Issue 2 2025 Magazine CPX 200: THE FUTURE OF TESTING TECHNOLOGY IS ALL YOURS
DEAR READERS, OMICRON electronics GmbH, Oberes Ried 1, 6833 Klaus (AT) OMICRON electronics GmbH up! consulting, Industriering 10, 9491 Ruggell (FL) OMICRON electronics GmbH, iStock.com (p. 4, 26–28, 39–43, 46, 58–59, 61), AdobeStock (p. 50–55), Actemium Cegelec Mitte GmbH (p. 36–37), Pro Integris (p. 60) magazine@omicronenergy.com Publisher Responsible for content Editorial team and implementation Picture credits E-mail for the editorial team Growth doesn’t happen in our comfort zones. It requires the courage to break new ground, question existing boundaries and methods, as well as the motivation to face new challenges. In recent years, this principle has been our driving force. We haven’t simply been focusing on developing another product for you. What we’ve created is an uncompromisingly functional solution. Our goal is always to deliver sustainable added value with targeted innovation. We not only strive to meet your requirements, but to exceed them. The result of our approach is a perfectly coordinated ecosystem – a well-thought-out solution that elevates efficiency, safety, and usability to a new level. As part of the development team, I’d like to share my insights about the CPX Ecosystem and its history with you. This is not only an invitation to learn about technical concepts and implementations, but also about the thoughts, challenges, and setbacks that have accompanied us on our journey. When all is said and done, it’s not just algorithms and circuit diagrams, but actual people with emotions, passion, and conviction that have made this extraordinary solution possible. It’s their personal stories that make it so unique. Enjoy reading! Yours sincerely, Michael Rädler Product Manager CPX Ecosystem 2
Magazine | Issue 2 2025 «Our goal is always to deliver sustainable added value with targeted innovation. We not only strive to meet your requirements, but to exceed them.» 3
6 CPX 200: evolutionary – revolutionary Test at the next level, and the future of testing technology is all yours! TABLE OF CONTENTS 34 Driving innovation across borders Transforming miles into meaningful customer value 26 The source of life destruction 39 The secret language keeping our lights on! The digital backbone that powers the grid and outsmarts cyber threats 44 Sparking joy in substation automation system testing Why smarter testing means happier engineers and safer systems 29 Less cables. More safety. Maximum efficiency. Measure cable impedance safely and efficiently with the CIB1 for the COMPANO 100 22 Test efficiently, work safely CMC 500 and CPX 200 – the benchmark in work safety 4
Magazine | Issue 2 2025 KNOWLEDGE SUPPORT INNOVATION QUALITY 62 Meeting expectations Testing air blast circuit breakers? No problem with CIBANO 500! 60 On site: OMICRON in Croatia Ivan Visic from Pro Integris shares his insights about the power sector with us. 70 What’s going on 47 Four years of sharing practical knowledge Our Energy Talks podcast series is celebrating over 100 episodes 50 Engineering the future IEC 61850-based substations SCL-driven engineering enables cross-vendor reusability and template-based testing. 56 Vulnerability management in power systems Correctly prioritize risks instead of blindly reacting to events 67 Safe and easy connections Plug-and-play partial discharge testing and monitoring 5
CPX 200: EVOLUTIONARY – REVOLUTIONARY Test at the next level, and the future of testing technology is all yours! 6
Magazine | Issue 2 2025 How it all began … Everyone in the industry is all too familiar with current and future challenges, such as unstable, decaying power systems, the growth market of renewable energies, decentralization, loss of knowledge due to retirements, and the skills shortage. So, we asked ourselves, “How can we contribute to the future of a secure supply?” Initially, we brought together seven experts from different teams, headed by Product Manager Michael Rädler and Project Lead Reinhard Gaurig, to tackle this challenge and let their minds run wild in a “Crazy Ideas Workshop”. This resulted in a colorful variety of fantastic ideas. Many more hours of focus, analysis, and conceptual planning led to the development of hardware variations, ranging from simple to complex. These variations were the foundation of the big question: “What exactly do our customers need?” How we found the sweet spot In the words of Theodore Levitt: “People don’t want to buy a quarterinch drill; they want a quarter-inch hole.” What Levitt meant by this is that customers buy products to solve problems. We took this vision one step further, with the goal of bringing it to life. So, we set about finding a solution. Thanks to our multifunctional pioneer, the CPC 100, we were able to generate a multitude of indicators. Customer feedback evaluated by our Technical Support team, sales channels, and OMICRON Academy training sessions was equally helpful. Our expertise and the analysis data provided the foundation for the evolution of a new multifunctional test set ready for the future dynamics and complexity of the market. The greatest challenge was differentiating between areas where a simple improvement would suffice and those where completely new solutions were needed. Modular and multifunctional – the devil’s always in the details Long conceptual phases, intensive field tests with prototypes, and continuous evaluations led us to develop a powerful control unit with modular components and flexible, clip-on system elements. We used the final concept as the foundation for a detailed plan. It was clear from the outset that we needed a high-performance solution that was also future-proof and scalable. Although the demands for hardware and software architecture are high, forward thinking and our active participation in specialist bodies and international working groups ensure we’re closely involved in technological developments for measurements and power systems. This participation quickly gave us an idea of the direction we need to take, allowing us to target specific future topics, such as cybersecurity, in the early stages of product development. What started as a technical revolution became a consistent and sustainable evolutionary path as development progressed. The limits of feasibility “According to the laws of aerodynamics, a bumblebee should not be able to fly. But it doesn’t know that, so it flies anyway.” While this entertaining fact identifies limits, it also shows that they can be overcome with new, innovative solutions. We faced multiple limitations while developing the CPX 200 – but we “simply” overcame the most challenging obstacles. For example, how could we generate 1,000 amperes without an installed transformer? Transformers are slow, heavy, and resource-intensive due to the copper required, but currently “For those who empower. The CPX 200 is made for you.” is the emotive campaign slogan for our brand-new multifunctional CPX 200 test set. But what does this statement mean? It means a vast amount of technical know-how, passion and pleasure for design, the curiosity to push the boundaries of possibility, and plenty of blood, sweat, and tears. Our customers empowered us with ideas and requests, we empowered each other to expect more from ourselves, and OMICRON. Our corporate philosophy and the support we’ve received at a managerial level have empowered us to develop the CPX 200 and its ecosystem. We proudly present the next generation of generalists. One that’s ready to test high and medium-voltage assets, thanks to modular configuration and multifunctionality. A device that’s safer, stronger, modular, lighter, and easier to use than ever before – a solution that’s simply made for you. 7
pandemic, was our greatest challenge. We didn’t know what happened during a global pandemic and wondered how we could continue working together. Innovation is driven by people who interact and challenge one another; they aren’t satisfied with simple solutions. So, naturally, this slowed the development process at first, but working from home was nothing new, and being able to see things from another perspective helped us quickly adapt and establish a digital plan. Having to plan our tasks at a granular level posed a significant challenge for us, but ultimately, it became our greatest strength. We previously held discussions in the hallway, at the coffee machine, or in meetings. Now, we suddenly had to define individual steps on online platforms to ensure a high degree of transparency. At the time, we were still in the prototype phase, not in the industrialization phase, and that certainly made the work easier. still represent the state of the art. The smart alternative was using power electronics. This idea took us into the unknown, but we still had a vision. Our ambition kept us going, and new customer benefits that were lighter, future-oriented, and offered completely new testing methods were our reward. The HVX10 system component’s transformer is another example. It took 150 prototypes until its function, design, and future viability satisfied our demands. When is the research phase complete? After 50? After 100 prototypes? We always had the option of being satisfied with where we were, but instead, we took it all the way until the results met our demands. We repeatedly pushed the bounds of feasibility, but ultimately, our know-how, the great trust and confidence placed in us by management, and the single-minded will to simply go further paid off. And, suddenly, our world came to a stop … It was a cold, grey February afternoon when we received the news that our project leader, Reinhard Gaurig, had passed away. His death was completely unexpected, and the sheer bewilderment was visible on all of our faces. We were given time and space to grieve, allowing us to process this terrible blow. But, after a while, we had to move ahead and continue the project. Ultimately, a joint decision was made to appoint Peter Künst as the new project lead. Peter had previously focused more on softwareoriented projects, but since hardware development was well underway, he received the full backing of management and the project team. As you can imagine, this was no easy task, and he had some big shoes to fill. Right from the start, Peter brought a sense of calm to the project that built trust, in addition to a new interdisciplinary team structure. The lateral move was an extreme challenge; Peter quickly became acquainted with all areas and quickly showed that he was more than up to the task. Without Reinhard and Peter, we wouldn’t be standing here today with the CPX 200 in our hands. Reinhard will certainly remain in our hearts and minds. To commemorate his contributions and accomplishments, we etched a small “Bremach Camper” on every PCB installed in the high-current module as a symbol of his passion and in remembrance of the fantastic human being he was. When it rains it pours The coronavirus pandemic and a component shortage were two issues that marked a turbulent period for us. The unbelievable level of uncertainty, particularly during the coronavirus 8
Magazine | Issue 2 2025 Michael, as Product Manager, you were involved in the project from the moment it began. What impressed you most during that period? Michael: What I found most impressive throughout the entire project was the team’s unbelievable combination of innovative spirit, trust, and cohesion. We could feel it right from the very beginning: With the CPX 200, we wanted to do more than just develop another device; we wanted to set new standards. For me personally, it was the fact that OMICRON not only went down this path with us but also actively supported us, providing us with a solid foundation of confidence. I found the interdisciplinary cooperation that took place particularly inspiring. Different experts from all areas came together to work on a shared vision. Each one of them applied their expertise with exceptional attention to detail, without losing sight of the bigger picture. But what made the project particularly unique for me was the consistency of customer focus. We didn’t hide our development behind closed doors. Users remained closely involved, we absorbed and scrutinized their feedback, and often, we even completely rethought our approach. This ongoing dialogue made us better, strengthening the team’s cohesion. In the end, we all knew what we were doing this for: for our customers and a product we could take pride in. If you had to choose two or three of the most challenging moments and the absolute highlights, what would they be? If I’m honest, it wouldn’t be fair to the project to only touch upon two or three things; there were simply too many unforgettable moments. You could fill an entire magazine with the highlights alone: from the first operating prototype to intensive customer feedback, and the team’s excitement when a complex problem was finally solved. The journey was full of highlights, both big and small, that kept us going and motivated. Naturally, there were difficult moments too. The most difficult one was certainly the loss of Reinhard Gaurig, not only as a project manager, but as a person, mentor, and friend. The fact that he’s not here to experience the achievement that we’ve all been working towards for so long is particularly painful now. And yet, his spirit remains part of this project. He shaped much of what we accomplished together. His passion, his humor, and his tireless energy live on in the way we work together as a team: with heart, with courage, and with a clear vision. On a scale from one to ten, what level of engineering is involved in the CPX 200, and why? If I had to rate the CPX 200’s engineering level on a scale from one to ten, I wouldn’t hesitate to give it a nine. I’m aware that, being someone who was involved in this project from the moment it began, I have a certain amount of bias. However, this isn’t my way of congratulating myself. I’m looking at its actual value and technical implementation from an objective perspective, and I believe it’s truly exceptional. We didn’t get bogged down in simply creating technology for its own sake; instead, we consistently worked towards solutions that would generate sustainable added value for our customers. Implementing requirements, whether in the field of safety, weight, multifunctionality, or performance, demands the highest level of engineering skill, and that’s exactly what it received. Personally, I lean towards simplicity, as I’m fascinated by achieving as much as possible with as little as possible. But when it comes to technology, simplicity isn’t a trivial matter. It denotes a reduction of the essentials, which reduces the error rate, increases robustness, and allows systems to be controlled and operated over a long period of time. The CPX 200 remains a highly complex system. However, we significantly expanded our technical and conceptual toolbox precisely to manage its complexity with precision, with a clear focus on ease of use and understanding the system. THREE QUESTIONS: Michael Rädler, Product Manager 9
Wernich, as Business Unit Lead, you had to provide direction in delicate situations. Was there a decision you found particularly challenging? Did anything keep you awake at night? Wernich: One of the most difficult decisions that kept me awake at night during my time as BU Lead was integrating the high-current source directly into the main device. Our road map originally provided a modular solution with an external current amplifier. This approach enabled flexibility and seemed technically appropriate. But, after receiving feedback, particularly from the distribution area, it became clear that the applications strongly supported an integrated solution. From a customer perspective, modular integration of the high-current source provided clear benefits: easier commissioning, improved operability, and a more compact design. This strategic change of direction had a major impact on our developmental planning and required considerably more adjustments than we initially expected. Despite this, we stood by our decision, knowing that ultimately, it would benefit our customers. At the same time, the interdisciplinary standardization of the safety concept from the CPX 200 and CMC 500 also posed a challenge. After a long journey, you finally have the CPX 200 standing in front of you. What’s going through your head? What inspires you when you think about the future? Wow, what a great question! The first thing that comes to mind is innovation that offers genuine added value to our customers. When I see how far the CPX 200 has come, I’m reminded of the passion and perseverance of our team – always pushing the limit, always refining things. What I’m most inspired by is how deeply motivated the team is. Particularly, when we feel our work is making a difference to customers. Their feedback is more than just welcome; it energizes us. It’s a dialogue that defines and drives our next steps. In terms of the future, I’m inspired by having the potential to create meaningful innovation and genuine added value by continuing to focus on what truly matters: the people who use our solutions every day. The CPX 200 and its entire ecosystem have given the world of primary testing equipment a brand-new test set. How and where do you see its application and role in the future? I see enormous potential for the CPX 200 and its comprehensive ecosystem. Three aspects deserve particular attention: › Efficiency throughout the entire test procedure: From test preparation to analysis, the goal is to simplify the test process and minimize time and effort for our customers to create a seamless and user- friendly procedure. › Creating added value that goes beyond testing: By actively supporting customer processes and interpreting their measurement data, we convert raw data into useful information that delivers deep insights into their assets – not just numbers. › Driving innovation by delivering value and exchanging ideas: This involves reconceptualizing our business model and pursuing innovative methods of collaboration and joint development with our customers. In the future, I could imagine the CPX 200 ecosystem potentially becoming part of a larger OMICRON vision that brings together the testing experience across different platforms. A future where true value not only lies in individual tools, but in how intelligently they work together to support the daily testing activities of our customers. This might just be a wild fantasy, but it could also be exactly the kind of ambition that we need. Wernich de Villiers, Business Unit Lead 10
Magazine | Issue 2 2025 Peter, your role as Project Lead began when the journey was already underway. What was your impression when you took over the project? Peter: It was a huge step for me! It meant giving up my career as a software developer and dedicating myself to project management for years to come. I was quite naive and had no idea what I was truly in for – that at least made the decision easier at the time … How did you find your way – what were the obstacles, what continued to motivate you and your team? The path turned out to be quite rocky! We were constantly battling with complexity and the challenges resulting from the compact design of the CPX 200. Fundamental components, such as the HVX10 transformer, the high-current module, and the safety interface, all took a long time to develop and, in some cases, were only finalized at a very late stage, which constantly made planning difficult. Personally, I went through some highly stressful phases: restructuring the project in 2020, two red flags that required massive replanning, and once, even put the technical feasibility of the device in question; that wasn’t an easy time for the developers, the core team, and me. Yet, despite the organizational challenges such as the coronavirus pandemic, the component crisis, and staff shortages due to other projects, seeing the product come together and how the results from different teams fed into each other to form a complete picture motivated us all! One or two project beers along the way obviously helped as well (laughs). Now that you’re approaching the end of the project – how are you feeling, what are your thoughts? I’m constantly impressed by the outstanding cooperation everyone’s displayed to reach one goal: to finally deliver our outstanding CPX 200 ecosystem to our customers! What are my feelings about this final project phase? I’m proud and eternally grateful to have been able to work together with such a wonderful team! And the longawaited relief? That’ll probably come after the first devices are delivered – or maybe not, as further releases and products will need to be planned and developed as soon as possible. Peter Künst, Project Lead 11
Michael Rädler, CPX 200 Product Manager You’re focused on the CPX 200’s hardware and accessories; what fascinates you the most about the way the components interact? Michael: What I find most fascinating is how the interaction of all the components, such as the hardware, accessories, and software, blends together to create a complete, harmonious system. One thing was clear to us from the start: If it’s not easy to use, it won’t be acceptable. That’s precisely why we were so focused on uncompromising functionality. For us, “Plug and Play” is more than just a marketing promise; it’s a principle that can be found throughout the entire system. We wanted to create a clear product language that’s intuitive, quickly understood, and supports the daily workflow of our customers. Every connector, every cable, every carry handle is the result of intense considerations, tests, and rounds of feedback. We know that nobody finds good hardware with poor accessories, or vice versa, impressive. So, we scrutinized each detail, held discussions with experts, iterated, and optimized. These days, the term “ecosystem” is often used carelessly. But with the CPX 200, it applies to its core: We’ve developed a system in which everything intertwines – functionally, physically, and digitally – to generate genuine added value. Ultimately, a chain is only as strong as its weakest link. That’s why we left nothing up to chance. An ecosystem that revolutionizes multifunctional testing The CPX 200 is more than just a test set! Tough and compact hardware provides a reliable foundation in the field, combined with the CPXpert software that’s been carefully tailored to hardware and applications with the most comprehensive safety functions on the market. Modular accessories such as the HVX10 system component or the slide-in High Current Module can be added at any time. CORTEX Grid combines all of your test data into a powerful, cloud-based software platform. It facilitates data management, assessments, and reporting for a variety of electrical installations. The interaction between all the components creates an exclusive next-generation test system. WHAT DO OUR PRODUCT MANAGERS HAVE TO SAY ABOUT THE NEW ECOSYSTEM’S FUNCTIONS? 12
Magazine | Issue 2 2025 Lukas Klingenschmid, CPXpert Product Manager With your focus on software and firmware, what benefits do you see in the new system? Lukas: I consider the new system to be a finely tuned cog with three interconnected parts: software, firmware, and hardware. Each of these areas is strong, but they only create something that goes beyond the sum of individual parts when they’re working together. This isn’t a zero-sum game, where one gain comes at the expense of another. It’s quite the opposite; the elements support and build on one another to ensure a consistently positive experience for all users. I’m particularly proud of the scalability and flexibility of our solution. From testing engineers in the field to installation managers in the office, CPXpert is practical and saves time for all of them. We don’t just provide measurement results; we create transparency, traceability, and efficiency at all levels. That’s precisely what I believe lies at the core of the CPX 200 ecosystem: It thinks, it adapts and remains open to everything yet to come. Jakob Hämmerle, Product Manager Safety Your focus is on user safety – how would you describe the CPX 200’s safety measures and benefits in action? Jakob: The CPX 200 sets new standards in terms of safety. Externally, you can see recognizable red/green signal lights and the new INTERLOCK key. The software provides support with individually tailored wiring diagrams and preliminary tests for specific measurements that validate the wiring. But we also made life easier for users with a whole host of other, smaller features, such as an automatic brightness sensor. This ensures the efficiency of the CPX 200, while also being the safest device in its class. 13
Bavley Farid, CORTEX Grid Product Manager CORTEX Grid, the long-awaited cloud solution that brings everything together, is part of the CPX 200 ecosystem. What are the benefits of the interaction between the CPX 200 and CORTEX Grid? Bavley: The interaction between the CPX 200 and CORTEX Grid enables seamless data continuity from the test site to the cloud. The test data recorded with the CPX 200 is immediately standardized and merged with results from other OMICRON test systems, such as CPC 100, TESTRANO 600, CT Analyzer, and CIBANO 500, to create a uniform and comprehensive asset record. This comprehensive overview enables more in-depth analyses, efficient reporting, and added value for the data in the long term throughout the entire life cycle of an asset. But CORTEX Grid is capable of so much more! Where is the journey headed? CORTEX Grid is constantly developing: It’s becoming a central data platform that supports fleet comparisons, advanced diagnostics, and data-driven maintenance strategies that help customers convert decades of test data into actionable findings. 14
Magazine | Issue 2 2025 Marcel Sigl, CPXpert Project Lead Marcel, as a CPXpert Project Lead, what are your highlights from the new software? What were the main challenges faced by your team? Marcel: Creating completely new, streamlined software architecture that provides space for future requirements, expansion possibilities, and innovation was the greatest challenge. It was and still is vital to integrate features that are powerful and flexible, while remaining simple and intuitive. Our goal was to create a technologically strong solution that could effortlessly help our users focus on the core aspect of their work: precise, meaningful measurement results. Personally, the highlights are definitely the flexibility and usability of CPXpert. We successfully created flexible and intuitive test procedures that let users save time without impacting the quality of their results. The three-phase current transformer test is another unique feature that tests all three phases with a seamless procedure. The practical multi-window views are an additional highlight that support parallel testing while simultaneously maintaining an overview of various assets. A great deal of thought also went into reporting, where we focused on making genuine improvements for our customers. Automatic result evaluation and reporting with the click of a button increases transparency and speeds up analysis. In addition, we had to ensure seamless automatic evaluation and synchronization with CORTEX Grid. All of this is perfectly balanced by a direct connection that ensures the central availability of all test results with up-to-date, high-quality data. Overall, finding the balance between complexity and usability was truly a team effort. The CPX 200 and its entire ecosystem were developed to solve existing and future problems. Multifunctionality, a modular structure, and its light weight help combat unstable power systems and decentralization. For example, commissioning and maintenance activities are perfect applications for the CPX 200. Service providers, manufacturers, asset managers, and test field engineers all benefit from the safest test set on the market, in addition to new, easy transport in a backpack or flexible transport case perfect for shipping. Many companies, including us, are facing a significant skills shortage combined with more work. Being fifty-nine percent smaller than the average test, and the world’s smallest and lightest multifunctional test set, the CPX 200 provides freedom for faster and more mobile operation, enabling users to accomplish more under safe conditions in less time. The improvements go well beyond the hardware; the CPXpert software also helps optimize test preparation, execution, and result analysis with modernized operating features. Topped off with CORTEX Grid, acquired data is available for various evaluations and interpretations worldwide in minutes, enabling the best possible condition assessments for all your assets. UNLEASH THE EXPERT 15
Unleash its full potential with: › 1,000 A AC/DC with the High Current Module › 10 kV AC/DC with the HVX10 system component › Test frequency range: 1–600 Hz and DC Developed with safety in mind Reduced risk of electrical dangers thanks to comprehensive safety features: › Red and green signal lights › Emergency switching off button › INTERLOCK key › Workflow according to EN 50191 › Wiring instructions with connector indicator lights › Optional external signal lamp (*available soon) Adjustable to meet your requirements Thanks to its modular hardware, software, accessories, and customized service offers, the CPX 200 can be configured precisely to your needs. You can start with a flexible, multifunctional test solution; later on, it can easily be converted into a specialized testing system that meets your specific requirements. Next-generation technology Our solution was specifically developed to meet the growing demands of modern and future power systems. › Developed and certified in accordance with international standards – for global application and maximum quality › Based on modern safety and cybersecurity guidelines for maximum protection in networked infrastructures › Ongoing support and reliable maintenance – for investment security and operation for years to come › Perfectly developed for the substation commissioning and diagnostic tests › High-quality components for hardware and software that include perfectly engineered accessories for professional use Always ready for use › Combined measuring channels reduce wiring efforts › Real three-phase voltage and transformation ratio measurements › Color multi-touch display with automatic brightness adjustment for unmatched readability in every environment › Guided test procedures with access to nameplate data – fast and safe for proper configurations › Multi-asset tests via standard user interface › Full, automatic documentation and evaluation of test results – seamless and compliant › Efficient test planning and reporting Maximum power per space All tests can be carried out with a total system weight of less than 30 kg. › CPX 200: 10.6 kg › High Current Module: 3.3 kg › HVX10: 14.8 kg › Better access in confined areas thanks to a carry or backpack solution. › No need for heavy lifting and transport restrictions due to the lightweight system solution. 16
Magazine | Issue 2 2025 Michael Siller, CPX 200 Product Owner As the CPX 200 Product Owner, which key features do you consider particularly important? Or which ones were particularly difficult to implement? Michael: Wow, that’s a very good question – there are a few. Depending on your point of view, there are several particularly successful and challenging features. I would put the model-based CT Excitation feature at the very top of the list, not only because it brought together all the different technical disciplines (signal processing, control technology, physics & mathematics), but also because it repeatedly generated discussions concerning sustainable software architecture. These findings helped establish a foundation for high-quality functionality and led to better, future-proof architecture for several other applications. We also took advantage of synergy potential and are perfectly equipped to handle the future challenges of other applications. Naturally, making all this possible has required a great deal of our time, sweat, and passion. In retrospect, it’s been an enjoyable investment that’s paid off and justified itself many times over with the successes we achieved. Aside from that, developing the HVX10 and its features was both a highlight and a challenge for me. We were able to learn a great deal from earlier systems, allowing us to improve and speed up a number of things from the beginning. However, the underlying electrical engineering and electronics were a significant challenge. Many issues only became apparent during development; we were able to adapt to some of them, but sometimes we had to go back to the drawing board. It was one of the first tasks that I tackled as Product Owner and one of the last that was finished. The HVX10 remained with me throughout the entire project, as both a highlight and a low point. That’s why we take great pride in being able to place this solution on the market. The most ambitious feature of the entire system is the CPX 200 High Current Module. A lightweight and flexible module that supplies 1,000 A AC and DC, in addition to constantly providing 100 A for winding resistance measurements. The final hardware concept arrived late and also contributed to the identification and resolution of the problems associated with this challenge. I can clearly remember the first baby steps we took while the rest of the system was nearly complete. We quickly began taking larger steps and were constantly optimizing. Based on feedback I received visiting various countries during the developmental phase, no other aspect of the CPX 200’s ecosystem has had the impact and history that the High Current Module has. I feel fortunate that I was able to experience that and tell you about it today. 17
Michael Rädler, CPX 200 Product Manager Michael, as Product Manager, you probably already have several ideas for further developing the CPX 200. Is there a specific challenge you’d like to tackle? Michael: As Product Manager, I’m constantly working on ways to continue the CPX 200’s development. Naturally, there are already plenty of ideas surrounding the direction that journey could take. What’s particularly exciting is that the CPX 200 is a platform designed with a forward-facing approach that applies to its hardware and software. Its modular architecture opens fantastic possibilities for seamlessly integrating new applications, test methods, and features into an existing ecosystem. Targeting and exploiting this potential will be a significant challenge in years to come, not simply from a technical perspective, but also in making sure we remain focused on our customers’ actual needs. We have a clear vision, and concrete initiatives are already on the radar, but for me, one thing is essential: active listening. Only by holding continuous discussions with our customers and partners and taking their challenges and ideas seriously can we develop solutions with pioneering technology that are also genuinely practical. As a Product Manager, this represents both my highest responsibility and the challenge I’m most attracted to. Some of you will likely be asking how the CPX 200 will fit into other test sets from our primary test equipment portfolio. The CPX 200 and CPC 100 are two of our multifunctional flagships and modern test sets for mediumand high-voltage assets. They provide considerable added value, particularly for current and voltage transformer segments and power transformer testing. The CPX 200 is the next generation of these devices and provides extended features with a modern platform. However, only the CPC 100 currently supports testing for grounding arrangements and rotating machines. In contrast to expert test sets such as the CIBANO 500, TESTRANO 600, or even the CT Analyzer, generalists have a broader application, while experts offer greater in-depth testing. Our sales department is more than happy to help you find the system that meets your needs. CPX 200, THE NEWEST MEMBER OF OUR TEST SET SUITE 18
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As our journey nears its end, we can proudly watch our latest innovation establish itself on the market. An enormous amount of passion and even more expertise has flowed into its development. You might begin to wonder if that notorious vacuum that often follows a peak performance is about to settle in. But wait! We’re also right back at the beginning. The modular concept behind the CPX 200 only has one limitation: the limits of our creativity. Our numerous ideas, some of them already in development, our eagerness to hear customer feedback, paired with motivation and a thirst for action, are what keep us happily pushing ahead. Join us as we look forward to the coming years! Until then: “For those who empower. The CPX 200 is made for you.” THE END OR THE BEGINNING? «For those who empower. The CPX 200 is made for you.» 20
Magazine | Issue 2 2025 Tobias Schmutzhard, Process Manager BU Prim Tobias, what does the CPX 200 mean to you and OMICRON’s further development? Tobias: In the coming years, the CPX 200 is going to play a key role in our product portfolio. Countless ideas, customer requests, innovative passion, and plenty of emotion all flowed into the development of this test set. The team supported each other, and the cooperation between different disciplines allowed seemingly insurmountable challenges to be transformed into outstanding solutions. As one of more than 250 people involved in this project, I’m proud that I was able to play a small role in its evolution. We’re looking forward to customer feedback, which helps us continuously improve the CPX 200 ecosystem. Ahmed El Hamaky, Regional Manager, Middle East and Africa Ahmed, how do you see this product from a global perspective? What are your expectations? Ahmed: The CPX 200 fulfills the increasing demands and expectations of utility companies and service providers for compact all-in-one test solutions. It offers speed, accuracy, and digital workflows that reduce downtimes and increase efficiency in the test environment. Derek Brown, Regional Manager, North America Derek, how do you see this product from a global perspective? What are your expectations? Derek: Following last year’s successful introduction of the CMC 500, we’re looking forward to launching our next major innovation on the market: the CPX 200. This impressive product will trigger another wave of innovation that’s sure to impress our customers and competitors. The initial package of features included in the CPX 200 is ideal for the service sector. Its lightweight, compact design, and high output power are significant unique selling points that will be popular amongst users. What truly sets this market launch apart is the improved software ecosystem and modular design. These improvements don’t just make the product more user-friendly; they pave the way for new business models and optimize order processing. We’re convinced that the CPX 200 marks the beginning of an exciting new chapter in our innovative history. 21
It begins with soft clicking, followed by a buzzing sound. A test cycle in an electrical installation is underway – precise automation in a fraction of a second. But an invisible force lies behind this routine: electrical power. It drives machines, supplies cities with light, and keeps entire infrastructures running. And yes, it also involves risks – especially where it is tested and connected. A lot has happened in the past five decades: The fact that fatal electrical accidents have fallen by about 90 percent, is clear evidence that safety measures are working. But the increasing electrification of all areas of life and work places ever greater demands on protection mechanisms, especially when testing electrical energy and protection systems, where high voltages and complex processes meet. In these areas, technicians at work are exposed to a higher risk of electrical dangers. As a result, the amount of safety in the electrical testing technology world is the benchmark for every test set that must be measured. But what exactly is personnel safety? Furthermore, how can we develop innovative safety functions that provide protection while making the test process more efficient? Innovative safety functions – efficiency meets safety The CMC 500 and the CPX 200 are setting new benchmarks. Their safety functions go well beyond simple compliance – they make the testing process safer and more efficient. TEST EFFICIENTLY, WORK SAFELY CMC 500 and CPX 200 – the benchmark in work safety Operational mode button Status light External emergency switching off button with safety light Interlock key 22
Magazine | Issue 2 2025 Status light One of the new key features is the status light that reliably shows whether the outputs of the test set are de-energized or still potential sensing. When testing inductive assets, dangerously high levels of energy may still be present, which is why measuring the current flow after testing and before rewiring is essential. The CMC 500 and the CPX 200 have a specially designed safe return measurement function and a status light that indicates the output state, for this specific reason. Operational mode button Another effective safety function in the CMC 500 and the CPX 200 is the operational mode button that can switch specific signal outputs on or off when it’s turned on. This allows the outputs to be de-energized with the push of a button if necessary. This provides the advantage of not having to completely switch off the test set to modify the wiring. So, disconnecting and reconnecting the test set and testing software after switching off is no longer an issue. Interlock key The INTERLOCK key is a new safety function that is available with the CMC 500 and the CPX 200. Removing the key from the test set ensures it cannot be activated unintentionally or by any unauthorized personnel. This is a particularly important factor in situations where numerous people may be working on an installation. After reinserting the interlock key, the test set is immediately ready for operation, and work can resume without further delay. External emergency switching off button with safety light Available soon: The external emergency switching off button with a safety light for the CMC 500 and the CPX 200 provides additional safety. The external emergency switching off button can be positioned according to requirements and is easily accessible in the event of an emergency. It is clearly visible, and activating it is quick and easy. Therefore, test setups with multiple emergency switching off buttons in accordance with EN 50191 can also be implemented. The integrated safety lamp indicates the safety state of connected devices. Interlock key Operational mode button External emergency switching off button with safety light Status light 23
How effective are these safety functions? The effectiveness of safety functions depends on many factors. More safety functions do not automatically mean more personnel safety. The right balance between usability and protection is critical. If a safety light uses numerous signal patterns instead of displaying clear signal colors such as red and green, signals may be misinterpreted, or even ignored. Detect dangers – reduce risks To put it simply, people need to be protected from harm resulting from potential dangers. That’s why we focus on dangers stemming from the environment, test set, or test procedure when we’re developing safety functions. Dangers posed by the environment › Sight and access: The visibility at test sites is often poor. This increases the risk that someone may accidentally enter a danger zone and identify the emergency too late. › System errors: When testing an entire system, defective components can trigger unpredictable reactions, such as faulty protection relays with incorrect signals. › External influences: Several people may often be working in the same area. In such cases, poor communication or accidental activation can be another danger source. Danger stemming from the test set or the procedure › Electrical shock: Test sets deliver high voltages. Before work begins, the test set (or its outputs) must be disconnected from the power system. Additionally, when connecting, the safety plugs must be used and the correct sequence must be followed. › Wiring errors: Large numbers of cables are difficult to manage. Errors can lead to damage or injury. Precision during wiring is just as critical. › Improper grounding: A disconnected protective conductor places people and devices in danger. Additional grounding is mandatory. › Procedural errors: Time pressure can lead to careless actions, such as rewiring while the device is switched on. › Measurement errors: Calibration can become inaccurate due to aging or environmental influences. Regular checks are required. 24
Magazine | Issue 2 2025 Standards are the foundation of safety Safety standards played a fundamental role in developing safety functions for the CMC 500 and the CPX 200. The safety functions for both devices were developed in close collaboration to ensure a consistent and compliant safety concept. The IEC 61010-1, ISO 13849-1 (with IEC 61508-3), and EN 5019 standards were particularly relevant in this regard. IEC 61010-1: Safety requirements for electrical equipment for measurement, control, and laboratory use IEC 61010-1 specifies general safety requirements for electrical measurement, control, and laboratory equipment. Its objective is to minimize the hazards for users and the environment. Among other things, it stipulates protection measures to eliminate electrical, mechanical, and thermal hazards and prevent the spread of fire that a faulty device might be cause. ISO 13849-1 – Functional safety This standard describes the principles for designing safetyrelated control system parts (including software) to minimize the probability of dangerous errors. It is supplemented by IEC 61508-3, which is valid for software, and applies regardless of the technology used – whether electrical, mechanical, or hydraulic. EN 50191 – Erection and operation of electrical test equipment This European standard regulates the setup and operation of electrical test equipment. Among other things, it contains specifications for protection measures, personnel, test procedures, and, for example, how to use lamp states (red/green) to signal operational status. Conclusion: Safety is not a compromise – it is a driver of innovation Developing innovative safety functions shows that personnel safety and efficiency are not mutually exclusive. Quite the contrary: In the CMC 500 and the CPX 200, they complement one another by setting a new benchmark for safer, smarter, and more sustainable testing processes. LISTEN TO THE PODCAST Interested in this topic? Then listen to our podcast series “CMC 500 – From conceptualization to the benchmark for personnel safety”. Scan the QR code or visit: omicron.energy/episode103 25
THE SOURCE OF LIFE DESTRUCTION 26
Magazine | Issue 2 2025 0.001 0.1 1 Insulation geometry Oil conductivity Moisture and aging of cellulose 0.01 0.001 Hz 1 Hz 1,000 Hz Dissipation Factor Frequency Figure 1: The dielectric frequency response curve provides information about different factors that influence the measurement result, such as the moisture content of the insulation. Test time FDS 5 hours 40 minutes FDS & PDC 30 minutes – 1 hour 45 minutes 33 hours FDS & PDC+ Figure 2: Thanks to the patented combination of FDS and PDC+, the DIRANA completes the dielectric analysis of a transformer insulation in 30 to 105 minutes maximum. The FDS method requires more than one day for results in the same frequency range (1 kHz to 10 μHz). The substation is operating according to plan. No unusual incidents, everything is functioning normally. And then suddenly, a loud bang can be heard as a transformer’s insulation is punctured. The most expensive asset used in power transmission and distribution has just suffered a complete failure – an asset owner’s nightmare. A precondition for safe operation Insulation failure is one of the main causes of transformer failures. Regularly monitoring a transformer’s water content can help detect impending failures early on. Water is a natural byproduct of aging cellulose insulation and, therefore, an indication of its integrity and remaining life span. When an asset’s moisture content level is known, its lifetime can be estimated and – if required – extended with targeted maintenance measures, such as drying. The measurement method of choice: dielectric frequency response Dielectric frequency response (DFR) can be used to reliably assess the moisture in a transformer’s paper insulation. The non-invasive method is scientifically proven by CIGRÉ and can determine the moisture content reliably. Determining the value directly in the cellulose, where most of the moisture is located, is what makes this method so accurate. Using dielectric analysis to determine the moisture content also avoids the pitfalls of other analysis methods, such as environmental influences or the final decommissioning requirements for an asset. Informative low frequencies Information about the insulation’s dielectric response can be gathered by measuring and analyzing the dissipation factor tan(δ) across a wide frequency range. The measurement curve has a characteristic “hump” shape at very low frequencies (Figure 1). This is due to the polarizing effects of interfaces in the oil-paper insulation. The range roughly 1 to 2 decades below this increase is primarily influenced by the dielectric response of cellulose insulation, and therefore, by the transformer’s moisture content. The crux of the measurement time The dissipation factor can be determined using several methods. Frequency Domain Spectroscopy (FDS measurement) provides fast and precise results for frequencies above 0.1 Hz. However, at lower frequencies, this method is relatively slow. This means a measurement from the kHz down to the µHz frequency range lasts hours or days. 27
This obstacle can be avoided by measuring the polarization depolarization current in the time domain (PDC measurement). In this scenario, an applied DC signal stimulates all frequencies simultaneously. Analyzing the dissipation factor with this method significantly reduces the duration of lower frequency range measurements. DIRANA moves at turbo speed Our DIRANA combines these two measurement methods and even goes one step further: It uses an advanced version of the PDC method – the dynamic “PDC+” algorithm. Compared with the traditional PDC method, this approach calculates up to 20 times more data in the frequency range based on the same time-domain information. The result is a process with a much shorter measuring time but the same amount of data (Figure 2). In many cases, the measurement also doesn’t need to be performed down to the smallest possible test frequency to properly assess the insulation’s state. Stopping the measurement earlier saves a lot of time. DIRANA therefore analyzes the real part of the capacitance (C'), ensuring the critical frequency range for moisture analysis is fully recorded and the measurement isn’t stopped prematurely. This way, the measurement is always performed as long as required but not longer than necessary. No expert knowledge necessary The method described above allows DIRANA to automatically apply the ideal frequency range for assessing the insulation. This process once required a great deal of experience, as did the subsequent assessment of the measurement results. This is due to factors such as insulation geometry, oil conductivity, and aging byproducts that influence the measurement curve (Figure 1). The DIRANA software automates all those steps: It compares the measured dissipation factor curve with modelled curves from a comprehensive database. The assessment automatically considers all these factors, and the temperature is all that an operator needs to enter. DIRANA also evaluates the results in accordance with national and international standards and prepares individually configured reports. Thanks to this pioneering test solution, comprehensive expert knowledge is no longer necessary for reliable assessments of transformer insulation’s moisture content which is the basis for assessing the remaining lifetime of the transformer. DIRANA › Reliable, non-invasive moisture content measurements for power transformers and oil-impregnated paper insulation (OIP) › Significantly shorter measurement times due to a combination of innovative test procedures and automatic frequency range determination › Simple, automated analysis that doesn’t require expert knowledge «Compared with the traditional PDC method, PDC+ calculates up to 20 times more data in the frequency range based on the same time-domain information.» 28
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