Compliance West MegaPulse Antenna Surge PF 65 User manual

MegaPulse
IMPULSE TESTER
Antenna Surge PF 65
Instruction Manual

Dear Customer:
Congratulations! Compliance West USA is proud to present you with
your MegaPulse Antenna Surge PF 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 0, September 2015

Table of Contents
An Introduction to Impulse Testing with the MegaPulse P series tester.....................................................2
Safety Precautions ........................................................................................................................2
Test Personnel................................................................................................................2
Testing Area...................................................................................................................2
Safety Techniques ..........................................................................................................3
Using the MegaPulse Impulse Tester ...........................................................................................3
Introduction ................................................................................................................................................5
Specifications ...............................................................................................................................5
Operation....................................................................................................................................................7
Setting up your Tester ..................................................................................................................7
AC Line Voltage Requirements....................................................................................................7
Fuse Replacement.........................................................................................................................8
Front and Rear Panel Features......................................................................................................8
Initial Checkout Procedure...........................................................................................................12
Testing..........................................................................................................................................13
Manually Enabling the Front Panel Buttons and Disabling the Voltage Stop ..............................14
Manually Disabling the Voltage Stop and Enabling the Front Panel Buttons ..............................14
Technical Assistance ..................................................................................................................................15
Maintenance and Calibration......................................................................................................................16
Introduction..................................................................................................................................16
Service Information......................................................................................................................16
General Maintenance....................................................................................................................16
Cleaning .........................................................................................................................16
Calibration Information................................................................................................................17

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 10000V 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 10 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 Antenna Surge PF 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 confirm by pressing the VOLTAGE ADJUST knob before
start any 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. 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 will not change the polarity on the Antenna
Surge PF, only positive pulses can be performed, the high voltage will appear on the OUTPUT
as a positive pulse relative to the RETURN jack.
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 Antenna Surge PF 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
The general diagram for the MegaPulse Antenna Surge PF is shown on Figure 1 and de
components designations are shown on Table 1. Then, Table 2 shows how to use the Load
Option Switch.
Note: Load Option (R2) and BNC voltage divisor (R3, R4) are optional.
Figure 1. General Diagram Megapulse Antenna Surge PF
Table 1. Components Designations.
`
Load Option
Switch
(Option 4M)
1000:1
(Option BNCV)
Waveform Max.
Voltage RS C1 R1 R2 R3 R4
Not defined 10KV 15MΩ1 nF 1kΩ4MΩ100MΩ100KΩ

6
Table 2. Load Option Switch.
Standard Load Option Switch Position
60065 IEC, paragraph 10.1
No Load
UL60950-1 Annex N, Table N.1, Line 3
No Load
EN 60065:1993 , Fig 7a, sub-clause14.2 performed on a
component comprising a capacitor only. 4M OHM LOAD
*NOTE:
C1 is being charged at a higher voltage to compensate the loss experienced when the switch is turned to the
ON position (Trigger), this due to the small capacitor of 1nF which starts discharging during the transition
from the OFF to the ON position.

7
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 Antenna Surge PF 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.

8
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 2 and
described in Table 2. The rear panel features of the MegaPulse are shown in Figure 3 and
described in Table 3.

9
Figure 2. Controls, Indicators, Connectors – MegaPulse Antenna Surge PF Front Panel.

10
Table 3. Controls, Indicators, Connectors – MegaPulse Antenna Surge PF Front Panel.
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 Will not change the polarity. It is used only for calibration and settings options.
3 NOR REV indicator Indication is for reference only.
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.
The meter will start to flash at 10100V to indicate that voltage is in the maximum limits.
If unit includes PC Interface and the Keyboard is locked, the display will show OFF when a button is pressed.
9 OUTPUT jack The impulse waveform appears on the OUTPUT jack, referenced to the RETURN jack.
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 Vout/1000 (optional) Option 1000:1 voltage divider. For reference only.
12 LOAD OPTION Switch This switch is to enable the 4M Ohm load.

11
Figure 3. Controls, Indicators, Connectors – MegaPulse Antenna Surge PF Rear Panel.
Table 4. Control, Indicators, Connectors – MegaPulse Antenna Surge PF Rear Panel.
ITEM NO. NAME FUNCTION
1 Appliance Inlet / Fuse holder
/ Power Switch
Use supplied cordset to connect the MegaPulse Antenna Surge PF 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
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.

12
Initial Checkout Procedure
The following procedure will verify that the MegaPulse Antenna Surge PF 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 Antenna Surge PF 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 4 as an example.
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.
7. Push the yellow CHARGE button. Verify the red TRIGGER indicator is now lit.
8. Push the red TRIGGER button, when the desired voltage is displayed on the front panel meter.
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. Adjust the digital VOLTAGE knob to “00000”. Turn the rear-panel power switch OFF.

13
Figure 4. Waveform Measurement Setup
Testing
This section describes how the MegaPulse Antenna Surge PF 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.
7. Push the yellow CHARGE button. Verify the red TRIGGER indicator is now lit.
8. Push the red TRIGGER button, when the desired voltage is displayed on the front panel meter.
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.

14
Manually Enabling the Front Panel Buttons and Disabling the Voltage Stop
If the MegaPulse Antenna Surge PF is displaying “OFF” on the meter when the front buttons are pressed,
it means that the front panel buttons have been disabled via the TestMinder software interface. It is
possible to enable them manually using the next sequence:
Note: Enabling the front panel buttons manually will disable the voltage stop setting.
Turn OFF the MegaPulse P tester.
Hold in the TRIGGER and NOR-REV buttons.
Turn ON the MegaPulse P tester.
Wait until the display shows rESE.
Release the TRIGGER and NOR-REV buttons.
Manually Disabling the Voltage Stop and Enabling the Front Panel Buttons
If the MegaPulse Antenna Surge PF tester is stopping the charge process automatically, it is possible that
the Voltage Stop feature has been activated by the TestMinder software interface. It is possible to
manually disable it by using the next sequence:
Note: Disabling the Voltage Stop feature enables the front panel buttons.
Turn OFF the MegaPulse P tester.
Hold in the TRIGGER and NOR-REV buttons.
Turn ON the MegaPulse P tester.
Wait until the display shows rESE.
Release the TRIGGER and NOR-REV buttons.

15
Section 4
Technical Assistance
Technical Assistance from Compliance West USA is available:
Phone: [phone]
Hours: 8:00 AM - 4:00 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
United States of America.
Phone: [phone]
FAX: [phone]

16
Section 5
Maintenance and Calibration
WARNING
MAINTENANCE AND CALIBRATION INSTRUCTIONS ARE FOR QUALIFIED
PERSONNEL ONLY. TO AVOID ELECTRIC SHOCK, DO NOT PERFORM ANY
SERVICING OTHER THAN THE CONTAINED IN THE OPERATING
INSTRUCTIONS.
Introduction
This section of the manual contains maintenance information for the MegaPulse Antenna Surge
PF impulse tester. A 1-year calibration cycle is recommended to maintain the specifications of
the factory. The test equipment required for the performance test is a digital oscilloscope, high
voltage oscilloscope probe, digital meter and a high voltage probe.
Service Information
The MegaPulse tester 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 post paid to the manufacturer.
Dated proof of purchase is required for all in-warranty repairs. The manufacturer is also
available for calibration and / or 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
To avoid contaminating the PWB with oil from your fingers, handle it by the edges or wear
gloves. If the PWB becomes contaminated, refer to the cleaning procedures given later in this
section.
WARNING
Dangerous voltages exist when energized. Exercise extreme care when working on an
energized circuit.
CLEANING
Clean the front panel and case with a mild solution of detergent and a damp sponge. Clean dust
from the PWB with clean, dry, low pressure (<20 psi)
CAUTION
Do not use aromatic hydrocarbons or chlorinated solvents for cleaning. These solutions
will react with the plastic materials used in the instrument.