Compliance West MegaPulse 10x700-2.5 User manual

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MegaPulse series
Impulse Tester
Instruction Manual
COMPLIANCE
WESTUSA

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Dear Customer:
Congratulations! Compliance West USA is proud to present you with
your MegaPulse Impulse Tester. Your instrument features a
groundbreaking logic-controlled circuit design and ergonomic front
panel and represents the latest in high voltage impulse testing.
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.

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Table of Contents
An Introduction to Impulse Testing with the MegaPulse series tester.......................................................1
Safety Precautions........................................................................................................................1
Test Personnel................................................................................................................1
Testing Area...................................................................................................................1
Safety Techniques..........................................................................................................2
Using the MegaPulse Impulse Tester...........................................................................................2
Introduction and Specifications..................................................................................................................5
Introduction..................................................................................................................................5
Figure 1..........................................................................................................................5
Specifications...............................................................................................................................5
Table 1. MegaPulse series specifications......................................................................6
Operation....................................................................................................................................................7
Setting up your Tester..................................................................................................................7
AC Line Voltage Requirements...................................................................................................7
Selection of a Suitable Power Cord .............................................................................................7
Fuse Replacement ........................................................................................................................7
Front and Rear Panel Features .....................................................................................................7
Figure 2. Controls, Indicators, Connectors – MegaPulse series Front Panel................8
Table 2. Controls, Indicators, Connectors – MegaPulse series Front Panel.................9
Figure 3. Controls, Indicators, Connectors – MegaPulse series Rear Panel..................10
Table 3. Control, Indicators, Connectors – MegaPulse series Rear Panel....................11
Figure 4. Controls, Indicators, Connectors – MegaPulse series Breakdown
Detection........................................................................................................................12
Initial Checkout Procedure...........................................................................................................14
Testing..........................................................................................................................................15
TestMinder Operation..................................................................................................................16
EN60335 Pulse Trains .................................................................................................................16
Breakdown Detection Circuit Option...........................................................................................16
Sensitivity setting using known good and known bad samples.....................................16
Approximate Sensitivity Setting using the supplied 50 ohm resistor ............................16
Defib-5 Checkout and Operation.................................................................................................17
Use of Measurement Terminals Y1 and Y2...................................................................17
Verification of Measurement Circuit Operation............................................................17
Testing with the Defib-5................................................................................................17
Technical Assistance..................................................................................................................................21
Maintenance and Calibration......................................................................................................................23
Introduction..................................................................................................................................23
Service Information......................................................................................................................23
General Maintenance ...................................................................................................................23
Interior Access...............................................................................................................23
Calibration Access...........................................................................................23
Cleaning.........................................................................................................................24
Performance Test .........................................................................................................................24
Calibration Procedure ..................................................................................................................25
Voltage Calibration Adjustment....................................................................................25
Figures 4-9.....................................................................................................................27

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Section 1
An Introduction to Impulse Testing with the MegaPulse series tester
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. Other methods of ensuring adequate insulation (AC or DC Dielectric Withstand testing,
measurement of over-surface creepage, through-air clearance, or distance-through-insulation) are all
extrapolated from the results of impulse testing. 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.
Safety Precautions
The impulse withstand test can generate voltages in excess of 7000 V peak at potentially lethal
current levels. Currents of as little as 5 mA at 120 volts can cause death; the MegaPulse can deliver
currents of more than 100 Amps peak for a very short time duration. The potential for serious injury or
death exists and personnel should be aware when they conduct this test.
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 tester. 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 high voltage circuit of the MegaPulse can be shut off at any time by turning OFF the rear
power switch. Note that there are residual voltages inside the equipment that may take up to 5 minutes to
bleed off to safe levels.
The MegaPulse tester is provided with a VOLTAGE ADJUST knob on the front panel. This
should always be adjusted fully counterclockwise to the minimum position at the start of testing. In
addition, this knob should be adjusted back to the minimum position at the completion of all testing.
The MegaPulse tester is provided with a CHARGE switch that is in the unarmed "Standby"
setting when the tester is first turned ON. When the yellow CHARGE button is lit, the tester will not
provide high voltage until the CHARGE Button and the TRIGGER Button have been pressed in order.
To prevent inadvertent operation, the operator should be instructed not to press the CHARGE Button until
the test is ready.
The MegaPulse tester has been designed for one-touch operation with the right hand. If possible,
it should be set up to the left and in front of the equipment under test. The equipment under test should be
connected to the MegaPulse tester and then left alone by the operator. After the operator is clear of the
Tester and the equipment under test, the operator should turn the rear-panel power switch to ON, press the
CHARGE Button, adjust the voltage to the desired level (as displayed on the front panel meter), then press
the TRIGGER Button, with his right hand. This will allow the greatest separation between the operator
and the test being conducted.
The MegaPulse tester is designed to bleed the high voltage away after the test has concluded. In
order to ensure that any voltage present in the equipment being tested has been completely bled away, the
operator should not unplug the equipment under test from the MegaPulse until the front panel meter reads a
safe level (40 volts or less is generally considered a safe level). Pressing the TRIGGER button before
disconnecting main power (or turning the equipment off) will ensure that the internal capacitors are
discharged as much as possible.
Using the MegaPulse Impulse Tester
The impulse withstand 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, both the
OUTPUT and RETURN leads must always be treated as Hazardous whenever the power switch of the
MegaPulse is in the ON position.
The MegaPulse impulse tester generates the impulse waveform only; it does not determine
Passing or Failing results. It is Operator’s responsibility to monitor the output waveform and determine
Passing or Failing results. In monitoring the impulse waveform, consider the following points:
The Impulse waveform is high voltage, and high frequency (short duration). Always ensure that
the measuring instrument (usually an oscilloscope with a high-voltage probe) is rated for the voltage
involved, and that the frequency response of the instrument and probe are capable of measuring the output
waveform of the MegaPulse Impulse Tester. A measuring instrument or probe with a low frequency
response will result in erroneous readings that could be mis-read.
Pressing the POLARITY switch on the front panel can change the polarity of the output
waveform. The polarity is Normal when the NOR indicator is lit. In this case, the High Voltage will
appear on the OUTPUT as a positive pulse relative to the RETURN jack. When the polarity switch is in
the Reverse position (REV indicator is lit), the High voltage will appear on the OUTPUT as a negative
pulse relative to the RETURN jack. The polarity switch only operates when the CHARGE LED is lit, i.e.
the output is not charged.
Note that the Voltage meter may indicate that some residual voltage is present on the main
storage capacitor, even when the tester is first turned ON. This is due to inherent charging of the internal
capacitors. Pressing the TRIGGER switch will discharge the capacitors (be sure not to touch the output
and return leads when pressing the trigger switch).

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Note that the peak amplitude of the measured output waveform is proportional to the voltage that
is read on the front panel of the MegaPulse, but it will always be somewhat lower. This is because the
meter on the MegaPulse is measuring the voltage on the main impulse storage capacitor (C1 in Figure 1).
This voltage will intentionally dissipate to some extent before reaching the output leads. Therefore, it is
important to measure the peak amplitude of the output waveform, and adjust the output of the MegaPulse
accordingly.
Determination of Passing and Failing results can prove difficult. To obtain the most accurate
results, it is generally necessary to perform multiple impulse tests on a few different test samples (that have
adequate insulation to pass the impulse test). Take note of the impulse waveshape, amplitude, and
duration. Also note how much variance there is in the waveshape from test to test. Also (if possible),
perform impulse testing on some test samples that are known to have inadequate (or damaged) insulation.
Take note of the impulse waveshape, amplitude, and duration, when an insulation breakdown occurs.
It is possible to perform simultaneous testing on multiple test samples. In order to accurately
determine Passing and Failing test results, it is generally necessary to perform multiple tests with a single
(failing) sample connected along with multiple “passing” samples. Make sure that it is always possible to
distinguish a group of tests samples that are all “passing” from a group with a single “failing” sample.

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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 series
Impulse Tester.
•In case of trouble, the test can be
immediately terminated at any time by
turning the rear-panel power switch to the
OFF position.
•Before the test can commence, the unit
must be armed by pressing the CHARGE
Button. The test will not begin until the
TRIGGER Button is pushed.
•Operator instructions are printed on the
rear panel for quick reference.
•Voltage is discharged by a resistor bank
within the MegaPulse tester upon test
completion. Discharge progress is shown
on the front panel meter.
Your Tester is warranted for a period of one year
upon shipment of the instrument to the original
purchaser.
Figure 1.
Specifications
Specifications for each individual model in the
MegaPulse series are listed in Table 1.
Component designations referenced in Table 1
are as shown in Figure 1.

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* Legend: A x B/C x D A= Voltage rise time B= Voltage duration C= Current rise time D= Current duration
Voltage rise time (A) is defined as follows (per ANSI/IEEE C62.41 and other standards): trise = 1.67(t90 - t30), where t90 and t30 = the times of the 90% and 30% amplitude points on the leading edge of the waveform.
Voltage duration (B) is defined (per ANSI/IEEE C62.41 and other standards) as the time between virtual origin and the time of the 50% pint on the tail. The virtual origin is the point where a straight line between the 30% and 90% points on the leading edge of the
waveform intersects the V = 0 line.
Current rise time (C) is defined as follows (per ANSI/IEEE C62.41 and other standards): trise = 1.25(t90 - t10), where t90 and t10 = the times of the 90% and 10% amplitude points on the leading edge of the waveform.
Current duration (D) is defined (per ANSI/IEEE C62.41 and other standards) as the time between virtual origin and the time of the 50% pint on the tail. The virtual origin is the point where a straight line between the 10% and 90% points on the leading edge of the
waveform intersects the I = 0 line.
∂Indicates Models using Compliance West USA IEC 65 Switch.
Note 1: 32 uF capacitor in series with a 500uH inductor having a DC resistance no greater than 10 Ohms.
Common specifications:
Meter Accuracy:
2500V output versions: +20 V
5000V, 7000V versions: +40 V
All models: better than 1% of full-
scale reading
Environmental:
15-40°C operating temperature
0-90% Relative Humidity, non-
condensing
Electrical:
Input Voltage: 120 V, 50-60 Hz
Input Current: 1 -7 A (model
specific)
Mechanical:
Weight: Approx. 16-85 lbs.
Dimensions: 11.25”W x 12”D x 5”H
To 24”W x 20”D x 36”H
Table 1. MegaPulse series specifications
Model Waveform* Max. Voltage C1 R1 R2 C2 R3
10x700-2.5 10 x 700/6 x 300 uS 2500V 20 uF 50 Ohms 15 Ohms 0.2 uF 25 Ohms
10x700-7 10 x 700/6 x 300 uS 7000V 20 uF 50 Ohms 15 Ohms 0.2 uF 25 Ohms
1.2x50-2.5 1.2 x 50/1 x 20 uS 2500V 1 uF 76 Ohms 13 Ohms 0.033 uF 25 Ohms
1.2x50-7 1.2 x 50/1 x 20 uS 7000V 1 uF 76 Ohms 13 Ohms 0.033 uF 25 Ohms
1.2x50-12 12 Ω
Fast Charge ∂1.2 x 50/1 x 20uS 12300V 2.75 uF 40 Ohms 7 Ohms 0.05uF 0 Ohms
1.2x50-12.3-1 1.2x50uSec 500 ohms 12,300 0.5uF 147 Ohms 328 Ohms 1 nF 253 Ohms
10x1000s-1 10 x 1000/10 x 1000 uS 1000V
10x360s-1 10 x 360/10 x0360 uS 1000V
2x10s-2.5 2 x 10/2 x 10uS 2500V
Defib-5 20 x 2200/50 x 800 uS 5000V 32 uF (1) 100 Ohms 50 Ohms None (open) 0 Ohms
Antenna Surge Not defined 10000V 1 nF - 1 kOhm - -
AXVI1-2.5, -7 1.2 x 50/0 x 7 uS 2500V, 7000V 0.25 uF 234 Ohms 62 Ohms 7800 pF 0 Ohms
AXVI2-2.5, -7 1.2 x 50/0 x 7 uS 2500V, 7000V 0.25 uF 234 Ohms 45 Ohms 7800 pF 0 Ohms
AXVI3-2.5, -7 .7 x 40/0 x 4 uS 2500V, 7000V 0.25 uF 234 Ohms 27 Ohms 7800 pF 0 Ohms
AXVI4-2.5, -7 0 x 40/0 x 4 uS 2500V, 7000V 0.25 uF 234 Ohms 27 Ohms None (open) 0 Ohms
AXVI5-2.5, -7 0 x 40/4 x 40 uS 2500V, 7000V 20 uF 3 Ohms 25 Ohms 3300 pF 0 Ohms
AXVI6-2.5, -7 .2 x 40/ 0 x 35 uS 2500V, 7000V 20 uF 3 Ohms 13 Ohms 3300 pF 0 Ohms
AXVI7-2.5, -7 .2 x 40/0 x 30 uS 2500V, 7000V 20 uF 3 Ohms 9 Ohms 3300 pF 0 Ohms
AXVI8-2.5, -7 .2 x 40/0 x 30 uS 2500V, 7000V 20 uF 3 Ohms 7 Ohms 3300 pF 0 Ohms
AXVI9-2.5, -7 .1 x 40/0 x 25 uS 2500V, 7000V 20 uF 3 Ohms 5 Ohms 3300 pF 0 Ohms
AXVI10-2.5, -7 .08 x 40/0 x 20 uS 2500V, 7000V 20 uF 3 Ohms 3 Ohms 3300 pF 0 Ohms