PDA Coupler Installation Guide

Installation Guide
With optional Tape Insulation

With optional 25kV Mounting Brackets
PDA Coupler
EPOXY Mica Sensors
This document is a guideline only. It is not a machine-specific detailed instruction.

The installation of PDA couplers must be directed by an IRIS specialist or performed by a person
trained in the installation procedure to ensure that the integrity of the system is not impaired. A
companion document, the Iris Verification Guide, provides guidance on how to validate the
installation.
Iris Power LP cannot take responsibility for installations performed by others.
Iris Power LP
The information contained in this document is the property of Iris Power LP, and
is to be considered proprietary material. No part of this document may be
reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying and recording, for distribution to a Third Party without the
express written permission of Iris Power LP
PDA Coupler Installation Guide -Version 2.9

Feb
Mar
Mar
Mar
Nov
Apr
May
May
May
2009 Version 2.9 [Figure 1]

2008 Version 2.8 [Figure 18]
2008 Version 2.7 [Company Address]
2006 Version 2.6 [Company Name]
2005 Version 2.5
2001 Version 2.4
2000 Version 2.3
1999 Version 2.2
1999 Version 2.1
Iris Power LP, 2008. All rights reserved
Contents
1.
Introduction .............................................................................................. 1
1.1 EMC Couplers ...................................................................................................................1
1.2 Description of EMC Couplers .........................................................................................2
1.3 Installation Schedule ........................................................................................................3
2.
Coupler Installation.................................................................................. 5
2.1 Overview ............................................................................................................................5
2.2 Coupler Location...............................................................................................................5
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
Single Circuit Directional PDA .........................................................................................6

Two Circuit Connections ......................................................................................................7
Three-Circuit Connections ...................................................................................................8
Four Circuit Connections .....................................................................................................9
Other Circuit Ring Configurations.....................................................................................10
Insufficient Circuit Ring ......................................................................................................10
2.3 High Voltage Connection...............................................................................................12

2.3.1
2.3.2
Coil Jumper..........................................................................................................................13
Circuit Ring ..........................................................................................................................13
2.4 Coupler Mounting Considerations................................................................................18

2.5 Insulating the EMC .........................................................................................................20
3.
Termination Box Installation ................................................................. 24

3.1 Overview ..........................................................................................................................24
3.2 Installation........................................................................................................................24
4.
Installing Coaxial Cable ......................................................................... 26

4.1
4.2
4.3
4.4
5.
Overview ..........................................................................................................................26
Installation........................................................................................................................26
Preparing Coaxial Cable at EMC End .........................................................................28
Coaxial Cables at Termination Board..........................................................................31
Customer Support Services .................................................................. 35

5.1 Technical Support...........................................................................................................35
5.2 Sales.................................................................................................................................35
5.3 Product Updates, New Products ..................................................................................35
Appendix A.
Template Guides ...................................................................... 37
Appendix B.
lnstallation Materials ............................................................... 39
Appendix C.
Off-line Testing......................................................................... 42
Appendix D.
Segregated IPB Systems......................................................... 43
Appendix E.
Glossary ................................................................................... 48
Appendix F.
Tape Insulation for the EMC.................................................... 49
Appendix G.
25kV EMC Brackets ................................................................. 53
ATTENTION
Read Before Starting Installation
WARNING: Installations are often carried out in conjunction with rewinds or
remedial work on a machine. It is possible to have an installation partially
complete but interrupted for AC Hi Pot testing. Refer to 0 for technical guidance.
NOTE: The Epoxy Mica Capacitor (EMC) should be kept clean during the
installation. Painting or coating the EMC with foreign materials may degrade the
electrical tracking resistance of the couplers. The surface of the EMC may be
cleaned with cloth moistened with alcohol or approved solvents. If in doubt of the
compatibility of the solvent with the EMC, contact Iris Field Service Technical
Support [ref. Section 5.1].
The 6.9kV and 16kV EMCs may be mounted in any position, vertical, horizontal
or suspended - where there is sufficient electrical clearance using the supplied
metal clamps. When using the standard metal clamps, supplied with the coupler
kit, the 25kV couplers can only be mounted in the vertical position. For horizontal
or tilted mountings involving 25kV couplers, refer to 0 for technical guidance.
Special mounting plates for installing EMCs within the iso-phase bus duct on
curved surfaces are optional and can be supplied upon request.
When routing the coaxial cables from the EMCs to the Iris coupler termination
box, the coaxial cables must be run along a grounded metallic surface. Inside
the generator, the coaxial cable can be routed and secured in place beside the
RTD cables or circuit ring supports until they exist the generator housing into a
conduit.
Dos and Donts
Do
Pay attention to electrical clearances, both phase to phase and phase to

ground.
Solidly ground the coupler termination box.
Ground the conduit to the coupler termination box and ensure that this is
the only point of grounding.
Follow IRIS installation procedures.
Dont
Dont ever use adhesive backed cable tie anchors unless secured by
mechanical means to secure the coaxial cables in place.
Dont run coaxial cables over top of the high voltage components where
they could eventually fall onto those HV components.
Dont ever connect iso-phase bus duct sheaths together, or ground across
insulated supports, using solid runs of metal conduit. (Use non-conducting
spacers, conduit, or insulators to maintain isolation between phases and
ground).
Dont bend HV cables to a radius less than 7 times the cable diameter.
Dont mount 25kV couplers in any orientation other then upright unless
correct mounting brackets are used.
Dont mount the EMCs suspended by the centre post.
1. Introduction
1.1
EMC Couplers
PDA couplers are high frequency sensors

used to detect partial discharges (PD)
occurring within stator windings of motors
and generators. The sensors are often
referred to as Epoxy Mica Capacitors or
EMCs [Figure 1]. Sensors can be used with
the portable instruments PDA-IV Lite and
TGA-P, or continuous monitoring systems
HydroTrac and HydroGuard1, hereafter
referred to as the Iris instruments.
The couplers or sensors are permanently
installed inside the generator with the high
voltage end connected directly to the
generator winding.
Typically only two couplers per phase are
installed on a winding regardless of the
number of circuits per phase.
Figure 1. EMC Couplers

6.9kV, 16kV and 25kV
Note: For information about the instruments or systems, please refer to

the appropriate users manual.
For units with multiple circuits, depending on the size and importance attached to
a unit, couplers may also be installed on some or all the circuits within a winding.
See Section 2.2 for coupler locations. As the most common installation involves
two couplers per phase, all references in the manual will refer to a two coupler
per phase installation unless specifically stated.
During installation, the coaxial cable lengths connected to the couplers are
adjusted such that a pulse originating from the system will travel through the
circuit rings to the connected EMC couplers, pass through the couplers and
travel down the coaxial cables to the termination box. Signals arriving at the
coupler termination box at identical times are classified as noise pulses. Pulses
that originate at the C1 or C2 couplers will arrive at different times and be
classified as C1 or C2 PD pulses, respectively.
PDA-IV Lite, TGA-P Lite, HydroTrac and HydroGuard are products of Iris Power
PDA Coupler Installation Guide
Introduction - 1
It is this ability to separate the machine PD from system (or noise pulses) which
allows for accurate assessments of the PD data obtained during testing.
Note: For information about verification please refer to the Iris
Verification Guide.
1.2
Description of EMC Couplers
Epoxy-Mica Capacitor (EMC) couplers are made from track resistant high quality
electrical grade epoxy, fully-rated for 25kV, 16kV or 6.9kV phase-to-phase class
installations [Figure 1].
The epoxy encapsulates an internal epoxy-mica
capacitor stack having a capacitance of 80-pF +/-4 pF for
25kV couplers and 80-pF +/-3 pF for 16kV and 6.9kV
couplers [Figure 2]. The EMCs have a minimum partial
discharge extinction voltage of 25kV, 16kV and 6.9kV
rms respectively, at 3pC sensitivity, tested according to
ASTM D1868 and IEC 60270.
Iris capacitor couplers are proof tested for 1-minute ac
voltage as follows:
15kV for 6.9kV
33kV for 16kV
51kV for 25kV
Figure 2. EMC Coupler
The EMCs resemble post type insulators and, except

for the high voltage termination, require no further insulation to be applied in the
field.
Figure 1 shows the three EMC coupler sizes offered by Iris, they are:
Voltage ratings
Height
Diameter
6.9kV
95mm (3.75 in)
89 mm (3.5 in)
16kV
130mm (5.1 in)
89 mm (3.5 in)
25kV
205mm (8.1 in)
89 mm (3.5 in)
All three-voltage classes have imbedded brass terminals, top and bottom, to
which the electrical connections are made [Figure 2]. The low voltage terminal is
recessed into the bottom of the epoxy and contains a 3/8-in stainless steel plug,
which is drilled and tapped to accept the small slotted screw to which the centre
conductor of a 50-ohm coaxial cable is attached. The brass terminal on the high
voltage end (top) of the coupler is drilled and tapped to accept a 3/8-in brass bolt.
The high voltage cable supplied comes with an L shaped ring lug crimped on
one end, which is suitable for bolting to the top of the EMC.
Introduction - 2
1.3
Installation Schedule
A typical PDA coupler installation can take from 2 to 4 days for a six-coupler
installation depending on the unit, mounting locations, amount of pre work
performed and the number of people assigned to the job. For a typical installation
supervised by an Iris specialist, the customer should provide 3 to 4 people,
based on the complexity of the installation, to support the Iris specialist on-site.
The EMC coupler installation procedure is divided into several discrete
components.
However, some aspects of the various components are
interdependent and should be done in a logical order to avoid repeating work.
The schedule below assumes that the unit is sufficiently dismantled, isolated and
grounded prior to the start of the installation.
With this in mind, a suggested order is as follows:
Day 1
Safety Training and Site Orientation
Verify isolation
permits/locks
Open unit sufficiently to enable work to be performed
Select the locations for mounting the EMC couplers and termination box.
Select routing for any conduit.
Review list of materials required (conduit lengths, mounting hardware

tooling required etc.).
Start to layout, drill and tap the holes for the EMC mounting plates
design and fabricate any mounting bracket supports required.
Start removing insulation for the EMC HV connection from areas identified
as the connection point.
and
grounding
points,
pull
(establish)
required
Day 2
Install the coupler termination box.

Note: The coaxial cable must run along a grounded metal
surface. Typically inside the generator, the coaxial cable can be
routed and secured in place beside the RTD cables or circuit
ring supports.
Introduction - 3
Install metallic conduit (rigid or flexible) between the couplers and

coupler termination box where required. If the conduit spans isolated
components or different ground planes, it is imperative that the
conduits not bridge the gaps in order to avoid circulating currents (see
0).
Conduit must be used once the coaxial cable exits the generator
frame to the Iris termination box. When routing the coaxial
cable inside a protected enclosure, it may not be necessary to
run in conduit.
Calculate the required coaxial cable lengths
Cut and prepare coaxial cable ends.
Attach the HV cable to the coupler and install the insulating boot (or
insulate for the required voltage class if tapes are to be used).
Connect the coaxial cables in the appropriate manner to the couplers.
Day 3/4
Mount the couplers in the required locations and run the coaxial cables
to the coupler termination box.
Connect the HV lead from the coupler to the copper bus
Perform initial calibration and trim coaxial cables to their final lengths.
Hard wire (solder) the coaxial cables in the coupler termination box.
Perform final calibration/verification
Insulate the HV/copper connection point of the EMC to the winding as

required and secure the coaxial cables.
NOTE: The HV end of the coupler must be insulated, even if
installed in an area of all bare bus.
Introduction - 4
2. Coupler Installation
2.1
Overview
Typically only two couplers per phase are installed on a winding regardless of the
number of circuits per phase. For units with multiple circuits, depending on the
size and importance attached to a unit, couplers may also be installed on all the
circuits within a winding. For noise separation, two couplers are paired during
the verification process.
Note: For optimal noise separation, the couplers should be installed within
1m (3ft) of the junction between the high voltage coil and the circuit ring.
As the most common installation involves two couplers per phase, all references
in the manual will refer to a two coupler per phase installation unless specifically
stated. Typically the site selected for the couplers will be the last circuit on a
circuit ring; this is referred to as a differential PDA installation [see Section 2.2.2].
In some circumstances, there is insufficient access to install the couplers within
the winding or circuit rings less than 1m (3ft) in length, so a directional PDA
installation is required [see Section 2.2.6].
Note: Each circuit ring must be at least 1m (3ft) in length.
The coupler termination box is usually located between the coupler locations, for
a generator to minimize the required lengths of coaxial cable. This is usually
directly (180) opposite of the incoming phase leads into the generator.
2.2
Coupler Location
An examination of the electrical arrangement and schematic drawings will assist

in the preplanning of the installation and will help identify the most probable
location of sensors. However, once at site, a visual inspection of the proposed
coupler locations is always necessary to confirm that coupler placements will not
interfere with the designed electrical integrity of the equipment. Consult Iris Field
Service Technical Support if in doubt about the correct application and location of
couplers [ref. Section 5.1].
When selecting the position to install the couplers, some consideration must be
given to the necessary mounting requirements and clearance [see Section 2.4],
and the coaxial cable routing [see Section 4].
If unsure of the selected site, then site verification using site verification couplers
(SVC) should be performed in accordance with the companion document Iris
Verification Guide.
Coupler Installation - 5
2.2.1 Single Circuit Directional PDA

With a single circuit machine, for each phase, one coupler (C1) is mounted as
close to the high voltage terminals as possible and measures the partial
discharge (PD) originating within the machine stator winding. The second
coupler must be installed a minimum distance of 2m (6ft) from the C1 coupler
and is referred to as the C2 coupler. This second coupler permits the Iris
instrument to recognize system noise and ensure that it is not counted as unit
PD. System noise and PD are recognized and classified by the Iris instrument
based on time of arrival.
Install the C1 coupler at the main leads (or as close as possible) for
maximum sensitivity to machine PD.
On small single circuit machines the couplers are installed external to the
machine, with the C1 coupler installed at the generator main lead/bus connection
point and the C2 coupler installed on the phase bus. This is referred to as
Directional PDA.
Single circuit with couplers external

to machine
Single circuit machine with circuit rings allowing both

couplers to be installed inside the generator
The C2 couplers are typically installed within the generator main bus duct or
iso-phase bus duct. In some cases the coupler may be installed in the voltage
transformer (VT) cubicle or in the circuit breaker cubicle. Please contact Iris
Field Service Technical Support if the either coupler is to be placed on a tap off
of the main bus (Section 5.1). If there is no VT cubicle, then the system end
couplers can be fitted into the circuit breaker cubicle, provided the verification for
installations involving taps has been satisfied [See the Iris Verification Guide].
It is desirable that there be no feeders, splits, CTs, VTs, etc. located between the
coupler pairs on a given phase. The presence of such between the couplers can
lead to signal distortion, and imperfect noise reduction. If necessary, it is better
to install the pair of EMCs on either side of the CTs rather than to have the CTs
between the stator winding and the C1 coupler.
In some cases surge capacitors are present near the machine terminals. In this
situation, it may be necessary to install either the C1 or C2 coupler on the bus
near the surge capacitors. Do not connect the EMC to the top of the surge
capacitor or after the cable connecting the surge capacitor to the bus, connect
the EMCs directly to the bus.
2.2.2 Two Circuit Connections
The circuit ring design may incorporate any one of the following configurations.
Split ring - One ring per each circuit

One common circuit ring with both circuits connected to it
2.2.2.1
Split ring
In most two-circuit designs, there

is sufficient distance between
circuits that both the C1 and C2
couplers are installed as close to
the line coil as possible. There are
some machines where there is
insufficient circuit ring length (less
than 1m (3ft)) to install one or both
of the couplers, in which case it
may be necessary to install the
couplers in a directional PDA
configuration [see Section 2.2.6].
2.2.2.2
One common ring
(Coupler C3)
(Coupler C2)
(Coupler C1)
For two circuits on a common ring, if

the unit is small to medium in size, then
a two coupler per phase directional
installation would be the probable
choice [see Section 2.2.1]. If the unit is
large, or the customer insists on full
coverage, then it is possible to install 3
couplers per phase as shown. The C1
(C3) coupler would be the common
coupler paired with C2 (C1) and C3
(C2). An alternative name schema is
also shown in parentheses.
If both circuits on a phase are within
2m (6ft) there is no advantage to
installing a coupler on each circuit.
2.2.3 Three-Circuit Connections

Regardless of the circuit ring design, there will be a single circuit on one side of
the mains and two circuits on the other. The circuit ring with the single circuit will
always be the C1 coupler circuit. The typical configurations will be:
Two couplers per phase

Three couplers per phase
2.2.3.1
Two couplers per phase
When installing two couplers on a

three-circuit machine:
the C1
coupler will be installed on the
circuit ring (or side) with the single
circuit. The C2 coupler will be
installed on the circuit farthest away
from the main leads.
Remember that each circuit ring
must be longer than 1m (3ft). If not,
refer to Section 2.2.6.
2.2.3.2
Three couplers per phase
The C1 coupler will be installed on

the side containing the single circuit.
The C2 coupler will be the circuit
farthest away from the main lead and
the C3 coupler will be the circuit
between the C1 and C2 circuits
(closest to the main leads on the two
circuit side). The circuit ring bus
length to the C3 coupler must be >1m
(3ft) in length, in order for the C3 to
properly function.
C1 will be the common coupler,
paired with both the C2 and C3
sensors. Note: verify C1 and C2 first
and then match C3 to the C1 circuit.
2.2.4 Four Circuit Connections

It is common to install only one coupler pair (two couplers) per phase on a multicircuit machine. However, in order to have the ability to further identify on which
path the partial discharges are occurring, a customer may choose to install
multiple pairs, usually two, per phase.
Installing couplers on a fourcircuit machine is identical to
installing two two circuit
installations (Section 2.2.2).
Typically, the last two circuits
on each ring (farthest from
the main leads) will be paired
together and be labelled the
C1 and C2 couplers. The
two circuits closest to the
main leads will be labelled
C3 and C4. This will be the
same, regardless of the
number of circuit rings.
All the circuit rings on which
an EMC coupler is to be
installed must be must be
>1m in length.
2.2.5 Other Circuit Ring Configurations

Any time there are an unequal number of circuits, the common coupler will be on
the side of the main leads containing the fewest number of circuits. Pair up the
couplers as per a normal installation, for the odd number circuit pick a
corresponding circuit to act as the common circuit.
To avoid long lengths of coaxial cable, the common circuit selected should be in
the same relative position on the winding. Never pair two circuits that are on the
same side of the main leads.
Note: it is very rare to install more than 4 couplers per phase and all
the circuit rings on which an EMC coupler is to be installed must be
>1m in length.
Some windings (wave wound) will have all the circuit rings for a given phase
running in the same direction. If the unit is a small diameter, the couplers should
be installed external of the machine in a directional PDA configuration [see
Section 2.2.1].
2.2.6 Insufficient Circuit Ring
When there is insufficient circuit ring, that is less than 1m (3ft) for a directional
PDA install, there are two typical configurations to consider:
Directional PDA
Couplers on the bottom of the winding
2.2.6.1
Directional PDA
Often the circuit rings will be <1m (3ft) in length. If this is the case, the EMC
couplers are installed in a PDA directional configuration, as shown for a single
circuit in Section 2.2.1.
2.2.6.2
Couplers on bottom of winding
A second installation option where there is

insufficient ring length is to install the EMC couplers
on the bottom end of the winding, relying on the
system noise to be attenuated as it passes through
the coil. This type of installation can be beneficial
when the customer requires each circuit in the
winding to be monitored and where there is no room
on the connection end to install the couplers.
Figure 3. Bottom of Winding
When calibrating, the test pulse signal is usually severely attenuated to a low
magnitude, 20 to 40mV. On large machines, the attenuation may make this
configuration a series of single ended installations where PD signals from the
system will not be detected by the couplers. Note: When calibrating, do not
confuse the ringing pulse as the calibrating pulse.
For bars, the couplers can be installed on the series clip connecting the line bar
to the second bar in from the line end. There are two possible configurations,
using the original series clip and an extended series clip.
Original Series Clip
Stud brazed to the bottom of a

series clip and the series cap
modified to allow the connection
of the EMC HV cable. The
difficulty with this configuration is
to adequately insulate over top
of the stud and HV cable.
Figure 4. Stud Brazed to Bottom
Extended Series Clip
Figure 5. Extended Series Clip
2.3
High Voltage Connection
The high voltage (HV) side of the EMC coupler is connected to the generator
circuit ring/terminals/bus using the supplied HV cable. For optimal noise
separation, the HV connection should be made within 1m (3ft) of the connection
between the high voltage coil/bar and the circuit ring.
The HV cable is fully insulated for 15kV or 25kV classes of operation (according
to machine voltage rating) and is unshielded; therefore, no stress relief is
required. The cable should be kept as short as possible and should be routed so
as to maintain adequate electrical clearances to ground or other phases for the
voltage class of the machine (see Section 2.4).
Remember, the 6.9 kV and 16kV couplers may be mounted in any orientation;
however, the 25 kV style couplers should only be mounted upright unless
optional mounting clamps are used [see 0]. Refer to Section 2.4 for Coupler
Mounting considerations.
In order to determine where the high voltage connections can be made, there
must be some understanding of the unit construction, type of insulation used
along with coil and circuit ring design. The most common windings encountered
are the roebel bar and multi-turn coil with an internal transposition, but there are
other coil designs that may be encountered. Depending on the design, certain
installation methods can be successfully performed on one machine and lead to

a potential failure on another machine.
2.3.1 Coil Jumper
In order to ensure the integrity of the
transposition for multi-turn coils, Iris
recommends that the high voltage
connection to the couplers be made
at either the jumper between the 1st
coil and the circuit ring, or directly to
the circuit ring.
If considering
another placement, please contact
the winding manufacturer or Iris
Technical Support (Section 5.1) for
assistance.
Figure 6. HV on Jumper
2.3.2 Circuit Ring

Depending on the type of circuit rings, the connection point can be via a drilled
and tapped hole, through-drilled (not as good as a tapped hole), brazed on tab or
fabricated clip.
2.3.2.1
Rectangular Copper Bus

Where the circuit rings are made of flat,
rectangular copper, and of sufficient cross
sectional area, a hole can be drilled and
tapped through the copper and the high
voltage cable connected directly to the bus.
Figure 7. Tap into Circuit Ring
Figure 8. Tab on Circuit Ring

Figure 9. L-shaped Bracket on Circuit Ring
If the rings are of insufficient cross-section, it may be necessary to braze or

fabricate a clip using the supplied copper strap. Where the circuit rings are made
of large diameter copper tubing, it is possible to drill and tap directly into the
tubing. When using this method, a flat spot should be filed in the ring to
accommodate the ring lug to ensure a solid electrical connection.
2.3.2.2
Stranded Circuit Rings
Where the circuit rings are made of

stranded copper, (typically found on
older coil windings), it is best to look for
a bulge in the insulation where the
circuit ring tap is connected to the coil
lead.
This is usually a brazed
(slugged) connection at which point a
small copper tap can be brazed, or a
copper clip fabricated that encircles the
circuit ring when tightened with a bolt.
Figure 10. Brazed Connection
Caution: If the strands are individually brazed and insulated from each other, it
is probable that the winding has an external transposition and the EMCs will
have to be mounted external to the machines in a directional PDA configuration.
This type of winding is now quite rare, normally found in older European
designed generators, but can also be found in North American designs as well.
For this style of winding, the couplers must be installed external to the winding in
a directional PDA configuration. [Section 2.2.1]
Figure 11. Two piece fabricated clip for a rectangular, stranded circuit ring
NOTE: the supplied copper strap is hard, un-annealed copper. To soften

(anneal) the copper, heat with a torch until the copper is a dull red colour,
allow it to cool slowly. Quenching or over-working will case harden copper.
Steps for preparing the HV cable:

Determine how the high voltage cable will connect to the
generator winding, the installation kit provides the
appropriate brass hardware in both imperial (3/8-16NC) and
metric (10mm). Two copper straps are also provided to
fabricate tabs or clips on site.
Whether the high voltage cable will connect to the circuit ring or the
jumper between the 1st coil and the circuit ring
Whether using a brazed or fabricated copper strap
When connecting the insulated high voltage cable directly to the circuit
ring/circuit ring tap, drilling and tapping is the preferred method,
although drilling a through hole and using a bolt and nut are also
acceptable.
Temporarily attach a high voltage cable to the EMC and select
the most suitable mounting location. See Section 2.4 for
Coupler Mounting Considerations, specifically coupler
orientation and electrical clearance requirements.
Ensure bend radius of cable is not less than 7 times cable diameter. It is
preferable that the HV cable be oriented to curve back across the top of the
EMC once installed.
Ensure main clearances phase-to-phase and phase-to-ground are not

comprised. [Section 2.4]
Where possible do not reach over top of an adjacent phase. If this is

necessary, use an insulated spacer block (Dacron felt and glass block)
saturated with epoxy and secure in position. This will ensure that the
high voltage lead does not come in contact with another phase.
NEVER simply arch it over a live point. It may sag over time.
If the installation is being performed on a unit that has been in
service, in all probability, insulation will have to be removed
from the EMC high voltage connection area.
Prior to cutting into the insulation, verify
the location of the coupler to insure that
the coupler can be installed in that area.
Only qualified personnel should remove
and reapply insulation. If unsure of the
site, before removing insulation, use site
verification couplers (SVCs) to measure
the response to a coupled signal. (See
the Iris Verification Guide).
Figure 12. Scarf Joint
A taper (scarf) must be cut in the

insulation to facilitate the re-insulation of
the joint. A 13.8kv machine should have
minimum of a 1-inch scarf joint.
A standard two-piece metal mounting bracket is used to secure

the EMC coupler in position. The mounting bracket slides
into a machined groove at the base of the EMC and it has
four slotted holes to accommodate 6mm ( in) bolts for
securing the brackets in place. Using the template in 0,
layout and drill the holes for the EMC mounting brackets.
Holes can be through drilled using a 7mm (5/16-in) drill bit,
or if the hole is to be tapped, a 5mm (13/64-in) drill bit is
required.
Assuming the insulated HV lead (supplied) is to be connected to
the EMC, determine the length of cable required to connect
the top terminal of the coupler to the selected spot on the
bus or connector. Allow sufficient length so the cable will not
be under tension. Remember to make some allowance for
thermal movement of circuit rings. Trim the HV cable to suit

and crimp on the straight ring lug supplied, or one suitable
for the installation.
Note: Where there is minimum separation, 2m (6ft), between the
C1 and C2 couplers, the high voltage connection leads must be cut
to identical lengths for each coupler pair.
If the supplied HV cable is not used then a cable of equivalent
rating (unshielded)must be used and kept to a minimum
length. IRIS recommends a maximum of 60cm (2 ft).
If a copper strap is used, a 10mm (3/8-in) hole should be drilled
in one end of the copper strap to accommodate the coupler
termination lugs (supplied) and the brass bolts (supplied).
The other end can be drilled to accommodate the bolt size
associated with the circuit ring and/or terminal connectors, or
brazed as a tab if desired. This copper strap will require
insulation on site as required.
NOTE: The EMC should be kept clean during the installation.
Painting or coating the EMC with foreign materials may degrade the
electrical tracking resistance of the couplers and must be avoided.
The surface of the EMC may be cleaned with a cloth moistened
with alcohol or approved solvents. If in doubt of the compatibility of
the solvent with the EMC, contact Iris Field Service Technical
Support (Section 5.1).
For re-insulating the connection area, a Y connected joint
[Figure 13] is much easier to tape than a T connection
[Figure 14] as shown below. When re-insulating using mica
tape, the tape width should be no less than 2cm (in) and
no wider than 2.5cm (1in).
Figure 13. Y-joint
Figure 14. T-joint
For class F windings, an epoxy or polyester resin must be used as a binder

and applied between every layer of insulation. If the winding is a class B
insulation, an air-dry varnish can be used. All taped joints will require at least
one layer of glass or Dacron tape be applied as a protective layer for the mica
tape.
Caution: Follow all standard safety procedures for winding repairs when
working within a winding. This includes cleanliness and proper insulation.
2.4
Coupler Mounting Considerations
When selecting the location for mounting the couplers, ensure there is sufficient
space to install the couplers without compromising the high voltage integrity of
the winding or output bus. There must be adequate voltage clearance between
the low voltage portion of the EMC coupler and coax cable to any high voltage
component. Similarly the high voltage portion of the EMC coupler and the
coupler HV leads must be a safe distance from any grounded structures and
other phases.
The recommended and absolute minimum distances in air between insulated
high voltage and low voltage components are:
Rated voltage
Recommended
Minimum
6.9kV
25 mm (1 in)
6mm (0.25 in)
16kV
50 mm (2 in)
20mm (0.75 in)
25kV
150mm (6 in)
63mm (2.5 in)
Each EMC is clamped into place on a suitably flat surface using a 2 piece
mounting clamp, fabricated for this purpose and supplied as part of the
installation kit. The 2-piece mounting clamp should fit snugly and securely in the
machined groove at the base of the EMC. If this is not the case, please contact
Iris Field Service Technical Support. The 6.9kV and 16kV coupler may be
mounted in any position, vertical, horizontal or suspended - where there is
sufficient electrical clearance, using the supplied metal clamps. The 25kV
couplers can only be mounted in the upright position with the conventional
bracket.
For installations requiring mounting the 25kV EMC in the horizontal or suspended
position, Iris Power can, as an option, supply special support blocks
manufactured for that purpose. Where necessary, Iris can supply, as an option,
mounting support brackets fabricated to tilt the EMC at no greater than a 45
angle to accommodate an installation. See 0 for further information, or contact
your Iris Sales Representative.
Iris also supplies special steel mounting plates for
installing EMCs within the iso-phase bus duct or
other curved surfaces as shown in Figure 15.
Please contact your Iris Sales Representative for
further information.
The plate is used to give the EMC a flat mounting
surface inside the iso-phase bus. The length wise
orientation of the plate and mounting brackets
along the duct allows for the maximum clearance
and stability to reduce mechanical stress on the
EMC.
Figure 15. Curved mounting

arrangement
In some situations, a plate to which the

couplers will be secured may need to be
fabricated and installed on-site.
An
example is shown in Figure 16.
If necessary, drilling new holes through
the supplied support clamps is allowable
only when the EMC is sitting on a flat
smooth surface. The clamp should not
be modified if the EMC is to be mounted
in the horizontal position or mounted
upside down.
Figure 16. Fabricated mounting plate
When installing in the horizontal position,

the EMC brackets should be aligned
vertically (12 and 6 oclock positions) for
maximum support of the EMC as shown in
Figure 17.
Figure 17. Horizontal mounting
2.5
Insulating the EMC
It is recommended that the HV connection at the top of the EMC be insulated

regardless of the location selected for the installation. The only exception is
where the EMC is installed inside an Iso-Phase bus and there is insufficient room
for the insulation.
Iris provides a pre-formed silicone rubber mould, or
Boot, which seals tightly over the high voltage cable and
the first shed of the coupler. For customers who prefer
tape insulation, please refer to 0.
The Boot and these tapes are designed for normal
operating temperatures, <130C, and non-radiation
environments.
For other application areas, the
customer must provide suitable insulation.
Steps for Insulating the EMC with a Boot:

Prior to installing the Boot, position the epoxy mica capacitor (EMC) on the
unit and determine which way the EMC brackets will be mounted, and the
position where the coaxial cable will exit the EMC in relationship to the EMC
clamps.
Due to the nature of the high voltage (HV) cable connection to the top of the
EMC, the cable will be offset from center and may influence the preferred
orientation with respect to the coaxial cable. Therefore, when installing the
high voltage cable, ensure the slot for the coaxial cable exit (at the bottom of
the EMC) is orientated in the right direction.
The boot has a two-step neck to accommodate both the 16kV and 25kV
high voltage cables. When installing with the 25kV cables it is necessary to
trim off the smaller diameter neck. Care must be taken when cutting off the
16kV neck to ensure that the remaining part of the boot is not damaged.
Use a sharp knife or razor knife for trimming the boot.
Take the boot in hand and collapse the boot like an
accordion. The boot will be installed over top of the
L ring lug. If desired, to assist installation, take the
HV cable and smear a light coat of Silicone
approximately 7cm (2in) up the HV cable from the
ring lug. The Silicone will act as a lubricant. The
recommended silicone is Clear Guide, a wire pulling
lubricant or SU5005RTV silicone adhesive, which is
both a lubricant and a sealant.
Carefully insert the ring lug
through the neck of the boot.
Push the boot high enough that
there is sufficient clearance to
install and tighten the bolt
through the ring lug to the EMC.
5. Bolt the HV cable to the top of the EMC;

check the orientation of the cable before
tightening to ensure that the cable will arc
over top of the EMC. Place a small dab of
loc-tite on the brass bolt and tighten in place,
but do not over tighten to the point where the
lock washer starts to spread.
Start the lip of the boot over the first

shed of the EMC, place hands on
each side and gently stretch and roll
the boot to the front of the EMC using
a slightly downward pressure. This
will force the boot over the shed and
snap into place. Unfold the boot and
snap into place over ONLY the first
shed of the EMC. No lubrication or
sealing is required on the EMC.
7. Once the boot is positioned over the EMC,

straighten the HV cable and position the neck
of the boot so that it is in a relaxed position as
shown.
8. Wipe off any excess silicone.
If RTV silicone adhesive is being used; allow it
to set for hour, then the EMC will be ready
for installation.
9. To remove the boot from the EMC - with

both hands hold the rim of the boot and
gently pull it away from the EMC and at
the same time peal it back towards the
HV cable.
Caution: Do not paint the silicone

boot or EMC.
NOTE: In the unlikely event the boot is a

loose fit over the 16kV cables, it is
recommended that two half-lap layers of
Silicon Guideline tape (provided by customer)
be wrapped around the top of the boot/cable.
This will seal the top of the boot to the cable
preventing the ingress of moisture and
contaminants. Recommended are a full layer
(i.e. the width of the tape) of Silicone
Guideline tape on the boot and a full layer on
the HV cable as shown.
3. Termination Box Installation

3.1
Overview
The coupler termination box contains the
BNC jacks/terminal board to which the
coaxial cables from the EMC sensors are
terminated. The BNC connections are
used for all Iris portable instruments and
continuous monitoring systems using
capacitive type sensors.
RG 58 (50 ohm) coaxial cables are used
to connect the couplers to the termination
box. The termination box contains a
1500 ohm resistor and 75 V surge
arrestor on each connector termination.
The arrangement ensures that the normal
60 Hz (or 50 Hz) voltage from the 25 kV
EMC couplers will be less than 600 mV
and less for lower voltage couplers and
limits voltage rise under abnormal
conditions.
Figure 18. Termination Box
3.2
The continuous monitoring systems, or

Tracs, use a junction box rather than a
termination box. Please refer to the
appropriate Trac installation guide for
directions regarding the installation of the
junction box.
Installation
The coaxial cables on a given phase are usually different lengths; but often
selecting a central location between the coupler pairs to mount the termination
box will minimize the total length of coaxial cable required and the amount of
excess cable that will have to be stored. This is usually directly opposite (180)
from the incoming phase leads into the generator. If it is not possible to centrally
locate the termination box, approximately 11m (36 feet) total of excess cable can
be stored in an open loop inside the termination box. A second box may be
required to store longer lengths of coaxial cable if required. The termination box
is mounted with the door hinge at the bottom and the locking clips at the top.
Termination Box Installation - 24
The standard coupler termination box is a NEMA 4X corrosion resistant

fibreglass box with no knockout provision for coaxial cable access (Iris has an
optional stainless steel box for special applications and when placed in highly
corrosive environments, but this would have to be specified at the time of order).
The coaxial cable access location (top, bottom, sides or back) and hole size is
determined at the time of installation and punched or drilled before mounting.
The termination box can be mounted on any vertical surface, such as a wall, the
side of a cubicle, structural I beam or generator terminal box. It should be
installed at approximately eye level and have reasonable access to a 110/220 V
power outlet. The termination box itself does not require power; power is only
required when performing online testing with the Iris portable instruments.
However, the Iris continuous monitoring systems do require permanent power.
Steps for Installing the Termination Box:

1. Determine a suitable location for the Termination Box.
2. Remove the internal circuit board from the box, and set aside for
safekeeping.
3. Drill out the appropriate size hole for the coaxial cable conduit at the
desired location in the Termination Box and install a suitable adapter. Use
an appropriate drill bit, hole saw or hole punch. [See Section 4.2 for
information about conduit sizes]
4. Using the template in 0, mark the holes for attaching the box.
5. Mount the Termination Box by drilling and tapping, or using bolts as
necessary.
6. Run the #4 copper wire (supplied, green jacket) from the ground bolt on
the right side of the termination box to a permanent station ground
location. This bolt is used to ground the components inside the termination
box and also the metallic conduit. This should be the only point where the
conduit is grounded to minimize risk of circulating currents due to differing
ground potentials.
Termination Box Installation - 25
4. Installing Coaxial Cable

4.1
Overview
The coaxial cable connects the low voltage terminal of the EMC coupler to the
termination board inside the coupler termination box. The coaxial cables from a
coupler pair in a phase will usually be different lengths and must be routed along
a grounded metal surface from the EMC to the termination box.
4.2
Installation
Typically, inside the generator, the coaxial cable can be routed and secured in
place beside the RTD cables or circuit ring supports until they exit the generator
housing into a conduit. Whenever the coaxial cables exit a metal enclosure,
such as the generator frame, the coaxial cables must run in grounded rigid or
flexible metallic conduit, preferably away from and not on open cable trays along
side power cables. Some customers may insist on using conduit inside the
generator. If so flex conduit is preferred over rigid conduit. To minimize conduit
runs, where possible, multiple coaxial cables can be run through a common
conduit.
The conduit must provide a continuous ground plane and should only be
grounded at one end. Iris recommends grounding the conduit only once at
the coupler termination box. Multiple ground points along a conduit may
result in high circulating currents, which may cause the conduit to
overheat and melt the coaxial cable insulation. This is especially true in
isolated phase bus arrangements.
Important: When installing conduit between various Isolated Phase Bus
(IPB) components, be very careful not to inadvertently short circuit or
jumper some IPB sheath insulated gaps. An insulated nylon bushing or a
short section ~ 5-10cm (2-4 in) of PVC conduit installed at the EMC
coaxial cable exit point will be sufficient to insulate the conduit from the
bus. It may also be necessary to insulate the conduit from the conduit
clamps and hangers to avoid ground loops. [0].
In order to minimize installation damage, all conduit sizes should comply with
local electrical safety codes. In absence of local codes, the minimum conduit
sizes in Table 4-1 are recommended.
Installing Coaxial Cable - 26
Coaxial cables
Conduit Trade
Size
3 to 6 Coaxial Cables
2cm (in)
9 Coaxial Cables
2.5cm (1in)
12 Coaxial Cables
3cm (1 in)
18 Coaxial Cables
4cm (1 in)
24 Coaxial Cables
5cm (2 in)
Note: These
measurements are
for rigid conduit only
and should be
increased 1 size for
the 3 to 12 coaxial
cable installations if a
flexible conduit is
used.
Table 4-1
Meets or exceeds Canadian Electrical Safety Code, Part 1, Rule 12-1014
Steps for Installing the Coaxial Cable:

1. Determine the route for conduit runs from each set of couplers to the location
of the coupler termination box. Conduit is not required within the generator
and enclosures where the coaxial cable can be securely fastened
continuously against a grounded metal surface.
2. Rigid conduit is preferred and should be used when spanning between the
generator frame and the generator pit wall.
3. Install the required metallic conduit between the coupler locations and the
coupler termination box. Since the conduit is only grounded once at the
termination box, install conduit insulators as required.
4. For each coupler, determine the path the cable. When cutting the coaxial
cable, add 3 m (10) extra to the calculated length for an adjustment
allowance. The complete path will include both that taken inside cubicles and
that running through the conduit installed in step 3 above.
5. Below is a suggestion for labelling the coaxial cables for easy identification.
Phase
C1 Coupler
C2 Coupler
A-1
A-2
B-1
B-2
C-1
C-2
4.3
Preparing Coaxial Cable at EMC End

1. Cut the outer jacket back
approximately 2.5cm (1in).
2. Carefully trim off the exposed
shield flush with the jacket.
Figure 19. Trimming of coaxial cable
3. Trim back the centre conductor

insulation approximately
9.5mm (3/8in).
Crimp on the ring lug

supplied in the kit.
Position the black
heat shrink tube,
centred over the
trim area of the
jacket and centre
conductor.
Using a heat gun
shrink the tubing
into position to
ensure the coaxial
shield
will
be
isolated
from
ground.
Figure 20. EMC coaxial cable connection
Caution: Overheating during the shrink process may damage the

centre conductor insulation, resulting in the centre conductor
grounding to the outer shield.
Prior to installing the

coaxial
cable,
check that the
stainless steel plug
is tight in the
bottom
of
the
EMC.
Figure 21. Bottom of EMC
Position the ring lug at

about the 9 oclock
position from the
machined groove
and tighten the
screw. Do not exit
directly through the
groove or try to
press the shrinkcovered
portion
into the groove. If
the EMC is to be
installed
in
a
caustic
environment such
as petrol-chemical
plants or subject to
severe vibration, a
covering of RTV
(silicone
rubber)
can be applied
over the exposed
brass insert, ring
lug and coaxial
cable.
Dab a small quantity

of loc-tite on the
small
coax
terminal
screw,
and then wipe off
any excess.
Figure 22. Coaxial cable connected to EMC
Once all the coaxial cables have been connected to the

couplers, the couplers can be permanently mounted in the
unit. Once mounted, route the coaxial cable to the conduit,
ensuring that the cable is run along a grounded surface.
Fasten the coaxial cables in place using mechanical
fasteners to prevent movement.
Note: Never secure the coaxial cables in place using adhesive
backed clips etc.
The coaxial cables MUST only be placed adjacent to the low
voltage portion of the coupler and secured to a ground plane.
Never place the coaxial cable adjacent to the high voltage end (top)
of the coupler or any high voltage component of the machine.
Avoid running the coaxial cable over top of the HV bus or
terminals, where failure of a clamp or support may allow the coaxial
cable to fall onto a HV component.
It is often necessary to pull slack or excess lengths of individual
lengths of coaxial cable back through the conduits to a
suitable storage location. Therefore, the practice of bundling
and taping the coaxial cables should be avoided. Although
this practice does make the cable pulling process more
manageable, it will create difficulties as the installation
process continues.
Pull any excess cable through the conduit and out through the
termination box. Note that unless the termination box is
perfectly centred between the couplers, three of the coaxial
cables will have longer lengths pulled out of the termination
box. Take care pulling cables not to kink or damage the
coax cables.
Once the coaxial cable has been pulled, there should be about
3m (10ft) of coaxial cable from each coupler extending out of
the termination box. Perform the initial (trial) verification test
as per the Iris Verification Guide. Remember, additional
cable had to be added to the shortest circuit ring on a given
coupler pair so one cable in a pair may be very long.
Once satisfied with the verification, trim the coaxial cable
leaving about 40cm (16in) of coaxial cable extending from
the box to provide enough slack to allow for hard wiring to
the BNC jacks.
NOTE: When trimming the coaxial cable ensure that the exact
same amount of coaxial cable is trimmed off each pair of cables.
Approximately 11m (36ft) of excess coaxial cable can be stored
in open loops inside the termination box. If there is an
excessive length of coaxial cable to be stored, it may be
necessary to install a second box, or the coaxial cable can
be pulled back into the machine or generator terminal box
and secured in open loops there.
The excess cable should be formed into an open loop not a coil,
as a coil can increase the inductance of the cable and may
distort the partial discharge pulses. If the coaxial cable is
pulled back into the machine, or terminal box, ensure that
the coaxial cable is securely fastened by mechanical
means away from the electrical components.
4.4
Coaxial Cables at Termination Board

4. Trim the outer shield of the coaxial
cable about 9mm (5/8in).
5. Carefully unbraid the shield and
divide into two equal parts and then
twist the strands together to
consolidate the loose strands.
Figure 23. Termination Board coaxial cable

connection
Strip the centre conductor insulation to approximately 6mm (in) from the
twisted shield.
Figure 24. Coaxial cable connected to termination board
Insert the exposed conductors into the fork terminals with the centre
conductor in the middle fork and each of the shield conductors on the two
side forks.
Secure all the coaxial cables in place with the cable ties. At this point, use
only the cable tie nearest the connection to be soldered.
Note: Care must be taken during soldering to avoid overheating
the shield conductors and melting the insulation between the shield
and the centre conductor. Do not try to solder all 3 points on a
given cable in quick succession.
Solder
the
connections.
Soldering the same terminal on
each of the coaxial cables in
sequence will allow sufficient time
for the insulation to cool before
soldering the next terminal.
Trim the excess strands flush with
the solder terminal.
Figure 25. Trimmed and soldered
connection
Inspect the soldered joints to

ensure proper soldering and no
missed or cold (dry) soldered
joints.
Check that no stray strands are
shorting out the terminals.
Position the coaxial cables and
use the last remaining cable ties
on the board to secure the three
cables in a bundle.
Figure 26. Securing coaxial cable with cable
ties
Secure the excess coaxial

cable
neatly
inside
the
termination box.
For most installations, the
excess coaxial cable can be
stored in an open loop inside the
fibreglass termination box.
By using sticky backs and
nylon cable ties, approximately a
total of 11m (36ft) of coaxial
cable can be stored inside the
termination box.
Secure the
excess cable as described in
Section 4.3 steps 15 and 16.
Finish the coaxial cable
installation with a final TDR,
verification and resistance check
as described in the Iris
Verification Guide.
Figure 27. Securing excess coaxial cable

in termination box
5. Customer Support Services

5.1
Technical Support
If you require additional technical support, please contact Iriss Field Service
Technical Support at e-mail techsupport@irispower.com or fax 1-416-620-1995
or telephone 1-416-620-5600 from 9:00 a.m. to 3:00 p.m. Eastern Standard
Time.
5.2
Sales
If you would like to obtain additional installation materials, please contact Iriss
Sales Department at 1-416-620-5600, 9:00 a.m. to 3:00 PM Eastern Standard
Time.
Please check our website http://www.irispower.com/ for the latest product
information, available services and software updates.
5.3
Product Updates, New Products
For firmware upgrades, software upgrades, product updates and new products,
visit our website, www. irispower.com regularly. Contact our Sales Department
at 1-416-620-5600, 9:00 a.m. to 3:00 p.m. Eastern Standard Time for more
information.
Customer Support Services - 35
Customer Support Services - 36
Template Guides
Coupler Mounting Bracket
Mounting clamps arrangement & dimensions.
Appendix A Template Guides - 37

End View
8.5" (216 mm)
Quick-Release Cover Enclosure
Side View
10.5" (267 mm)
4.94"
(125 mm)
6.0"
(152 mm)
6.0"
(152 mm)
0.41"
10 mm
0.12"
(3 mm)
1.31" (33 mm)
#10-32
Pan Head
3/8 NC
Grounding Stud
0.31"
0.50"
x
Slot
8 mm
13 mm
Drawn By: Dave Prosser

Date Drawn: July 9, 1999
Approved By:
Date Approved:
ctb-dims.cdr
Drawing #: ISO- 039
Revision #: 00
P O W E R E N G I N E E R I N G
IRIS
Iris Power Engineering

1 Westside Dr., Unit 2
Etobicoke, Ontario, Canada M9C 1B2
tel (416) 620-5600, fax (416) 620-1995
Coupler Termination Box Mounting Dimensions
Notes:
1) Mounting feet are 0.16" (4 mm) thick.
2) Quick release clamps not shown in "End View".
3) The grounding stud MUST be connected to station ground.
Bottom View
10.5" (267 mm)
9.12" (232 mm)
10.94" (278 mm)
Termination Box Mounting
Coupler termination box dimensions.
Appendix A Template Guides - 38
lnstallation Materials
The following list (next page) is typical of the materials supplied by Iris to install a
set of PDA couplers. PDA coupler sets may be composed of 6 EMC couplers, or
a higher multiple of 3. The table shown provides information on quantities for a
full 6-coupler installation kit. Any variations of these installation types would
include only the appropriate components of these lists. Other materials may be
substituted provided that the materials used are intended for electrical use and
are compatible with the electrical installation.
Note: Additional items, NOT SUPPLIED by Iris but which may be
required to provide a complete installation, are shown on the next
page of this Appendix.
Six EMC Coupler set - supplied

Item
Quantity
Product Description
Epoxy type coupling Capacitors, fitted with coaxial cable

crimp ring lug and screw at base
High Voltage Cable
6 pieces
16kV or 25kV jumper cable 60 cm (24 in) with L- shaped

coupler end ring lug installed
Ring Lug
6 pieces
Burndy #2 AWG - 1/2 in. for jumper cable, straight
Copper Strap
2 pieces
Strips 60 cm (24 in) x 2.5 cm (1 in) x 0.32 cm (1/8 in) - to

provide termination points for coupler cable lugs to bus.
12 sets
For connecting Epoxy - Mica Capacitor cable ring lugs

to high voltage connection point
6 sets - 3/8in x 1in imperial thread
6 sets 10 mm
Preformed high voltage insulating boot for coupler HV

connection
Epoxy - Mica Capacitor
Bolts/washers/lock
washers
Insulated Boot
Clamps
Coaxial Cable
Polyolefin Shrink Tube
6 sets
150 m (500 ft)
6 pieces
Termination Box
Insulated Wire - #4
1
3 m (10 ft)
Hold-down clamps for Epoxy - Mica Capacitors

RG58 C/U 50 ohm coax cable
2.5 cm (1 in) to insulate coaxial cable, coupler end
shield braid
Termination of coupler output coaxial cables
600 V insulated wire for grounding coupler termination
box. (Green)
Appendix B Installation Materials - 39
Optional Materials and Hardware

Item
Quantity
Product Description
25kV EMC Horizontal

Mounting Kit
2 pc block designed for mounting the 25 kV couplers in

the horizontal or suspended positions
Angled Support Bracket
Designed for tilting the 25 kV couplers at a 45 angle to

accommodate an installation
Iso-Phase Bus Mounting

Brackets
For mounting the EMC couplers on a curved surface
SAP Tape - 5 cm (2 in)

wide++
2 rolls**
Self-Amalgamating Polymeric Tape.

used to insulate. ROTUNDA 2501
Black in colour,
Silicone Rubber Tape - 2.5

cm ++ (1 in wide)
2 rolls**
Self Fusing - Orange in colour ROTUNDA Protective

cover over SAP tape
Electrical Putty - 5 cm (2 in)

wide++
8 strips
Electrical Putty to mould around connections to be taped.

Supplied in strips 33 cm (13 in) long
**Note: Insulating materials supplied are sufficient for insulating

the EMC; additional quantities of tape may be required.
++Note: Only required if boot is NOT used.
Additional Materials
For a complete coupler installation, depending on bus coupler installation
configuration and layout, additional materials may be required.
Note: These additional materials are supplied by the customer and
do not form part of the Installation Kit supplied by Iris.
These additional materials may include some or all of the following:
Materials Required - Conduit
Metallic Conduit
Rigid or flexible may be used

Conduit should have continuity over the length and may require
simple point grounding to avoid ground current circulation.
Ground at the termination box
Recommended conduit sizes for:
6 coaxial cables 2.5cm (1in)
12 coaxial cables 3cm 1in)
Miscellaneous Conduit Fittings
To run conduit from the EMC to the termination box

Note pull boxes are recommended ~ every 15 feet
Conduit Mounting Brackets
Insulated clamps/brackets may be required to avoid circulating

currents in the conduit.
Materials Required Typical Hardware

Nuts, bolts, lock & plate
washers -20 x 1in
Miscellaneous Hardware
Cable ties and clamps
Termination Box Qty 4

EMC Mounting Brackets
3 couplers Qty 12
6 couplers Qty 24
Depending on installation, additional hardware and materials for
fabricating mounting brackets may be required
Required to fasten the coaxial cables into place.
No adhesive backed fasteners can be used, unless also
secured mechanically.
Materials Required Miscellaneous

Miscellaneous hand tools
Electric drill, drill bits, and taps
Vacuum
Crimping tool for Burndy #2 AWG in ring lug
Razor Knives, wood chisels, files
Loc-tite, RTV, epoxy
Off-line Testing
Hi-Pot Testing
PROVIDED the EMCs are correctly terminated into the Iris termination box by
means of the coax cable with the box grounded, in accordance with the Iris
installation manuals, it is safe to carry out both AC and DC hi-pot tests of the
stator winding. Should there be a need to conduct a winding test AFTER the
high voltage connection to the coupler has been made, BUT BEFORE the
coaxial cables have been properly terminated then the ends of the coax cable
must be stripped bare, shields and center conductors twisted together and the
whole lot grounded.
Each EMC is tested by IRIS prior to shipment at twice rated voltage plus 1kV
!
!
!
6.9kV EMC's are tested to 15 kV for one minute

16kV EMC's are tested to 33kV for one minute
25kV EMC's are tested to 51kV for one minute
The design of the EMC is such that the breakdown and tracking voltages of the
EMC's are far in excess of this value. The only factor that may affect
performance during hi-pot testing is heavy contamination on the EMC. To that
end, a visual inspection and cleaning (if required) of the EMC is recommended
prior to testing, especially if there is heavy contamination on the bus or other
components.
Off Line hi-pot testing of machines that have Iris EMCs installed can safely be
carried out without risk of any damage to the EMC up to industry standard levels
of:
!
!
AC Hipot - twice rated machine voltage + 1000 volts

DC Hipot - (twice rated machine voltage + 1000 volts) x 1.7
Other Off-Line Tests

The presence of the EMCs during other off-line diagnostic tests, for example
Partial discharge, Dissipation / Power Factor tests, Megger and PI, will not affect
the machine winding characteristics or have a detectable impact on measured
results. The EMCs are 80pF capacitors, which is negligible in comparison to the
winding capacitance and are certified as discharge free up to twice rated phaseto-ground voltage.
If you still have questions or concerns regarding off-line testing of your
machine that has Iris EMCs installed, please feel free to contact your Iris
Sales representative, who will put you in touch with the appropriate field
service engineer.
Appendix D IPB Installs - 42
Segregated IPB Systems

Important: When installing conduit between various Isolated Phase Bus (IPB)
components, be very careful not to inadvertently short circuit or jumper some IPB
sheath insulated gaps. An insulated nylon bushing or a short section ~ 5-10cm
(2-4 in) of PVC conduit installed at the EMC coaxial cable exit point is sufficient
to insulate the conduit from the bus. It may also be necessary to insulate the
conduit from the conduit clamps and hangers to avoid ground loops.
IPB Configurations
Figure 28
Figure 29, and Figure 30 illustrate three (simplified) typical ISO phase Bus
configurations, showing insulated bus support mounts and insulated bellows with
segregation at the Generator (Figure 28) or Generator Transformer (Figure
29Figure 28and Figure 29 show systems where each phase is insulated
separately and Figure 30 where they are common.
The KEY factor is that the phase buses are grounded at ONE point only to
ensure that circulating currents within the system are prevented.
Generator
Gen Tx
Insulation
Insulated Bus mounts

Figure 28
Generator
Gen Tx
Insulation
Figure 29
Generator
Gen Tx
Insulation
Figure 30
Ground Loop
Figure 31 illustrates the effects of a ground loop in a ISO phase bus.
The dotted line indicates the circulating currents in the ISO phase should it be
grounded at both the Generator and Generator Transformer.
The dotted/dashed line indicates the effects of a conduit or metallic pipe that is
grounded and attached to the ISO phase bus.
It should be note that 1000s of amps could flow and any pipe introducing a
second ground on the ISO phase bus system will eventually melt and cause
damage to internal cables.
conduit
Generator
Gen Tx
Potential circulating currents due to grounding at

both ends of IPB 1000s amps can flow
Figure 31
Typical Conduit Runs with IPB Systems

Figure 32 and Figure 33 illustrate typical conduit runs with insulated conduit
supports and an insulated bushing at the connection of the conduit to the ISO
phase bus (Figure 35). Note the Conduit is Grounded at the Term box only.
Figure 34 illustrates an alternative method where flexible plastic conduit is used
at the connection between the ISO phase bus and the conduit, and the conduit is
not in a continous run. Insulated bushings are installed to break up the conduit
run, each section of conduit is grounded indididually so as to prevent circulating
currents.
NOTE: Both for safety and measurement, the conduit MUST be
grounded. It is essential that the coax runs in grounded metal
conduit or against a grounded plane to reduce unwanted noise.
IPB
Insulated supports
& Spacers
Generator
Insulated Nylon
Bushing
Term
Box
Figure 32
Conduit run insulated from IPB

as well as ground
Term
IPBs mounted on
insulated expansion
mounts
Box
Figure 33
IPB
Insulated supports
Generator
Insulated
Spacers
Term
Box
Flexible Plastic
Conduit
Figure 34
Outer shield of Coax

isolated from Ground and not
connected
Metal Conduit
Coax Cables
Generator
Enclosure
Nylon insulated Bushing
Figure 35
Glossary
Terms
Angle Plate
Bar
Definitions
Coaxial Cable
Coil
Coupler Pair
Offsets the coupler at a 45 deg angle

Half coil, typically roebeled, full coil consists of 1 bottom bar and 1 top bar.
Continuous PD monitoring system using PDA couplers as the sensors with the
ability to trigger off of operating conditions based on analog inputs
Continuous PD trending system using PDA couplers in a double-ended
installation as the sensors
Old style 80pF capacitor made from wire shielded high voltage cable
Copper bus or cable which connects the line coils to the generator terminals.
Depending on the machine design, each circuit may have a dedicated ring or
may have multiple circuits on each ring.
RG 58 Coaxial cable, normally 152m (500ft) supplied
Multi-turn, full coil
The two couplers on a given phase which are paired together as C1 and C2
CTs, VTs
Current or Potential transformers used to monitor machine parameters.
HydroGuard
HydroTrac
Cable Coupler
Circuit Rings
/Collector Rings
Differential Install
Directional PDA
Installation
EMC Coupler
EMC Mounting
Clamp
Typically installed on Hydro machines Couplers are connected to the line

coils/circuit rings on each circuit in a phase. There must be a minimum of 1m
(3ft) of circuit ring on each circuit. Noise separation is done by time pulse time
of arrival.
Where there is insufficient circuit ring length, couplers are installed external of
the unit on the bus (same as a bus installation) but calibrated as a PDA.
Epoxy Mica Capacitor 80pF
Standard two piece clamp used to secure the coupler in place
Feeders, splits
Taps on bus bar to auxiliary circuits.
Ground Cable
Green 10 cable used to ground the Iris termination box to a station ground.
Red silicone rubber tape used for environmental protection has excellent
tracking properties
A 2-foot length of HV cable, which connects the HV side of the EMC to the
generator winding. Requires cutting to length.
Moulded silicon rubber boot designed to replace the Sap and Silicone tapes
The last coil in a circuit having the highest voltage in the circuit
Used to mount 25 kv couplers in any position other than Vertical
Instrument required to perform the on line testing
Time required for a pulse to increase from 10%-90% of its pulse magnitude.
Black 1.5inch wide HV insulating tape, requires 30% stretch to self
amalgamate.
Turbo Generator Analyser portable instrument to measure PD using PDA
couplers as the sensors.
Guideline Tape
HV Cable
Insulated Boot
Line Coils
Mounting block
PDA IV
Rise time
Sap Tape
TGA-P Lite
Appendix E Glossary - 48
Tape Insulation for the EMC

In some circumstances the customer may prefer to use tape insulation as
opposed to the pre-fabricated silicone rubber boot. These materials are supplied
at additional cost OR to be sourced by client.
Item
Quantity
Product Description
SAP Tape 5 cm (2 in)

wide++
2 rolls**
Self-Amalgamating Polymeric Tape.

used to insulate. ROTUNDA 2501
Black in colour,
Silicone Rubber Tape

2.5 cm ++
2 rolls**
Self Fusing Orange in colour ROTUNDA Protective

cover over SAP tape
8 strips
Electrical Putty to mould around connections to be taped.

Supplied in strips 33 cm (13 in) long
(1 in wide)
Electrical Putty 5 cm (2
in) wide++
Tooling and materials

required to insulate the
EMC with tapes
Figure 36
There are three basic materials as part of the insulation system [Figure 37]:
Wrapfast that is used to form a cone around the connection to facilitate

taping
Self-almagamating (SAP) tape that provides the dielectric strength
Silicone rubber (Guideline) tape to provide protection from electrical

tracking and some dielectric strength
Appendix F Tape Insulation for EMC- 49
High Voltage Cable

Minimum insulation overlap 1"
The putty should

be formed into a
cone shape
Right angle ring lug
2" wide black SAP tape

Number of layers depends
on the voltage class
Tapes should only cover
the first skirt of the EMC
2 half-lap layers of
silicone rubber tape
(Guideline)
Figure 37
Prior to insulating the EMC, position the

EMC on the unit and determine which way
the EMC brackets will be mounted and the
position where the coaxial cable will exit
the EMC in relationship to the EMC
clamps.
Because of the nature of the HV cable

connection to the top of the EMC, the
cable will be offset from the centre and
may influence a preferred orientation with
respect to the coaxial cable. Therefore,
when installing the high voltage cable,
ensure that the slot for the coaxial cable
exit at the bottom of the EMC is orientated
in the right direction.
Figure 38
Tighten the brass bolt, but do not over tighten, to the point where the lock washer
starts to spread. It is preferable that the HV cable be oriented to come back across
the top of the EMC once installed. It is easier to insulate if you can secure the
coupler to a stable surface as shown in Figure 38.
Warming the wrapfast putty first will soften the material making it easier to form.
Apply the electrical putty (wrapfast) around

the top connection to the EMC. The
accompanying photo shows the wrapfast
moulded into a cone shape. This shape
creates a smooth taping surface over top
of the EMC.
The wrapfast should extend out or close to

the edge of the EMC, but not over the
edge. Once the wrapfast has been
applied, the coupler is now ready for
insulating.
Figure 39
The first layer of tape to be applied is the SAP tape, which is a stretchable, selfamalgamating tape. This tape requires a 30% stretch to properly bond the tape
layers. The tape comes with a vinyl layer that must be removed during the taping.
If insufficient stretch is applied, the tape layers will not bond creating a bulky, poorly
insulated joint. Overstretching will cause thinning or tearing of the tape, reducing the
electrical value of the insulation and causing the tape to creep or roll after
application.
The number of layers applied depends on the voltage rating of the machine
Machine Voltage
Number of half lap layers
Up to 7 kV
4 layers
Up to 11 kV
5 layers
Up to 14 kV
6 layers
Up to 18 kV
7 layers
Up to 24 kV
8 layers
Figure 40
Figure 41
As this is a stretch tape, it is important to lock the tape within the top
groove on the EMC to prevent the insulation from rolling over the rim.
To lock the tape in the groove, position the tape so that 2/3 of the tape
is inside the top groove of the EMC [Figure 40]. Apply two turns of
insulation in this position and then continue to tape up the EMC [Figure
41]. Each successive layer of tape must be locked within the top
groove.
The final step is the application of two halflap layers of Guideline tape over top of the
SAP tape. Start the tape inside the groove,
covering all the black SAP tape as shown
in Figure 42.
Guideline tape is self-amalgamating and

does not require a stretch to bond the
layers. A slight stretch will allow the tape to
lay flat and bond properly. If the tape is
stretched too much, the tape will roll or
tear, be difficult to apply, and the electrical
properties of the tape will be compromised.
Figure 42
This Guideline tape, along with

having very good electrical insulating
properties, also has excellent
tracking resistance.
Once finished, the coaxial cable can

be attached and the EMC mounted
on the machine
25kV EMC Brackets

Due to its weight and length, the largest (25kV) coupler can only be mounted
vertically upright, using the standard metal clamping plates. Special (optional)
horizontal mounting blocks are used when the 25kV couplers require mounting in
any position from the vertical. The blocks may be assembled directly to the unit
in the horizontal or suspended positions, or mounted to an angle-mounting
bracket.
Horizontal Mounting Bracket

The Labadie2 Block was designed for
ease
of
retro-fitting
existing
installations where the conventional
Iris mounting brackets were used.
While physically larger, the slotted
mounting holes are drilled to the same
centres as the conventional steel
mounting brackets.
Mounting Kit:
2-piece machined
mounting block, Two clamping bolts, 4
mounting bolts and epoxy (not shown).
Selecting Mounting Location
Temporarily assemble 1 set of
components to be used for laying
out the mounting positions for the
EMC and drilling the mounting holes
Figure 43
When selecting location for mounting, ensure that there is sufficient room
for the mounting block and adherence to all electrical clearances [Section
2.4].
This specialized mounting block was designed for the Ameren UE, Labadie Power Plant.
Appendix G 25kV Mounting Brackets - 53
Assembling the Components

1. Trial fit the EMC couplers to the
Labadie Block. Due to machine
tolerances it may be necessary to
try several EMCs in a given
block to achieve the best fit.
Once properly fitted, the EMC
should contact the block in two
positions. The space between
the two mounting blocks sections
should be equally spaced. The
bottom of the EMC should be
flush with the mounting block.
Once the EMC has been paired with the

blocks, disassemble and apply a bead of
epoxy around the machine mating surfaces
of the block, as shown in figure 2. The epoxy
is used to fill the voids where the EMC is not
in contact with the Labadie Block.
The epoxy has a working life of
approximately 20 minutes so prepare the
assemblies one at a time.
Match the coaxial cable duct machined in the
Labadie Block with the cutout on the EMC.
This is extremely important since there must be
a channel for the cable. Once the epoxy sets, it
will be impossible to adjust the base.
Bolt the assembly together applying equal
pressure on each bolt. Once tight, the spacing
should be equal on each side and the faces
parallel.
Note: When tightening the bolts, only sufficient
pressure should be applied so that the EMC cannot
be rotated within the block. Over tightening may
damage the EMC. Loc-tite must be used.
After tightening, wipe off the excess

epoxy that has been extruded out and
allow to set.
If the base of the EMC is not flush with
the bottom of the mounting block, file the
bottom of the EMC using a medium file
until flush.
Assemble the coaxial cable [Section 4].
A small amount of epoxy can be applied
inside the cutout to secure the coaxial
cable in place. The counter sunk bolt
holes should be filled with epoxy to
positively lock the mounting hardware
Insulate the top of the coupler as

described in Section 2.5 for the preformed boot and 0 for tape insulation.
The assembled coupler is now ready to
be mounted on the unit.
A 25kV coupler mounted

horizontally using a
Labadie block at a
generator terminal.
25 kV Mounting Bracket - 45
The
45
bracket
requires no special
instructions.
The
optional bracket is
mounted at a suitable
location and then the
standard installation
procedures
are
followed.

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