Compliance West MegaPulse Series User manual

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Dear Customer:
Congratulations! Compliance West USA is proud to present you with your
MegaPulse Coupling/Decoupling Network.
To fully appreciate all the features of your new instrument, we suggest that you
take a few moments to review this manual. Compliance West USA stands by
your instrument with a full one-year warranty. If the need arises, please don't
hesitate to call on us.
Thank you for your trust and confidence.
Rev 3, January 2018

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Table of Contents
Section 1.................................................................................................................................................... 1
An Introduction to Impulse Testing with the MegaPulse CDN 240/8....................................................... 1
Safety Precautions....................................................................................................................... 1
Test Personnel ............................................................................................................................. 1
Testing Area................................................................................................................................ 1
Safety Techniques ....................................................................................................................... 2
Using the MegaPulse CDN 240/8 ............................................................................................... 2
Introduction and Specifications................................................................................................................. 3
Introduction................................................................................................................................. 3
Operation................................................................................................................................................... 4
Setting up the CDN 240/8 ........................................................................................................... 4
AC Line Voltage Requirements .................................................................................................. 4
Selection of a Suitable Power Cord............................................................................................. 4
Front Panel Circuit Breaker......................................................................................................... 4
Front Panel Features.................................................................................................................... 5
Testing....................................................................................................................................................... 7
Technical Assistance ................................................................................................................................. 8
Maintenance and Calibration..................................................................................................................... 9
Introduction................................................................................................................................. 9
Voltage Waveform Tolerances.................................................................................................... 9
Current Waveform Tolerances .................................................................................................... 9
Service Information..................................................................................................................... 10
General Maintenance................................................................................................................... 10
Calibration Access....................................................................................................................... 10
Interior Access............................................................................................................................. 10
Cleaning ...................................................................................................................................... 10
Performance and Calibration Test............................................................................................... 11

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Section 1
An Introduction to Impulse Testing with the MegaPulse CDN 240/8
The impulse test is designed to simulate impulse surges which occur in everyday life due to nearby lightning strikes,
switching transients, and other high-frequency faults on the power distribution network. Impulse testing is the
fundamental method for empirical verification of the adequacy of insulation. The impulse test is performed to ensure
that the insulation in question will be able to function properly when subjected to similar impulse surges in the field.
•The MegaPulse CDN 240/8 is designed to allow surge testing to be conducted on the mains line of operating
equipment. The CDN is designed to EN 61000-4-5 Figure 7 and protects the attached Surge Tester outputs
from line voltage, and the mains voltage generator from the Surge Tester outputs.
•The MegaPulse CDN 240/8 does not generate surge voltages.
•Connection of a surge tester to the INPUT jacks and the appropriate mains voltage for the DUT is required.
•The mains input of the DUT is connected to the OUTPUT jacks of the MegaPulse CDN 240/8.
•The MegaPulse CDN 240/8 is suitable for use with 120V/8A max or 220-240V/8A max 50/60Hz mains
voltages.
Safety Precautions
An impulse withstand test can generate high voltages at potentially lethal current levels. Currents of as little
as 5 mA at 120 volts can cause death; and any MegaPulse model can deliver lethal current levels for a very short time
duration. The potential for serious injury or death exists and personnel should be aware when they conduct this test.
All inputs and outputs of the MegaPulse CDN 240/8 should be considered hazardous. The front panel input and output
jacks contain the surge pulse; the rear panel is connected to mains voltage and is to be considered hazardous as well.
Test Personnel
Personnel require special training to conduct the impulse test. They should understand electrical
fundamentals clearly, and be aware that high voltage is adept and creative at completing a path to ground. Instructions
should include a warning against any metal jewelry. Operators should not allow others in the testing area, especially
when tests are being conducted. Organization is to be stressed. The operator should keep the area free of unused
leads and equipment.
Testing Area
The area used for conducting the dielectric withstand test should be as remote as possible from normal
production line activities. Only personnel actually conducting the test should be allowed in the area, and it should be
taped or roped off to preclude casual entry by other employees. In addition, the area should be marked "WARNING
- HIGH VOLTAGE TESTING" or the equivalent to warn others of the nature of the testing taking place.
The bench being used should be non-conductive, and any exposed metal parts should be tied together and
grounded. If a conductive surface must be used, it should be grounded.
Because of sparking during an impulse test failure, it is not safe to conduct impulse testing in combustible
atmospheres.
It is imperative that a good ground be provided to the MegaPulse CDN 240/8. Before connecting the
equipment, ensure that the building wiring provides a low-resistance ground. If the MegaPulse tester is used on a
high-resistance grounding circuit, dangerous high voltages may be present to the operator. In addition, the power to
the Testing Area should be provided with an easily reached shutoff switch which can be actuated by personnel outside
the Area if needed.

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Safety Techniques
The MegaPulse CDN 240/8 has an ON/OFF switch on the front panel which also functions as a 15A circuit breaker.
During testing, this switch should be left in the ON position. However, when the switch is in the ON position, mains
voltage exists at the Line Output jacks. The case is grounded but the correct operation of the grounding is dependent
on proper connection of the building ground to the AC inlet on the rear panel of the CDN 240/8.
Using the MegaPulse CDN 240/8
The impulse surge test involves high voltage and caution should be exercised when using the Tester. The
RETURN lead is referenced to building ground when properly connected. However, the INPUT, OUTPUT and
RETURN leads must always be treated as Hazardous whenever the power switch of the MegaPulse CDN 240/8 or
the MegaPulse Surge Tester connected to its INPUT jacks is in the ON position.
Use of the MegaPulse Surge Tester and measurement of the resulting waveform is covered in the MegaPulse
Surge Tester Manual. This Manual covers only the connection of the MegaPulse CDN 240/8 to the Surge Tester and
the DUT.
The MegaPulse CDN 240/8 is constructed to the specifications of EN 61000-4-5 Figure 7. Some circuit
values are not specified in this Standard and the manufacturer has chosen values for good general operation. However,
special instances or test procedures unknown to the manufacturer may yield unacceptable shielding of the line
generator from the output of the MegaPulse Surge Tester connected to the INPUT jacks of the MegaPulse CDN 240/8.
We strongly recommend that the mains source of supply not be a device with outputs coupled to FETs or similar.
Perhaps a transformer and a variac for AC sources; and a battery for DC sources would be best.
Excessive inductance in the test setup can compromise the current waveform. To minimize inductance of the
test circuit, it is recommended to twist the pair of cables connected at the input and also at the output.

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Section 2
Introduction and Specifications
Introduction
This manual contains complete operating, maintenance and calibration instructions for the Compliance West USA
MegaPulse CDN 240/8.
•The CDN 240/8 does not produce a surge by itself; it only integrates the surge delivered to its INPUT jacks
with the line voltage applied to the power receptacle on its rear panel and delivers the resulting waveform to
its OUTPUT jacks.
•Its primary function is to protect the mains voltage generator from the output of the Surge Tester; and to
protect the output of the Surge Tester from mains voltage.
•Certain circumstances could allow a substantial portion of the surge voltage to appear to the mains voltage
generator. We recommend that a mains voltage generator operating with FETs not be used with the CDN
240/8 for this reason, as it’s conceivable that damage could result.
•The CDN 240/8 was constructed to the specifications of EN 61000-4-5 Figure 7 as shown below.
•Your MegaPulse CDN 240/8 is warranted for a period of one year upon shipment of the instrument to the
original purchaser.

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Section 3
Operation
This section describes how to set up and make measurements with your CDN 240/8. We recommend that you read
the entire section carefully so that you can use all of the features of your Tester.
Setting up the CDN 240/8
Your Tester is shipped in a special protective container that should prevent damage to the instrument during shipping.
Check the shipping order against the contents of the container and report any damage or short shipment to Compliance
West USA. The container should include the following:
•
The MegaPulse CDN 240/8
•
Two high-voltage test leads
•A return lead
•
A 18 AWG Line Power Cord
•
This Instruction Manual
If reshipment of the instrument is necessary, please use the original shipping container. If the original shipping
container is not available, be sure that adequate protection is provided to prevent damage during shipment. We
recommend that the instrument be surrounded by at least two inches of shock-absorbing material on all sides of the
container.
Remove the CDN 240/8 from its container and place it on a test bench.
AC Line Voltage Requirements
The MegaPulse CDN 240/8 does not require AC line voltage for operation. The AC line voltage requirements for the
DUT are to be checked. The AC line voltage requirements for the DUT are to be applied to the rear panel AC inlet
of the MegaPulse CDN 240/8. The CDN 240/8 is designed for supplying single phase line voltage up to 240V, 50/60
Hz at a current draw of up to 8 amps. If the DUT requires mains voltages or currents outside these parameters, do not
use the MegaPulse CDN 240/8.
Selection of a Suitable Power Cord
The cord packaged with your MegaPulse Tester is for use in the United States. If another power cord must be used,
the cord must be rated for the maximum current noted on the rear panel. It must also meet the requirements of IEC
227 or IEC 245, and mains cords that are certified or approved by any recognized national test house are regarded as
meeting this requirement.
Front Panel Circuit Breaker
The front panel ON/OFF switch is a 15A circuit breaker. If this circuit breaker trips, check the test setup and make
sure the DUT input requirements are within the range of the CDN 240/8.

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Front Panel Features
Before using your Tester, take a few minutes to become familiar with the use of its connectors. The front panel features of the MegaPulse are shown in Figure 1
and described in Table 1
Figure 1. Controls, Indicators, Connectors –MegaPulse CDN 240/8 Front Panel

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Table 1. Controls, Indicators, Connectors –MegaPulse CDN 240/8 Front Panel
ITEM
NAME
FUNCTION
1
ON/OFF Switch/Circuit
Breaker
Used to control the mains voltage. When this switch is ON, the line voltage connected to the rear panel of the
CDN 240/8 is present at the LINE OUTPUTS. When this switch is OFF, the line voltage is not present at the
LINE OUTPUTS. Note: Do not leave the CDN 240/8 in the test setup with the switch OFF while testing other
than power line circuits. The pulse output to the DUT is compromised by the CDN 240/8.
2
IMPULSE INPUTS
Connect the MegaPulse Surge Tester outputs here. Observe output polarity. To apply an inverted pulse, use the
switch on the MegaPulse. Do not reverse the lead polarity on the Pulse Input.
3
LINE OUTPUT
Connect to the line input of the DUT. Observe Mains Voltage and Current requirements when connecting line
voltage to the rear panel of the CDN 240/8. The RED jack has the hot side of the line, and the BLACK jack has
the neutral.
4
GROUND
Connect to the chassis of the DUT. This is directly connected to the grounding pin on the AC Inlet Receptacle
on the rear panel of the CDN 240/8.

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Testing
This section describes how the MegaPulse CDN 240/8 is used to conduct a test. Care must be taken as voltage is
present on the Output Jacks whenever the Front Panel switch is ON.
1. Connect the CDN 240/8 to a proper source of supply for the DUT using the included 14 AWG power supply
cord. Note: Because of the possibility of damage, we do not recommend using a FET coupled voltage
generator.
2. Plug the Output test leads of the MegaPulse Impulse Tester into the Surge Input jacks on the front panel.
3. Connect the Line Output test leads from the CDN 240/8 to the AC power inlet of the DUT.
4. Connect the Return test lead to the chassis of the DUT.
5. Use the MegaPulse Surge Tester as usual to apply a pulse to the DUT.

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Section 4
Technical Assistance
Technical Assistance from Compliance West USA is available:
Phone: [phone]
Hours: 8:30 AM - 4:30 PM Pacific Time.
Also available on our web site at: www.compwest.com
Contact:
Compliance West USA
650 Gateway Center Way Suite D
San Diego, CA 92102 USA.
Phone: [phone]
FAX: [phone]

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Section 5
Maintenance and Calibration
WARNING
THESE SERVICE INSTRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL ONLY.
TO AVOID ELECTRIC SHOCK, DO NOT PERFORM ANY SERVICING OTHER THAN
THAT CONTAINED IN THE OPERATING INSTRUCTIONS UNLESS YOU ARE
QUALIFIED TO DO SO.
Introduction
This section of the manual contains maintenance information for the MegaPulse series impulse tester. This
maintenance information is divided into service information, general maintenance, a performance test, and a
calibration procedure. The performance test is recommended as an acceptance test when the instrument is first
received, and later as a preventative maintenance tool to verify proper instrument operation. The test equipment
required for the performance test is a MegaPulse Surge Tester, an oscilloscope, a 0.1 ohm current shunt and a high
voltage probe. The calibration consists of ensuring that the output of the CDN is within the specification of IEC 1180
for the voltage waveform generated by the MegaPulse Surge Tester connected to the Impulse Inputs.
Voltage Waveform Tolerances
Waveform definitions from IEC 1180 are as follows:
T= time from 30% to 90% of peak voltage
Rise Time = 1.67 x T
Duration Time = time from virtual origin to 50% of peak voltage on trailing edge
Waveform tolerances from IEC 1180 using the definitions above:
Voltage: Peak voltage 3%
Rise Time: ±30%.
Duration: ±20%.
Current Waveform Tolerances
Waveform definitions from IEC 1180 are as follows:
T=time from 10% to 90% of peak current
Rise Time = 1.25 x T
Duration Time = time from virtual origin to 50% of peak current on trailing edge
Waveform Tolerances from IEC 1180 using the definitions above:
Current: Peak current ±10%
Rise Time: ±30%
Duration Time: ±20%

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Service Information
The MegaPulse CDN 240/8 is warranted to the original purchaser for a period of 1 year. This warranty does not cover
problems due to misuse or neglect.
Malfunctions which occur within the limits of the warranty will be corrected at no charge. Mail the instrument prepaid
to the manufacturer. Dated proof of purchase is required for all in-warranty repairs.
The manufacturer is also available for repair of instruments that are beyond their warranty period. Contact the
manufacturer for a cost quotation. Ship the instrument and your remittance according to the instructions given by the
manufacturer.
General Maintenance
Calibration Access
There are no adjustments inside the CDN 240/8. If the CDN 240/8 fails calibration, it must be returned to the
manufacturer for repair.
Interior Access
Use the following procedures to gain access to the calibration adjustments of your instrument.
1. Set Line Power switch to OFF.
2. Disconnect the power cord from the rear of the instrument.
3. Remove the four screws securing the top to the rest of the CDN 240/8.
4. Grasp the top cover and slide it back until is it free of its channel.
NOTE
With the power cord replaced, the instrument is operational for service.
WARNING
Dangerous voltages exist when energized. Exercise extreme care when working on an energized
circuit.
5. To reassemble, reverse steps 1-4 above.
Cleaning
CAUTION
Do not use aromatic hydrocarbons or chlorinated solvents for cleaning. These solutions will
react with the plastic materials used in the instrument.
Clean the front panel and case with a mild solution of detergent and a damp sponge.

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Performance and Calibration Test
The performance test evaluates the performance of your instrument to ensure that is working properly. This test is
recommended for incoming inspection, as a preventative maintenance check, and to verify proper operation during
the calibration procedure. It is not necessary to disassemble the instrument to conduct these tests. If the instrument
fails any part of the performance test, repair is indicated.
Allow the instrument to stabilize and perform the test at an ambient temperature of 23C 5C (73F 9F).
1. Connect the CDN to a proper source of supply using the included 14 AWG power supply cord.
2. Do not plug the Output test leads from the reference MegaPulse Surge Tester into the Impulse Inputs of the
CDN 240/8.
3. Connect a suitable high voltage scope probe (Tektronix P6015A or equivalent) to the Outputs of the
MegaPulse Surge Tester.
4. Perform a Surge Test and capture the waveform of the Surge Tester for comparison to the output of the CDN
240/8 later in this procedure.
5. Plug the Output test leads from the reference MegaPulse Surge Tester into the Impulse Inputs of the CDN
240/8.
6. Connect the high voltage probe to the Line Outputs of the CDN 240/8. Turn the MegaPulse Surge Tester
on. Leave the CDN 240/8 off.
7. Conduct a Surge Test. Compare the output of the CDN 240/8 to the output of the Surge Tester and ensure it
is within Tolerance for the Voltage waveform as noted above.
8. Repeat the entire test sequence above using a 0.1 ohm current shunt to determine the current (short circuit)
waveform of the MegaPulse Surge Tester and the CDN 240/8, and compare them to ensure they are in tolerance
as noted above.