result of the intellectual work of the
manufacturer. Unauthorized copying, distribution, and modification of
information about the equipment and its design features without approval by the
manufacturer is strictly prohibited.

Attention! This manual has been compiled in accordance with the current copy of
the design documentation for TOR-80A unit and practical experience of
operation. This manual, as well as the design of the unit, may be changed or
supplemented without notice to the client.

2. Safety

Safety is the highest concern when operating the unit!

Always consider all information regarding safe application of this equipment

contained in this manual.

TOR-80А unit may be operated by electriсians at least 18 years of age certified for
at least electrical safety group III over 1000 V, supervised by an electrician
certified for at least electrical safety group IV over 1000 V, after preliminary
medical examination, as well as workplace safety and industrial health briefing.

When operating the equipment, follow the guidelines of all relevant

documentation, such as:
 This manual;
 Local consumer electrical devices operation regulations;
 Local electrical equipment design regulations;
 Local electrical equipment operation safety regulations;
 Local regulations on application and testing of protective devices in
electrical equipment and requirements thereto;
 Local workplace instructions;
 Local workplace safety regulations;
 All other regulations and documentation in effect.

Follow all local fire safety instructions.

Use the unit only for the intended purposes. Study this manual carefully before
operating the unit. Make sure you clearly understand the instructions. Before
using the TOR-80A high voltage unit, make sure you have sufficient knowledge on
its application, safety and potential hazards of operation.

The responsibility for safety lies entirely with the operating personnel (the
operator)!

Prohibited:

 Connecting the unit to a power supply outlet that has no grounding wire
and the corresponding terminal in the socket;
 Operating the unit with body panels removed;
 Installing and removing the measuring cell without turning off the power;
 Operating the unit with visible damage, failures and defects.

WARNING

Never assume that testing or measurement is safe WITHOUT taking necessary

prior safety precautions.

 Ensure safety when operating the unit as per local regulations and
instructions.
 All cables and connections must be clean and secure. Use additional
grounding if possible. Test secure grounding on the outlet terminals every
time before using the unit.
 Avoid operating the unit alone. Always work with someone who can
provide first medical assistance if necessary.
 NEVER connect improvised wiring or components to the unit. Any
modification of the unit or its components is prohibited, as it may entail
additional risks. For confidence in safe operation of the unit, any repairs or
upgrades can only be performed by the manufacturer or by an authorized
service center.
 FLAMMABLE MATERIALS

 Testing the materials (liquids) with flashpoints below 110oC is prohibited.

 Remove cleaning solvents completely from the measuring cell and the
electrodes before performing a high voltage test.

TOXIC MATERIALS AND WASTE

Solvents and oil samples must be processed and disposed of according to

respective manufacturer instructions.

3. General information.
3.1. Warranty
The manufacturer guarantees normal operation of the unit, subject to following
the rules of operation, maintenance, transportation and storage contained in this
manual.

Warranty period is 12 months from the date of shipment to the client.

If, during the warranty period, through the fault of the manufacturer, defects or
failures of the unit or its components and the parts included in the delivery set
are revealed, the client has the right to submit a complaint to the manufacturer
(seller) within five days, in the form of a memo and notify the manufacturer
(seller) about the event. At the same time, disassembly of the unit and repair by
the client is prohibited.

3.2. Icons and explanations.

Study the manual before operating or servicing the unit.

Attention: do not operate with open covers.

Attention: electrical hazard.

 No smoking.

No open fire.

Wear protective gloves.

3.3. General requirements

It is imperative to read this operating manual before operating the

unit.

Mains voltage and operating conditions must comply with the

specifications and operating limits of the unit contained in this manual or in other
accompanying documents.

Before connecting the unit to the power supply:

– Place it so as to ensure unobstructed power connections;

– Place the power cable so as to prevent any damage;

– Place the unit so as to ensure free access for personnel, opening and
closing the cover, installing and removing the measuring cell and removing any oil
spilt it necessary. Make sure the unit will not be hit accidentally: this may damage
the unit or injure personnel.

Timely maintenance is required to keep the unit in good working condition.

Operation with overloads or in modes not described in this manual is prohibited.

During operation, transportation, and storage, the unit must not be tilted more
than 20ᴼ from the horizontal plane in any direction. It is strictly prohibited to
put the unit on its side and to turn it over!

If malfunctions are found, first turn off the power to the unit using the switch or
by unplugging the power cord from the socket.
The unit can only be serviced or repaired by qualified and authorized personnel.

4. Application

The unit is designed to measure the breakdown voltage of transformer oil and
other liquid dielectrics according to IEC 60156, VDE 0370, ASTM D877, ASTM
D1816, IRAM 2341. This list of standards can be supplemented and modified
taking into account the preferences of clients and with the introduction of new
versions of standards.
The unit is a fully automatic device that ensures testing according to the
procedures defined in these standards, as well as according to the user
procedures specified in the appropriate section of the unit menu.
The unit can operate offline without connection to a power supply for at least 8
hours continuously with fully pre-charged batteries.

5. Description and operation

5.1. Specifications
Specifications of the unit are listed in Table 1.

Table 1 – Specifications.
No Item Value Comment
1 Operating AC voltage, V 85 – 264
2 Power frequency, Hz 48 – 63
3 Power requirement, VA. Not more than
250
4 Max output voltage, kV Sinusoidal, up to 80
kV RMS.
5 Output voltage measurement ±1 %
tolerance
6 Voltage increase rate, kV/sec From 0.1 to 5 Adjustable
7 Resolution of output voltage 100
indication, V
8 High voltage shutoff time after 10 max,
breakdown, mcs 4 typical
9 Measuring cell volume, cm3 500
10 Ambient temperature 0 – 100
measurement range, deg. С
11 Temperature measurement 1
resolution, deg. С.
12 Integrated printer yes
13 Battery power pack yes
14 Time of continuous offline 8h
 operation (based on the battery
power pack)
15 Charging time for batteries 8h
16 Operating temperature, deg. С, From 0 to + 50/40
Operation/charging
17 Transportation and storage From - 15 to + 40
temperature, deg. C
18 Relative humidity, % Up to 90 without
condensation
19 Atmospheric pressure, mm Hg 630 – 800
20 Dimensions, mm 510х300х413
21 Weight, kg, no more than 38.1

5.2. Scope of supply

The scope of supply of the TOR-80А unit is shown in Table 2.

Table 2 – Scope of supply

Label Item Amount Comment
TOR-80А unit 1
Measuring cell 1
2.5 mm gap set 1 Included with
measuring cell
Magnetic oil agitator 1 Included with
measuring cell
Magnetic stick for agitator 1 Included with
extraction measuring cell
Electrode polishing material 1 Included with
measuring cell
Semi-spherical electrodes 2 Included with
measuring cell
Flat electrodes 2 Сustom-made
Spherical electrodes 2 Сustom-made
2 mm gap gauge 1 Сustom-made
2.54 mm gap gauge 1 Сustom-made
1 mm gap gauge 1 Сustom-made
USB Flash drive 1
Power cable 1
Jumper-type power 1
cable
Fuse, 4А 2
Paper roll of cash 1
register tape type
Operating manual, 1
 data sheet
Stowage box 1

5.3. Description of the TOR-80A unit and component operation

The general view of the unit is shown in Figures 1.1, 1.2, and 1.3.

Figure 1.1. Front panel view of the unit

14 2 3 4
1

9
8

8
5

15

18 16

19 7
17
6

Figure 1.2. Back panel view of the unit

10
2
 7

13

12

11 19
21 20

Figure 1.3. General view of the unit with lifted cover and installed measuring cell
 2

14

Components depicted in Figures 1.1, 1.2 and 1.3:

1. Front panel.
2. Top cover.
3. Thermal printer.
4. 3.5” color LCD touch-screen display.
5. USB Flash socket.
6. Supports.
7. Side panels.
8. Handles.
9. Panel screws.
10. Top cover hinges.
11. Fuse holders.
12. Power cable socket
13. Power switch.
14. Measuring cell installed under the cover.
15. Batter pack mode switch.
16. Battery charge indicator.
17. Сharge indicator ON button.
18. Inverter and charger status LEDs.
19. Battery power pack (BPP).
 20. Power cable socket.
21. Block-type socket for jumper connection.

The front panel (1) is equipped with the following controls and devices:

The thermal printer (3) prints the reports on oil testing results. The color LCD
touch-screen display (4) controls the operation of the unit, allows entering test
data and other information, indicates the operating modes, test progress, test
results, operational and service information to control operation of the unit, to
set the operating modes and input other necessary parameters. Detailed
description of display and printer use is provided in section 5.4.4 User interface.

Top cover of the unit (2) protects the samples and the operating zone of the
instrument against contamination, shields the environment from electromagnetic
interferences generated by the high voltage transformer and breakdowns, as well
as prevents the possibility of danger to personnel when working with high voltage
equipment. To this end, the cover is equipped with a position control device
(open/closed) which locks the voltage rise when the cover is open.

Measuring cell (14) is installed on the high voltage contacts of the step up
transformer. It is described in greater detail below.

USB Flash drive socket (5) is designed to connect a flash drive for recording the
information from test archives for later copying to a computer. The USB Flash
drive is also used to read and copy the measurement templates.

The handles (8) are integrated into the side panels of the unit (7).

The power switch (13) and the mains power socket (12) are structurally a single
block for connecting/switching on the power supply of the unit. Power is supplied
using a standard computer power cable connected to the socket. If the unit runs
on the battery power pack, the power is supplied by the batteries using the
jumper-type power cable.

The supports of the unit (6) are designed to prevent the unit from sliding on the
surface of a laboratory workbench. Along with the panel screws (9), they are
unscrewed for disassembly of the unit during repair and maintenance by
representatives of authorized departments.

Top cover hinges (10) ensure damping and smooth opening and closing.
The fuse holders (11) are equipped with replaceable 4 A fuses, which serve to
prevent emergencies in case of malfunctions. The unit also includes fuses for
replacement if necessary.

The battery pack (19) is located at the bottom of the unit. The front panel of the
pack has the following indication and control elements:

- Battery pack operating mode switch (15),

- Battery charge indicator (16),
- Button for turning on the charge indicator (17),
- Inverter and charger status LEDs (18).

On the rear panel of the battery pack there is an plug for the UPS input power
supply (20), an output socket for connecting the power cable (“jumper”) of the
unit from the battery pack, and a fuse holder (11).

The battery operating mode switch can be in three positions: up, middle and
down.

The switch must be moved to the up position when the unit is powered by the
batteries. The power cable must be disconnected from the unit and from the
battery pack, and a “jumper” power cable must be installed between the input
instrument power plug (12) and the output instrument socket of the battery pack
(21). In this mode, the battery pack inverter operates from the built-in battery,
the supply voltage (modified sine wave) is supplied to the input power connector
of the unit from the output connector (socket) of the battery pack through the
jumper cable. The battery charger is switched off, the batteries are not being
charged.

In the middle position of the operating mode switch, the batteries are charged. In
this case, the inverter is turned off, the charger is turned on. The power cable
must be connected to the UPS instrument power plug (20). The power cable
"jumper" can be either connected or disconnected. At the same time, power is
not supplied to the TOR-80A unit, it is turned off.

When the switch is in the down position, the unit operates normally from the
external power supply. In this case, the power cable “jumper” must be connected.
The mains cable must be connected to the UPS mains input plug (20). The inverter
in this mode is turned off, the charger is turned on and the batteries are being
charged.
When connecting the mains cable directly to the unit's input socket (12), which is
possible only when the jumper is disconnected, TOR-80A operates from the
mains, the battery can be in any of the above states. For example, the batteries
can be charged when the battery power cable is connected and the operating
mode switch is in the middle or down position.

The battery charge indicator (16) turns on only when the indicator switch button
(17) is pressed. It indicates the state of the battery with an battery image, as well
as in digital form, as a percentage.

Battery pack status LEDs (18) show:

- Inverter status (red LED), lit when the inverter is on,

- Charger status (green LED), on when the charger is on, flashing when the
charger is in a fault condition.

Internal structure of the unit is shown in Figures 2.1 – 2.5

 Figure 2.1. Internal structure of TOR-80А unit

6 7
5

4
3 8

10 9

Figures 2.1 – 2.4 show the following components:

1. Front panel.
2. Front electronics compartment.
3. Display control board.
4. Thermal printer.
5. Tray.
6. Measuring cell.
7. Cover.
8. Rear electronics compartment.
9. Battery power pack.
10. High voltage transformer.

Figure 2.2. Front panel internal view

 7 2
3
11 1 4
12

11. Side panel.

12. Side panel handle.

Figure 2.3. Internal view of rear electronics section.

 8
9 15
13 14

13. Controllable inverter.

14. Power unit.
15. Power connection module.

Figure 2.4. Placement of the measuring cell in the unit

 7
6
5 16 16

19
11 17 17 8
10 18

16. Supports with electrodes.

17. Output electrodes of the high voltage transformer.
18. Stirring electric motor.
19. The mechanical stirring drive with magnetic elements.
Figure 2.5. Internal view of the battery pack.

21 22 23
20

24
25 26

20. Input and output power connectors.

21. Charger.
22. Inverter.
23. Batteries.
24. Сharge indicator ON button.
25. Battery charge indicator.
26. Battery mode switch.
The core of the unit are the high voltage transformer (10) and the electronic
modules (3, 13, 14). The principle of operation of the devices is to gradually
increase the voltage on the secondary winding of the high voltage transformer
from zero to the maximum value, or until an electrical breakdown occurs in the
liquid dielectric in the measuring cell (6) on the high voltage contacts of the
transformer, part of its output electrodes (17).

The voltage on the high voltage contacts of the transformer’s secondary windings
is raised by raising the voltage on the primary winding when supplying sinusoidal
voltage from the controllable invertor (13).

In the shielded front electronics compartment (2) located on the front panel (1) of
TOR-80A unit, there is a control board (3) with a touch color LCD display. Its
intended purpose is to ensure functioning of the user interface and digital control
of all electronic modules of the unit. In the compartment, there is also a thermal
printer (4) which is used to print reports containing the data of performed tests.

A plastic tray (5) serves to prevent the leakage of oil accidentally spilled during
installation/removal of the measuring cell into the unit.

A measuring cell (6) is used to be filled with a sample of oil for testing and to
apply test voltage to the sample.

Near the back panel of the unit, there is a rear electronics compartment (8) which
ensures shielding and mechanical fastening of electronic modules: a controllable
inverter (13) and a power pack (14). At the bottom of the back panel, there is also
a mains power connection module (15) which includes a fuse holder, a power
switch, and a housing plug for connecting the mains power cord of the unit.

The side panels of the unit (11) have integrated handles for carrying the unit (12).

With the cover of TOR-80A unit open, the measuring cell is installed using its
supports (16) containing the contacts of input electrodes directly on the contacts
of output electrodes (17) of the high voltage transformer.

In addition, the structural module of the measuring cell setup includes an oil
stirring actuator consisting of a controllable electric motor (18) and a T-shaped
plastic stirring actuator (19) with magnets built in its upper part and transmitting
the rotational force from the motor to a magnetic stirrer located inside the
measuring cell cup.
In the bottom of the unit there is a separate battery pack compartment (Fig. 2.5).
The batteries provide for autonomous operation of the TOR-80A unit in the
absence of a power supply at the place of operation of the unit.

The battery pack includes two batteries (23) connected in series, from which a
constant voltage of +12V is supplied to the inverter (22). The purpose of the
inverter is to convert the DC voltage coming from the batteries into AC (modified
sine wave) suitable for powering the unit.

The batteries are charged using the charger (21). The battery pack also has a built-
in charge level indicator (25) with a button to turn on the indicator (24).

The choice of the battery pack operation mode (charging, operation, charging +
operation) is made using the operation mode switch (26) with the appropriate
connections of the jumper cable and the mains power cable on the input and
output power connector section (20) and the mains plug of the power supply
connection module (15).

The selection of battery pack operating modes and the corresponding

arrangement of power cables are described in detail in the explanations to
Figures 1.1 - 1.3.

The appearance of the upper part of the unit with the measuring cell is shown in
Figure 3.

Figure 3. Placement of the TOR-80A measuring cell.

For the general view of the high voltage transformer, see Figure 4.

Figure 4. High voltage transformer.

2 3

Figure 4 shows the following components:

1. High voltage contacts of the output electrodes,

 2. Oil stirring drive,
3. Attachment plate,
4. Primary winding,
5. Secondary winding coils,
6. Magnetic core.

A microcontroller managing the invertor controls voltage increase. The unit

control board commands the controlled inverter

During a test, AC (50-60Hz) is supplied from the secondary winding contacts

through the cell electrodes to the liquid sample in the cell. The breakdown occurs
between the cell electrodes over the space filled by the liquid dielectric.

For general view and the internal structure of the measuring cell, see Figures 5.1
and 5.2.

Figure 5.1. Measuring cell general view (cover removed).

1
2

3
Figure 5.2. Measuring cell.

2
1
6
5

4 3

Figures 5.1 and 5.2 show the following components:

1. Measuring cell high voltage electrodes,

2. Electrode housing with conductors,
3. Sample container,
4. High voltage supply contacts,
5. Conducting supports,
6. Adjustment wheels.

The high voltage supply contacts (4) in the operation position rest on the
transformer high voltage electrode contacts. Electricity flows through conducting
supports (5) to the cell high voltage electrodes (1), between which the breakdown
can occurs through the oil or another liquid in the container (3). The electrode
housing (2) is made of an insulating material and contains conductors (5),
shielding them from the environment. The adjustment wheels with notches are
designed to adjust the gap (clearance) between the high voltage electrodes of the
cell. The clearance is checked by gauges supplied with the unit.

5.4. Operation.

5.4.1. Preparation.
Extract the unit from its package box and place it on a work desk.

Turn on the battery level indicator, check the charge level. If necessary, switch the
battery pack to charge mode and charge the batteries. To do this, connect the
power cable to the UPS mains input plug and set the UPS operation mode switch
to the appropriate position, as described in section 5.3.

Install the jumper power cable between the battery pack jumper socket and the
unit power supply socket. Move the battery operation mode switch to the
position corresponding to the selected mode. Depending on the selected
operating mode (battery or regular power), connect or disconnect the mains
power cable.

5.4.2. Measuring cell setup.

Extract the measuring cell from the box. Remove protective grease from the
electrodes with a piece of cloth soaked with petrol, then wipe with clean dry cloth
that will not leave fibers on the surfaces.

Check the clearance between the electrodes using one of the gauges. If the thin
part of the gauge plate (marked 0) passes freely between the electrodes, while
the other side (marked 1) does not, the clearance is set correctly. If both sides of
the gauge pass freely, the gap is too large. If none do, the gap is too small. You
can adjust the clearance by rotating the adjustment wheels.

The surface of the gauge must be clean and smooth, without deformations
or notches.

Store the gauge covered in grease and wrapped in waterproof paper.

Store the measuring cell in clean, dry and dust-free location. We

recommend polishing the electrodes and then rinsing with clean dielectric fluid
after long storage or long use. To do so, increase the gap to the maximum and
detach the electrodes. Be extremely careful when installing the electrodes to
prevent damaging the polish; avoid touching the polished surfaces. After installing
the electrodes, check the clearance between them as described above.

5.4.2.1. Preparing a liquid dielectric sample.

A sample is a volume of the liquid, taken into one vessel from a device where the
liquid is used. A portion is part of the sample in the measuring cell.
 The test is performed at portion temperature of +15 to +35ᴼС. The
temperature of the dielectric liquid must be the same as the ambient
temperature. To this end, let the sample rest for at least 30 minutes in the test
room before performing the test. Before the test, keep the sample in a tighly
closed container protected against direct sunlight.

Carefully turn the sample container over several times for even distribution of
suspended particles in the sample, but make sure not to produce bubbles.

After that, carefully pour a portion of the liquid into the measuring cell and let
it stay there for 10 minutes before running the test.

5.4.3. Operating procedure.

Open the cover of the unit, carefully install the measuring cell with the
portion of the sample on the high voltage electrodes and close the cover.

Connect the jumper cable. Using the battery operating mode switch, select the
desired operating mode.

Turn on the power switch.

Supplying high voltage without the measuring cell installed is strictly prohibited!

5.4.4. User interface.

The start screen is displayed after turning on the power (Figure 6.1).

Figure 6.1. TOR-80A start screen.

In a few seconds the start screen is replaced with a test start screen (Figure 6.2).

Figure 6.2. Test start screen.

On this screen, the operator can choose a test template and the type of oil.

Tapping the corresponding text on the screen opens drop-down selection lists.

The oil selection drop-down list is shown in Figure 6.3.

Figure 6.3 Oil type selection drop-down list.

The operator can choose from the following oil types:

- Mineral oil,
- Silicone oil,
- Synthetic ester oil,
- Natural ester oil.
By default, one of the oil types selected previously is selected. It is labeled by a
checkmark. Oil type can be changed by tapping the corresponding line, which
opens the drop-down list of oil types. Tap a line to select the corresponding oil
type; the newly selected type will be displayed in this field with a checkmark.

Test template is chosen as shown in Figure 6.4.

Figure 6.4. Test template selection.

Originally, the previously selected template (standard or user) is selected. It is
labeled by a checkmark. The template can be changed by tapping the
corresponding line, which opens the drop-down list of test templates. Tap a line
to select the corresponding template; the newly selected item will be displayed in
this field with a checkmark.

Next, the operator taps the Start button (with a lightning symbol). This opens the
temperature input window as shown in Figure 6.5.

Figure 6.5. Sample temperature input window.

The sample temperature can be measured beforehand by a non-contact IR
sensor, a mercury thermometer or in any other way.

The temperature is set in decimal degrees Celsius and confirmed by tapping the
Enter button. The unit then automatically begins the test.

The test progress window is shown in Figure 6.6.

Figure 6.6. Test progress window (voltage increase).

This window shows the following information:

- The number of the current voltage raise in a series (in the example above, 1
of 5).

- Current voltage (the round scale).

- The current process between breakdowns: the clock with a rotating hand
showing a countdown. If the propeller symbol in the bottom of the screen is
rotating, the current process is stirring. If the propeller image is stopped, the
current process is holding.

The operator can stop the voltage increase and discontinue the test with voltage
cancellation by tapping the Stop button.

When the test series is over, the screen shows the results of the test as shown in
Figure 6.7.

Figure 6.7. Test results.

This screen displays the breakdown voltages in the current series in graphical
form.

The text below the graph displays parameters pertaining to the test quality:

- V Max, V Min are the maximum and minimum breakdown voltages in the
series.

- M is the mean breakdown voltage in the series.

- SD is the standard deviation.

- SD/M is the ratio of the standard deviation to the mean.

The operator can also print the report using the integrated printer (The Print
button).

The operator can view the numerical breakdown voltage values in each cycle of
the series. To do this, tap the corresponding point on the graph as shown in
Figure 6.8.

Figure 6.8. Numerical BDV display.

If the cover of the unit is lifted during the test, the voltage increase is immediately
cancelled, the voltage is dropped to zero and the screen displays the message
shown in Figure 6.9.

Figure 6.9. Test interrupted by lifting the cover.

When the unit is running in test mode, it constantly self-tests the critical modules
and their interconnections. If the inverter suffers a malfunction, or there is no
connection between the inverter and the control module, the screen displays the
following message (Figure 6.10).

Figure 6.10. Inverter connection error.

In this case the test stops, the voltage is reduced to zero, and the message to
contact a GlobeCore service center is displayed.
The next section of the user menu is test data archive management. This archive
automatically stores all successful test series reports. To enter this section, tap
the “file” icon at the top of the screen.

The archive management screen is shown in Figure 6.11.

Figure 6.11. Archive management.

The operator has access to the following functions:

- Open a list of reports in the archive (Open),

- Save the reports from the archive to a USB memory device (Save),
- Clear the archive (Delete),
- Access archive fill information (Information).
The list of the test reports accessed by tapping “Open” icon is shown in Figure
6.12.

Figure 6.12. Report list.

After tapping the necessary report, it’s contents are displayed as shown in Figure
6.13.

Figure 6.13. Report contents.

The report contains the following data:

General info:
- Company and unit name,
- Firmware version,
- Date and time of the test.
Test data and results:
- Test standard or user template,
- Test ID number,
- Electrode type,
- Clearance between electrodes,
- Test frequency, Hz,
- Voltage increase rate, kV/sec,
- Sample temperature, ˚С,
- Liquid type,
- Number of cycles in the test procedure,
- Average BDV,
- Standard deviation.
The report can be printed by the integrated printer by tapping the Print button.

After tapping the Information icon, the operator accesses information shown in
Figure 6.14.

Figure 6.14. Information screen.

The screen shows the filled capacity of the archive in percent in numeric and
graphical forms. This information is useful to make the decision to save the
archive to an external USB drive and clearing the memory to store subsequent
records.

The contents of the archive can be cleared or saved by tapping the Delete and
Save icons respectively.

The info screen displayed in case of an unsuccessful attempt to save the archive
to external USB memory is shown in Figure 6.15.

Figure 6.15. USB flash storage error.

This message may be caused by absence or failure of the connected USB storage
device.

Touching the next icon in the top row opens the Settings menu as shown in Figure
6.16.

Figure 6.16. Settings menu.

This menu allows access to the following settings:

- Test templates,
- Test ID,
- Time,
- Date,
- Menu language,
- Printer modes,
- Mixer modes,
- Display modes,
- TOR-80A Device status (parameters),
 - Return to Factory settings.
The Templates menu is shown in Figure 6.17.

Figure 6.17. Templates Config menu.

The TOR-80A has two main test template modes: standard and user-defined. The
Standard templates are pre-programmed and cannot be changed by the user. The
standards programmed and the specific standard settings can only be amended
and edited by the manufacturer’s service centers.

Up to five user-defined templates (User Template) are programmed by the user

and represent the most common test procedures used by the specific operator,
usually amending or simplifying the standard presets.

The list is navigated by touching and moving the scroll-bar in the right of the
screen.

The user settings are selected as shown in Figure 6.18.

Figure 6.18. User-defined test template settings.

Each user modification includes a set of parameters editable by the operator. The
totality of the parameters defines the user template.

The parameters are as follows:

- Test count: the number of voltage raise cycles in this test procedure,

- Stir continuous: duration of the stirring cycle,

- Pause before test (sec): the duration of a delay between test start and
voltage increase,

- Stir before test (sec): the duration of stirring before the first voltage
increase,

- Pause after (sec): the holding time without stirring after every voltage raise
cycle (except the last cycle),

- Stir after (sec): the duration of stirring after every voltage raise cycle
(except the last cycle),

- Frequency (Hz): the frequency of the test current.

Set the number of voltage raise cycles by tapping the corresponding menu item in
the open window.

Setting the continuous stirring mode is shown in Figure 6.19.

Figure 6.19. Setting the continuous stirring mode.

In this mode, the user can set or cancel the continuous stirring more during the
test.

To return to the menu, tap the X button.

The pause setting window allows setting the holding time before after a voltage
rise cycle (Pause after test), as shown in Figure 6.20.

Figure 6.20. Pause setting.

Set the pause duration in seconds (from 0 to 1800) after the end of the previous
voltage rise cycle (Pause After) by tapping the corresponding arrow buttons
(increase or decrease). Exit the mode by tapping the X button.

You can set the stirring time duration (Stir after test) in a similar manner (unless
the continuous stirring mode is selected).

It’s possible to set the pause duration and stirring before test (before the first
voltage rise cycle, pause before test, stir before test) in a similar manner after
tapping the corresponding menu buttons.

If a standard test procedure is used, the measurement standard is selected by

tapping the corresponding item in the menu (Figure 6.21).

Figure 6.21. Test standard selection.

Test ID number can be selected as shown in Figure 6.22.

Figure 6.22. Test ID setting.

The test number is set by tapping the on-screen keypad and tapping “Enter”.

The current time setting is shown in Figure 6.23.

Figure 6.23. Current time setting.

The hours, minutes and seconds are set by scrolling the corresponding “wheels”
on the screen.

The current date is set as shown in Figure 6.24.

Figure 6.24. Setting the date.

The date is selected on the calendar on screen. The year and the month can be
set by tapping the corresponding screen buttons.

Language selection is shown in Figure 6.25.

Figure 6.25. Interface language selection.

The language is selected by tapping the corresponding line and then confirming
the selection by tapping the check button in the bottom of the screen.

Printer settings are shown in Figure 6.26.

Figure 6.26. Printer mode and test.

The following items are available:

Check “Printer Enable” to use the printer.

Check “Report print” to print every cycle report by default.

Press “Test” to print a test page.

Setting the stirring mode (Mixer motor) is shown in Figure 6.27.

Figure 6.27. Mixer motor settings.

Setting the mixing drive is done using software “sliders” on the screen.

The operator has access to the following settings:

- Speed: the speed of rotation in revolutions per minute between 0 and 600.

- Current (I): the maximum motor current setting. As a rule, it is kept at its
default factory setting. The operator can change it based on experience in
operating the unit. It is recommended to increase the maximum current when
testing liquids of higher viscosity.

- Acceltime (0 to 5): the time of rotation acceleration during stirring (с). The
operator can change it based on experience. It is recommended to increase
acceleration time when testing liquids of higher viscosity.

- The “ON” button tests the stirring system. When this button is tapped, the
propeller icon above the button rotates.

Setting the background color and display brightness are shown in Figure 6.28.

Figure 6.28. Background color and brightness settings.

To set the main color of inscriptions and images, tap the desired color circle.

The display brightness is adjusted using a virtual “slider” with simultaneous

indication of the brightness as a percentage of the maximum.

The checkmark next to “Dark theme” means that the display is in dark
background mode. Otherwise, the display background will be light.

The checkmark next to “Auto” means that the power saving mode is enabled, that
is, there will be a gradual decrease in the brightness of the display if it has not
been touched for the last three minutes.

The content of the “Device status” window is shown in Figure 6.29.

Figure 6.29. “Device status” window.

“Device status” can be used for quick checking of the unit’s condition.

This window displays the following parameters:

- “Battery”: charge of the battery of the non-volatile time and date memory.

- “Device cover”: cover status (open/closed).

- “Inverter PCB temp”: inverter board temperature. This parameter is a

diagnostic feature in case of malfunctions of the unit.

- “Inverter connection”: status of the data line between the inverter and the
control module.

- “Temperature”: temperature of the control board (close to the ambient

temperature and equal to it when the unit is turned on)).

5.4.4.1. “Factory Settings” menu section

Entering the menu section “Factory Settings” is possible only after entering the
password. The password entry window opens immediately upon entering this
section and is shown in Figure 6.30.
Figure 6.30. Password entry window.

The password is set by the factory firmware and does not change during the
operation of the TOR-80A unit. The password is specified in a separate
documentation describing operation with factory settings.

After entering the password, its correctness is confirmed by tapping the virtual
“Enter” button.

After entering the correct password, the main window of this mode opens, as
shown in Figure 6.31.

Figure 6.31. Main window of the factory settings menu.

Window contents:

- - “Save Templates” – writing test templates from the unit's memory to a

USB flash drive. Must be carried out by authorized and trained personnel.
- - “Templates Upgrade” – recording from the USB flash drive of test
templates to the unit's memory. Used to update templates. This must be
carried out by authorized and trained personnel only.
- - “Inverter settings” – setting the inverter operation parameters. These
settings significantly affect the accuracy of measurements and the
operation of the unit as a whole. Incorrect settings can lead to incorrect
operation, or to unit failure.
Only highly qualified and specially trained personnel, provided with
special technical documentation and authorized by the service
department or the manufacturer, are allowed to access these settings!
- “Voltage Test” – this mode allows you to check the condition of the unit, as
well as its metrological characteristics. This can be used for metrological
confirmation of the correctness of the unit by authorized metrological
control services.
Due to the fact that the “Save Templates”, “Templates Upgrade” and “Inverter
settings” functions can be performed exclusively by authorized service personnel,
their description is not covered in this OM. It is provided in a special document
intended for service personnel.
This OM only describes the “Voltage Test” mode, since this mode can be used to
check the operability of the unit during maintenance, as well as for the purposes
of metrological control and confirmation of suitability for operation.

The “Voltage Test” mode window is shown in Figure 6.32.

Figure 6.32. “Voltage Test” mode window.

The following settings are available here:

- Output voltage frequency (Set Hz),

- Final amplitude of the output voltage (Set kV).

In the same window, the following are displayed during the test and after the
results of the test are obtained:

- Measured output voltage (Out V (kV)),

- Calculated output voltage (Calc V (kV)),

- Transformer primary current (IFDBK (A)). (Only used during factory setting).

Starting the test procedure (setting the voltage of a given amplitude and
frequency) is done by pressing the “START” button.

The window for setting the final amplitude of the output voltage is shown in
Figure 6.33.
Figure 6.33. Setting the final amplitude of the output voltage.

Set the value of the output voltage by tapping the corresponding menu line, then
tapping the “increase” and “decrease” buttons in the menu window that opens.
Confirm the selection by tapping “X”.

The window for setting the output voltage frequency is shown in Figure 6.34.

Figure 6.34. Setting the output voltage frequency.

Set the value of the test voltage frequency by tapping the corresponding menu
line, then tapping the “increase” and “decrease” buttons in the menu window
that opens. Confirm the selection by tapping “X”.

After the start of the voltage rise (“START” button), the information is displayed in
real time.

As the voltage rises, the values of Out V, Calc V, IFDBK will change as the output
voltage rises. After the end of the increase, the values of these parameters
stabilize.

The TOR-80A is considered to meet the measurement accuracy requirements if

the Out V value after voltage stabilization differs from the value measured by the
TOR-81 or TOR-101 calibration cell by no more than ± 1%.

The procedure for metrological control of the installation using a calibration cell is
described in more detail in the “Methodology for confirming the metrological
characteristics of the TOR-80A unit”.

In the absence of a calibration cell and the use of the “Voltage Test” mode for
current or periodic monitoring of the unit, it is considered sufficient if the
stabilized value of Out V differs from the set value of Set kV by no more than ±2
kV in the entire range of output voltages (from 10 up to 80 kV).

5.4.4.2. General information window.

The information window (the right icon in the top row of the main window of the
installation user interface) is shown in Figure 6.35.

Figure 6.35. Information window.

This window contains the following information:

- Unit title,

- Firmware, GUI LVGL versions,

- Serial number,

- Date of manufacture,

- Manufacturer logo.

5.4.5. The measuring process.

After filling the measuring cell with oil as described in section 5.4.2.1, installing it
into the unit and turning on the power as described in section 5.4.3, the display
will show the start screen (Figure 6.2). After selecting the test template and the
oil type (Figures 6.3 and 6.4), the operator taps the Start button (with the
lightning symbol). After tapping the button and entering the oil sample
temperature (Figure 6.5), the unit automatically begins the test process.
For the purpose of this manual, the following is a custom test procedure, which
includes two cycles with stirring, a pause and a printed report.

When the test process begins, the unit automatically starts raising the test
voltage (unless the template settings specify a pause and a stirring cycle before
the first voltage increase). The screen is shown in Figure 6.6.

As the unit raises the voltage, stirs the sample and holds, the screen displays
information shown in Figure 6.6.

When the stirring is active, there is a rotating propeller icon in the bottom left of
the screen, the clock hand is moving and the numbers above the clock countdown
the seconds until the end of the stirring cycle. The round voltage scale shows the
voltage of the previous breakdown.

Another visual indication that the stirring is running is the motion of the magnetic
stirring rod inside the measuring cell with oil. This is shown in Figure 7.1.

Figure 7.1. Magnetic stirring rod in the measuring cell.

When the stirring is complete, the unit pauses before the next test cycle.

During the oil settling pause, the propeller icon does not rotate, the clock hand is
moving, the digital timer counts down the time until the pause ends in seconds.
The round voltage scale continues to display the voltage of the previous
breakdown.

After the settling pause, a new voltage increase cycle begins.

As soon as the last cycle breakdown occurs, a summary of the test is displayed on
the screen, as shown in Figures 6.7 and 6.8.

If the operator taps the PRINT button, the test report is printed as shown in Figure
6.13.

5.4.6. Emergency stop and interlock.

The unit stops and further operation is prevented during testing when the cover is
lifted or the STOP button is pressed during the test.

The test voltage is immediately turned off, if at this time it was being increased.

The testing process is interrupted and the unit returns to the start screen. The
screen is shown in Figure 6.9.
 6. Maintenance.
6.1. General instructions.

Maintenance of the unit must be carried out from the date of its
commissioning and is intended to prevent and detect malfunctions. The essence
of maintenance is the timely performance of work to ensure the operability of the
unit.

Maintenance can only be performed by persons older than 18 years, with all
relevant electrical safety and certificates, briefed on workplace safety and
sanitary requirements.

6.2. Types of maintenance:

- Primary,
- Operating,
- Periodic.

Primary maintenance is to prepare the unit for operation and is described in

sections 5.4.1 and 5.4.2 of this document.

Operating maintenance is performed every time before using the unit, usually by
the operators:

- Check grounding,
- Check power cable insulation,
 - Check operation of the high voltage interlock when opening the high
voltage compartment cover,
- Check visually for physical damage,
- Check battery pack charge.

There are two types of periodic maintenance: monthly and annual.

Monthly checks and maintenance is usually performed by the operators

and includes cleaning the high voltage outputs of the measuring cell and the
insulators of the unit with clean dry cloth wetted with spirit or aviation petrol, as
well as operating maintenance checks.
Annual maintenance includes the above, as well as test of the unit’s
operation.

6.3. Operation test.

6.3.1. Prepare the unit for operation as described in sections 5.4.1 – 5.4.3 of
this document.
6.3.2. After turning on the power, the unit will display the start screen (Figure
6.1) with GlobeCore logo. The unit will self-test and open the
measurement start screen (Figure 6.2).
Images shown in figures 6.1 and 6.2 indicate correct power connection
and start of the control program.
6.3.3. Touch screen check.
After completing the items in section 6.3.2, tap the Selected oil line on
the screen (Figure 6.2). The oil type selection menu will open (Figure
6.3). Confirm the selected oil type and return to the previous menu. If
these actions were successful, the touch screen works correctly.
6.3.4. Voltage safety interlock check.
Enter the Settings menu as described in section 5.4.4 (Figure 6.16),
select “Device status” (Figure 6.29).
Ensure that when the cover is closed, “Close” is displayed next to
“Device cover”. Then open the cover and make sure the text changes
from “Close” to “Open” and then back to “Close” when the cover is
closed; this signifies that the cover position interlock operates correctly.
6.3.5. Printer check.
The printer is tested by printing a test page.
Enter the Settings menu as described in section 5.4.4 (Figure 6.16),
select “Printer” (Figure 6.26). Tap the “Test” button. This will cause the
printer to output a test page.
6.3.6. Stirring check.
 Enter the Settings menu as described in section 5.4.4 (Figure 6.16),
select “Mixer”. This will open the “Mixer motor” window (Figure 6.27).
Tap the ON button; stirring of oil in the measuring cell will begin. If the
stirring rod in the measuring cell is rotating (Figure 7.1), as well as the
propeller icon on the screen (Figure 6.27), the stirring system operates
correctly.
6.3.7. Testing the USB Flash drive:
- Open “Archive” menu (Figure 6.10).
- Connect a USB Flash drive to the corresponding port (Figure 1.1, sign (5)).
- In the report window, tap the Save function line.
- Disconnect the USB flash drive from the TOR-80A and connect it to a PC.
Read the contents of the copied archive.

The USB flash drive is working correctly if the archive on the flash drive
corresponds to the archive in the unit’s memory and there is no warning
message (Figure 6.15).

For correct operation with the TOR-80A, a USB flash drive must meet several
requirements.

- We strongly recommend using a USB flash drive supplied with the

TOR-80A unit!
- When using a third party USB flash drive, it must first be formatted in
FAT32!
- The volume of a third party USB flash drive must not exceed 4 Gb. If a
larger USB flash drive is used, the manufacturer cannot guarantee
correct operation.

6.3.8. Breakdown voltage measurement test.

The breakdown voltage check is performed as described in section 5.4.5. To

reduce the duration of the check, use a custom test procedure with one
voltage increase cycle, without stirring or pauses. Such mode can be
programmed as described in section 5.4.4, Settings menu, Templates section,
Figures 6.16 – 6.18.

The check is successful if the unit registers the breakdown and displays the
test results as shown in Figure 6.7.
 If no breakdown occurs before the voltage reaches 80 kV, which is possible
when the oil quality is particularly high, reduce the clearance between the
electrodes (Do not let the electrodes touch!) using the regulation wheels
(Figure 5.2) and repeat the procedure above.

6.4. Metrological control, calibration, correction of factory settings.

6.4.1. General insturctions.

For a description of the “Factory settings” menu, refer to section 5.4.4.1.

Entering the “Factory settings” menu is only possible tor users and service
personnel authorized by the unit’s manufacturer.

The menu is protected by a password, as described in Figure 6.30.

6.4.2. Metrological control.

After entering the correct password, the window shown in Figure 6.31 is
displayed.

Select “Voltage Test” by touching the corresponding menu line.

Further actions required for the metrological test of the unit are illustrated by
Figures 6.32 – 6.34 and are described in the accompanying text.

The criterion of compliance with operating or periodic maintenance checks is the

following:

Stabilized Out V differs from the selected Set kV by no more than ±2 kV

throughout the entire range of output voltage (10 to 80 kV).

6.4.3. Calibration and settings correction.

Calibration of the unit, including the correction of adjustable parameters, can be

carried out exclusively by employees of authorized service centers, or by
employees of the manufacturer.

Calibration of the unit is carried out using a TOR-81 or TOR-101 calibration cell
manufactured by GlobeCore, or two certified kilovoltmeters connected
differentially to the output contacts of the high-voltage transformer of the TOR-
80A unit using special connection devices.
The calibration procedure, indicating the equipment used, is described in the
“Methodology for Calibrating the Metrological Characteristics of the TOR-80”,
available for specialists authorized by the manufacturer after a special training
course.

6.5. Printer maintenance.

6.5.1. Printer general view and design are shown in Figures 8.1, 8.2, 8.3, 8.4.

Figure 8.1. Printer with paper installed.

The following components are shown in Figure 8.1:

1. Printer button.
 2. Printer cover handle.

3. Printer cover.

Figure 8.2. Printer internals.

2
3
4

The following components are shown in Figure 8.2:

1. Paper tear edge.

2. Internal structure of the printer.
3. Printing head.
4. Roller.

Figure 8.3. Internals of the printer with paper roll installed.

The following components are shown in Figure 8.3:

1. A new roll of printing paper.

Figure 8.4. Printer before closing the cover.

The following components are shown in Figure 8.4:

1. A new roll of unwrapped printer paper.

6.5.2. To install a paper roll, open the cover using the handle (positions 2 and 3
in Figure 8.1) and insert the roll as shown in Figure 8.3.
Then, separate the outer edge of the paper and pull it a couple
centimeters beyond the paper tear edge (рис. 8.4), after which close the
printer cover.
6.5.3. The printer should be dusted daily, also remove any traces of oil or
cleaning fluids.
6.5.4. To remove paper dust accumulated inside the printer, open the cover,
extract the paper roll, wipe the printing head (position 3 in Figure 8.2)
and the holding roller (position 4 in Figure 8.2) with alcohol swap.
Reinstall the paper and close the cover.
6.5.5. The printer is powered simultaneously with the unit. When the power is
on, the printer button (position 1, Figure 8.1) is blinking red.
6.5.6. To start a test print, press the printer button while the unit power is off.
Then turn on the unit power. When the power is on and while the
button is pressed, a test page shown in Figure 8.5 will be printed, which
signifies that the printer is operating correctly.

Figure 8.5. Printer test page.

 7. Troubleshooting.

No Problem Description Solution

1. After turning on No mains power Check power output of the supply
the power supply to the unit grid (outlet).
switch, there Change the fuse (position 11 in
are no signs of Figure 1.2).
turning on the
power supply of If the symptom persists, contact
the unit (clause the service department.
6.3.2)
2. Message: Unit cover open Check that the cover is closed.
W 0x01 or cover position If the symptom persists, contact
Run test failed! sensor defective. the service department.
Close the cover.
3. Message: Connection error Turn unit power off and back on.
Error Inverter of the control If the symptom persists, contact
Err 0x01 module and the the service department.
Error connect. inverter.

4. Message: Write error to Check the USB Flash drive for

Error Save! USB flash drive. compliance with the
Error save to requirements of section 6.3.7.
 USB drive. Change the USB Flash drive.
Turn unit power off and back on.
If the symptom persists, contact
the service department.

8. Transportation and storage conditions.

TOR-80A can be transported by covered transport in its original packaging in

temperatures from -15 °С to +40 °С.

There are no restrictions on transportation by air, subject to the temperatures

during transportation.

Protect the unit from shocks and stresses during transportation.

During transportation and storage, do not allow more than 20 ° tilt from the
horizontal plane.

Store packed in heated and ventilated areas in ambient temperatures from +5°С
to +35°С. A short-term extension of the storage temperature range from –15 to
+40°C is allowed. Relative humidity no more than 90% at +25°C, non-condensing.

In case of long-term storage, check the unit at least once every year.

9. Service life and storage duration.

Provided the unit is operated and handled correctly, its estimated service life is at
least 10 years with 20 000 hours MTBF.

The duration of storage in manufacturer packing before commissioning is 1 year.

 10. Warranty.

10.1 Warranty certificate.

The manufacturer guarantees the performance (compliance with the declared

performance characteristics) of the product

Product TOR-80A _____________

Product name Type Serial number

for 12 months from the date of transfer (shipment) of the unit to the first end-
user, provided the unit is operated and handled as described in the
documentation.

The warranty period begins on …………………………………… .

Manager …………………………… …………………………………

Signature Name

Stamp …………………………………………………………………….

Year Month Day

10.2 Warranty terms.

The manufacturer guarantees normal operation of the unit, provided that the
user observes the rules for installation, operation, maintenance, transportation
and storage established by this manual.
 Warranty period is 12 months from the date of shipment of the unit from
the supplier's warehouse. If, during the warranty period, manufacturing
defects and/or failure of the unit and/or its parts due to the fault of the
manufacturer occur, the user has the right to file a complaint with the
manufacturer (seller) without disassembling the unit or its mechanisms. Within
five days, the consumer draws up a memorandum to notify the manufacturer
about the defect.
 11.Packing certificate.

Unit TOR-80A ____________________

Product name Designation Serial number

Packed at GlobeCore ____________________________

Packing date __________________________________________

Year, month, day

QC representative ____________________ _____________________

Signature Name

__________________________________________
STAMP Year, month, day

12. Acceptance certificate.

Unit TOR-80A ____________________

Product name Designation Serial number

Manufactured and commissioned in accordance with the current documentation

and recognized as suitable for use.

Production date __________________________________________

Year, month, day

QC manager ____________________ _____________________

Signature Name
 STAMP __________________________________________
Year, month, day

Special notes