Compliance West MegaPulse 1.2x50-12.3PF-1 User manual

MegaPulse
IMPULSE TESTER
1.2x50-12.3PF-1
500ohm 0.5J
Instruction Manual

Dear Customer:
Congratulations! Compliance West USA is proud to present you with your
MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J 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.
Rev 1.0, March 2016

Table of Contents
An Introduction to Impulse Testing with the MegaPulse PF series tester...................................................2
Safety Precautions........................................................................................................................2
Using the MegaPulse Impulse Tester...........................................................................................3
Introduction..................................................................................................................................5
Specifications...............................................................................................................................5
Operation....................................................................................................................................................9
Setting up your Tester ..................................................................................................................9
AC Line Voltage Requirements....................................................................................................9
Fuse Replacement.........................................................................................................................10
Front and Rear Panel Features......................................................................................................10
Setting the Peak Output Voltage ..................................................................................................14
Initial Checkout Procedure...........................................................................................................15
Testing..........................................................................................................................................16
Technical Assistance ..................................................................................................................................18
Maintenance and Calibration......................................................................................................................19
Introduction..................................................................................................................................19
Service Information......................................................................................................................19
General Maintenance....................................................................................................................19
Calibration Information................................................................................................................20
Voltage Stop Disable / Keyboard Enable by Keyboard. ..............................................................20
Impulse Testing Waveforms and Relay Performance.................................................................................21

1

2
Section 1
An Introduction to Impulse Testing with the MegaPulse PF 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 creep age, 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 12000V peak at potentially lethal
current levels. Currents of as little as 5mA at 120 volts can cause death; the MegaPulse can
deliver currents of more than 1000 Amps peak for 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 impulse 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.

3
Safety Techniques
The high voltage circuit of the MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J can be shut off at any
time by turning OFF the rear power switch. Always press TRIGGER to discharge the tester
before turning OFF.
The MegaPulse tester is provided with a digital VOLTAGE ADJUST knob on the front panel.
This voltage setting should always confirmed by pressing the VOLTAGE ADJUST knob before
starting any test.
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. Note that
the CHARGE process will stop after 2 minutes if the TRIGGER button is not pressed.
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 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 the 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.

4
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).
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. 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.

5
Section 2
Introduction
This manual contains complete operating, maintenance and calibration information for the
Compliance West USA MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J 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.
Your tester is warranted for a period of one year upon shipment of the instrument to the original
purchaser.
Specifications
Specifications for the MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J are listed in the Error! Reference
source not found. below and the component designations are shown in Figure 1.
Figure 1. General Electrical diagram.
Output
Waveform
Voltage
C1
R1
R2
C2
1000 Vp, 0.5 J
1.2x50 us
1000Vp +0, -10%
1 µF
68 Ω
500Ω
0.8 nF
5000 Vp, 0.5 J
1.2x50 us
5000Vp +0, -10%
40 nF
1700 Ω
500Ω
0.8 nF
12000 Vp, 0.5 J
1.2x50 us
12000Vp +0, -10%
6.9 nF
9792 Ω
500Ω
0.8 nF
Table 1. Nominal Component Values for MegaPulse Circuit.
Note: Multiple output if apply, otherwise single one.
The nominal component values are determined based on the requirement to have 0.5 Joules (J) of
stored energy in capacitor C1, and deliver the 1.2 x 50 uS open-circuit impulse waveshape with
the specified peak voltage (Vp) to the output through a series resistance (R3) of 500 Ohms.
Nominal component values are determined from the calculations provided in IEC 60255-5 Annex
C, which is copied in Figure 2.

6
Figure 2. Annex C from IEC 60255-5
Note that the tolerance of R2 and C2 are 1% as specified, however the component values of R1
and C1 may be modified to account for secondary circuit effects in order to generate the
specified output waveform, which is described in Figure 3, as copied from IEC 60255-5.
Figure 3. Waveform characteristics from IEC 60255-5

7
Methods of calculation of front time (T1) and time to half-value (T2) are as specified in IEC
61180-1, shown in Figure 4.
Figure 4. Waveform time measurements from IEC 61180-1
Recommended test voltages and tolerance on peak voltage are as specified in IEC 60255-5
section 6.1.3.3, which is shown in Figure 5.

8
Figure 5. Test Voltages and Tolerance from IEC 60255-5

9
Section 3
Operation
This section describes how to set up and make measurements with your Tester. We recommend
that you read the entire section carefully so that you can use all of the features of your Tester.
Setting up your Tester
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 1.2x50-12.3PF-1 500ohm 0.5J Tester
Two high-voltage test leads, 1 red and 1 black
An 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
three inches of shock-absorbing material on all sides of the container.
Remove the tester from its container and place it on a test bench.
AC Line Voltage Requirements
AC line voltage requirements for your Tester are noted on the rear panel of the instrument. Do
not connect the instrument to a different voltage source. 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.

10
Fuse Replacement
There is a user-replaceable fuse (F1) located on the rear panel of the instrument. It is located
behind a door in the Power Inlet-Power Switch-Fuse Holder device. The fuse rating is noted on
the rear panel. Do not attempt to replace it with a fuse of any other rating.
Use the following procedure to replace the fuse F1:
1. Turn the power switch to the OFF position.
2. Unplug the instrument from the source of supply.
3. Remove the power inlet cord from the instrument.
4. Using a small screwdriver, pry open the fuse holder door.
5. Replace the fuse with a new one of the correct rating.
6. Replace the fuse holder door and power inlet cord.
Front and Rear Panel Features
Before using your Tester, take a few minutes to become familiar with the use of its controls,
indicators and connectors. The front panel features of the MegaPulse are shown in Figure 6 and
described in Table 2.The rear panel features of the MegaPulse are shown in Figure 7 and
described in Table 3..

11
Figure 6. Controls, Indicators, Connectors –MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J Front Panel (image for reference only)

12
ITEM
NAME
FUNCTION
1
VOLTAGE
Adjust Knob
Adjust the digital voltage set point in the tester.
Press the voltage knob to display the voltage set point. This setting will blink for a few seconds on the front meter.
Turn Clockwise to increase the setting Voltage Setting Point before pressing CHARGE button.
2
POLARITY
switch
Toggles the output pulse polarity from Normal to Reverse, Normal for positive and Reverse for Negative, The pulse will appear on the Output jack relative
to the return jack
The polarity switch only operates when the CHARGE indicator is lit and the voltage on the display meter is less than 180V. The polarity is Normal when
the NOR indicator is lit and, Reverse when the REV indicator is lid.
3
NOR REV
indicator
Indicates the state of the Output Polarity switch.
NOR indicates Normal (Positive) position.
REV indicates Reverse (Negative) position.
4
CHARGE
switch
Starts the charge process of the tester capacitor.
The CHARGE indicator will turn off after the CHARGE switch is pressed, and the TRIGGER indicator will turn on.
The charge process will stop after 2 minutes if the TRIGGER button is not pressed.
5
CHARGE
indicator
This Yellow indicator is lit to show that pressing the CHARGE switch is the next logical step in a test sequence.
CHARGE indicator is lit when the tester is turn ON an after pressing TRIGGER button.
CHARGE indicator will go out after pressing CHARGE button.
CHARGE and TRIGGER Indicators will be blinking if the Interlock Switch is open. (Only testers with Interlock Switch Option)
6
TRIGGER
switch
Triggers the output impulse waveform.
The impulse waveform will appear across the output leads.
7
TRIGGER
indicator
This Red indicator is lit to show that the tester can be trigger.
TRIGGER indicator is lit for 2 minutes after the CHARGE button is pressed.
TRIGGER indicator will go out after pressing TRIGGER button.
TRIGGER and CHARGE Indicators will be blinking if the Interlock Switch is open (Only testers with Interlock Switch Option)
TRIGGER indicator will blink at when the Voltage. This effect will remain on until the TRIGGER switch is pressed. (Only testers with PC Interface
option)
8
VOLTAGE
meter
Displays the output voltage set point.
The voltage reading will increase from zero to the voltage set point when the CHARGE button is pressed. 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. Note that the peak amplitude of the measured output waveform is proportional to
the voltage that is read of 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. This voltage will intentionally dissipate to some extent before reaching the output leads.
9
OUTPUT
jack
The impulse waveform appears on the OUTPUT jack, referenced to the RETURN jack. When the POLARITY switch is in the Normal position (NOR
indicator is lit) the output will be a positive pulse. When the POLARITY switch is in the Reverse position (REV indicator is lit) the output will be a
negative pulse.
10
RETURN
jack
This is the return for the impulse waveform. This jack is referenced to the chassis of the MegaPulse, and is referenced to earth ground as long as the
MegaPulse is properly grounded. Even though this jack is referenced to ground, it should be treated as hazardous whenever the MegaPulse is turned ON.
11
OUTPUT
switch
Used to select the waveshaping network components that are specified for each nominal output voltage. Refer to Table 1 for additional details. (optional,
just in case that multiple output was ordered)
Table 2. Controls, Indicators, Connectors –MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J Front Panel

13
Figure 7. Controls, Indicators, Connectors –MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J Rear Panel (image for reference only)
ITEM NO.
NAME
FUNCTION
1
Appliance Inlet / Fuse holder /
Power Switch
Use supplied cordset to connect the MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J tester to an appropriate
source of supply. Fuse holder provides access for Fuse replacement, and the Power Switch is used to turn
the tester ON and OFF.
2
RS-232 Interface (Optional)
Allow the communication between the tester and computer interface; a RS-232 to USB is available.
3
Interlock Switch (Optional)
Emergency Stop
Close: Enables the tester buttons for operation.
Open: Stops any process in the tester and disables the buttons. The TRIGGER and CHARGE Indicators
will be blinking
4
Fuse replacement warning /
Rating of power supply
Specifies replacement fuse and required supply voltage.
Table 3. Control, Indicators, Connectors –MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J Rear Panel
1
4
2
3

14
Setting the Peak Output Voltage
Select the desired output using the Output switch (if apply, Figure 6 item 11). Adjust the output
voltage setting using the Voltage adjust knob (Figure 6 item 1) to the voltage specified in Table 4.
Note that the front panel meter reads the voltage of C1. Depending on the waveshaping network
that is selected, this voltage will be higher than the peak voltage of the output waveform.
CAUTION: DO NOT SET THE VOLTAGE ABOVE THE MAXIMUM VOLTAGE
SETTING SPECIFIED IN Table 4. DOING SO MAY DAMAGE THE EQUIPMENT
Output Switch
Setting
Desired Peak Output
Voltage (Vp) (1)
Output Voltage
Setting (Vs)
Maximum Voltage
Setting
Calculation for other
voltages
1000V
950V
985
1500
Vp = 0.96 Vs
5000V
4750V
5050
6500
Vp = 0.94 Vs
12000V
11400V
14500
14500
Vp =0.78 Vs
Table 4. Output Voltage Setting.
1. Note that the tolerance on the peak output voltage is +0, -10%. Therefore the center of this
tolerance band is -5%, corresponding to 950V, 4750V, 11400V for the 1000V, 5000V, and
12000V settings respectively.
2. Multiple output if apply, otherwise single one.

15
Initial Checkout Procedure
The following procedure will verify that the MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J tester is working
correctly. We recommend that this procedure be conducted periodically to ensure proper operation of the
tester. The following items are needed to conduct this procedure: A measuring instrument to monitor the
output waveform. 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 1.2x50-12.3PF-1 500ohm 0.5J
tester. A measuring instrument or probe with a low frequency response will result in erroneous readings
that could be mis-read.
CAUTION
High voltage generated by the MegaPulse tester is exposed during this test. A risk of shock
exists. Exercise care when using the MegaPulse tester.
1. Connect the tester to a proper source of supply using the included 18 AWG power supply cord.
2. Plug the Output and Return test leads into the jacks on the front panel.
3. Connect the ends of the test leads to an appropriate measuring instrument (typically an oscilloscope
with a high-voltage probe). Note that the RETURN lead is referenced to the chassis ground of the
tester. See Figure 8 as an example.
4. Turn the Tester on. Toggle the POLARITY switch if necessary so that the NOR indicator is lit.
5. 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).
6. Adjust the digital VOLTAGE knob to the desire value.
7. Push the yellow CHARGE button. Verify the red TRIGGER indicator is now lit.
8. Adjust the VOLTAGE knob so that the front panel LED display is reading a voltage that is suitable
for the measuring instrument that is being used. Push the red TRIGGER button, and view the
resulting impulse waveform on the measuring instrument.
9. Note that the peak amplitude of the measured output waveform is proportional to the voltage that is
read of 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. This
voltage will intentionally dissipate to some extent before reaching the output leads.
10. Repeat steps 5 through 8, except this time toggle the POLARITY switch so that the REV indicator
is lit. Note that the impulse waveform will now be a negative pulse, so it will probably be
necessary to make adjustments to the measuring instrument to get a proper reading.
11. Adjust the digital VOLTAGE knob to “00000”. Turn the rear-panel power switch OFF.

16
Figure 8. Waveform Measurement Setup.
Testing
This section describes how the MegaPulse 1.2x50-12.3PF-1 500ohm 0.5J tester is used to conduct a test.
The test can be stopped immediately at any time by turning OFF the rear-panel power switch.
1. Connect the tester to a proper source of supply using the included 18 AWG power supply cord.
2. Plug the Output and Return test leads into the jacks on the front panel.
3. Connect the ends of the test leads to the equipment under test.
4. Turn the Tester on.
5. 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).
6. Adjust the digital VOLTAGE knob to the desire value. CAUTION: DO NOT SET THE
VOLTAGE ABOVE THE VALUES SPECIFIED IN Table 5. DOING SO MAY DAMAGE
THE EQUIPMENT:
Switch Setting
Maximum Voltage Setting
0.5J, 1KV
1500V
0.5J, 5KV
6500V
0.5J, 12KV
14500V
Table 5. Maximum Voltage Settings.
Note: Multiple output if apply, otherwise single one.