Compliance West MegaPulse Defib-5PF-002 User manual

MegaPulse
IMPULSE TESTER
Defib-5PF-002
Instruction Manual

Dear Customer:
Congratulations! Compliance West USA is proud to present you
with your MegaPulse Defib-5PF-002 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, July, 2017

Table of Contents
Section 1................................................................................................................................................ 6
Introduction to MegaPulse....................................................................................................... 6
Safety Precautions.................................................................................................................... 6
Test Personnel ......................................................................................................................... 6
Testing Area ............................................................................................................................ 6
Safety Techniques.................................................................................................................... 7
Using the MegaPulse Impulse Tester........................................................................................ 7
Section 2................................................................................................................................................ 9
Introduction............................................................................................................................. 9
Specifications........................................................................................................................... 9
Figure 1. Type A Diagram.......................................................................................... 10
Figure 2. Type B Diagram.......................................................................................... 10
Figure 3. Impulse waveform type A............................................................................ 11
Figure 4. Impulse waveform type B............................................................................ 11
Section 3................................................................................................................................................ 12
Operation................................................................................................................................. 12
Setting up your Tester.............................................................................................................. 12
AC Line Voltage Requirements................................................................................................ 12
Fuse Replacement .................................................................................................................... 12
Front and Rear Panel Features.................................................................................................. 13
Figure 5. MegaPulse Defib-5PF-002 Front Panel....................................................... 13
Table 1. MegaPulse Defib-5PF-002 Front Panel........................................................ 14
Figure 6. MegaPulse Defib-5PF-002 Rear Panel......................................................... 15
Table 2. MegaPulse Defib-5PF-002 Rear Panel ......................................................... 15
Initial Checkout Procedure....................................................................................................... 16
Figure 7. Waveform Measurement Setup.................................................................... 17
Testing..................................................................................................................................... 17
Section 4................................................................................................................................................ 18
Technical Assistance ................................................................................................................ 18
Section 5................................................................................................................................................ 19
Maintenance and Calibration .................................................................................................... 19
Introduction............................................................................................................................. 19
Service Information.................................................................................................................. 19
General Maintenance................................................................................................................ 19
Cleaning................................................................................................................................... 19
Calibration Information............................................................................................................ 20
Voltage Stop Disable / Keyboard Enable by Keyboard. ............................................................ 20
Appendix 1 ............................................................................................................................................ 21
Commands table....................................................................................................................... 21

5

6
Section 1
Introduction to MegaPulse
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 up to 5000V 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.

7
Safety Techniques
The high voltage circuit of the MegaPulse Defib-5PF-002 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 should always be adjusted 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. 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.

8
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.

9
Section 2
Introduction
This manual contains complete operating, maintenance and calibration information for the
Compliance West USA MegaPulse Defib-5PF-002 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.
Specifications
Specifications for the MegaPulse Defib-5PF-002 are listed in the table below and the component
designations are shown in Figure 1 and Figure 2. For impulse waveform look at
Figure 33 and Figure 4.
ELECTRICAL
Output Voltage:
0 - 5000 V tolerance ±1%
Main Capacitance:
0.13 uF ±10% Type A, 0.50 uF ±10% Type B (600,000 cycles life)
Voltage Control:
Digital Set point adjusted by frontal VOLTAGE knob or by PC
TestMinder.
Voltage Display:
4 Digit LED Display.
Voltage Meter resolution:
2V
Duty Cycle:
1 pulse every 20s.
Selectable Input Voltage:
120V~ 60Hz
240V~ 50Hz
ENVIROMENTAL
Operating Temperature:
15 - 40 ºC
Relative Humidity Range:
Altitude
0 - 90% non-condensing
0 - 3000 meters
GENERAL
Dimensions:
17” wide x 15.75” high x 17” in deep
Weight:
50 lbs. approx.

10
Figure 1. Type A Diagram.
Figure 2. Type B Diagram.

11
Figure 3. Impulse waveform type A.
Figure 4. Impulse waveform type B.

12
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 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:
•Qty 1 MegaPulse Defib-5PF-002 Tester
•Qty 10 PN:00-HVTL-R (High Voltage Test Lead Red)
•Qty 1 PN: 70-101 (Power Cord 18 AWG)
•Qty 1 Defib-5PF-002 Instruction Manual
•Qty 1 Testminder set
•Qty 1 External Load (52.299kΩ and 7.492kΩ +/-5%)
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.
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. A second fuse can be
found next to the input voltage selector switch
Use the following procedure to replace a fuse:
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. Open the fuse holder door.
5. Replace the fuse with a new one of the correct rating.
6. Replace the fuse holder and power inlet cord.

13
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 and
described in Table 1. The rear panel features of the MegaPulse are shown in Figure and described
in Table 2.
Figure 5. MegaPulse Defib-5PF-002 Front Panel

14
Table 1. MegaPulse Defib-5PF-002 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
Disable
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.
The meter will start to flash at 7100V 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
500:1 BNC
500:1 reference to verify delivery of pulse
10-19
OUTPUTS
10 Channel multiplexer outputs, each channel capable of delivering the pulse, channel
activation is via commands on the back of the unit.

15
Figure 6. MegaPulse Defib-5PF-002 Rear Panel
ITEM
NAME
FUNCTION
1
INPUT Switch
The switch allows the selection of 115V or 230V input
2
Fuse B
The fuse B is to protect the unit when supplying 230V.
3
Appliance Inlet
Use supplied cordset to connect the MegaPulse Defib-5PF-002 tester to an
appropriate source of supply.
4
Fuse replacement warning
/ Rating of power supply
Specifies replacement fuse and required supply voltage for 115V input.
5
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
6
RS-232 Interface
(Optional)
Allow the communication between the tester and computer interface; a RS-
232 to USB is available.
7
FANS
The Fans on the rear panel maintain the air flow to cool down the tester.
CAUTION: When installing equipment, make sure not to cover the fans and
have it on a proper ventilated area.
Table 2. MegaPulse Defib-5PF-002 Rear Panel

16
Initial Checkout Procedure
The following procedure will verify that the MegaPulse Defib-5PF-002 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 is capable of measuring the output waveform of the
MegaPulse Defib-5PF-002 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
2. Plug a pair of leads to the Output on the front panel. Use channel 1 and 2 for this test.
3. Connect the 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, in this case we will connect channel 1 to the return of the probe, connect channel 2 to
the High Voltage of the probe.
4. Turn the Tester on. And connect the computer to the TestMinder port on the rear panel of
the tester.
5. For the following steps refer to the commands table.
5.1 Send command to select channel 2 output
5.2 Send command to set voltage at 500V
5.3 Send command to charge
5.4 Send command to trigger
6. Capture de waveform on the oscilloscope.
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.
7. Repeat step 5 charging at 5000V.
8. Manual control checkout. Note: Multiplexor control can only be set via commands
8.1 Turn the VOLTAGE knob to 500V and press the knob to set the voltage
8.2 Press the charge button, verify the meter reach the set voltage.
8.3 Press TRIGGER to discharge.
9. Capture the waveform on the oscilloscope.
10 Repeat step 8 at 5000V.

17
Figure 7. Waveform Measurement Setup
Testing
This section describes how the MegaPulse Defib-5PF-002 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. Select the input voltage (115V or 230V) from the switch on the back and connect the tester
to a proper source of supply using the included 18AWG power supply cord.
2. Plug the leads to the Outputs of the tester
3. Connect the ends of the test leads to the equipment under test.
4. Connect the Computer to the TestMinder port on the back of the tester
5. Turn the Tester on.
5. Use table of commands to operate the tester.
6. Set desired voltage.
7. Select multiplexor channel.
8. Charge.
9. Trigger
Note: Polarity is disable and the multiplexor can only be operated via commands.

18
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
United States of America.
Phone: [phone]
FAX: [phone]

19
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 Defib-5PF-002
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.

20
Calibration Information
The Calibration Procedure should be performed annually and any time the instrument has been
repaired. The calibration procedure should be performed at an ambient temperature of 23C 5C
(73.4F 9F). The procedure consists on internal components tolerance verification and
calibrating the meter reading to agree with the capacitor bank. The Calibration procedure must be
performed by qualified personnel, for more information contact Compliance West USA.
Voltage Stop Disable / Keyboard Enable by Keyboard.
If the MegaPulse Defib-5PF-002 tester includes TestMinder option and has the Voltage Stop by
the PC command activated, it is possible to disable it using the next keyboard sequence:
Note: Disabling Voltage Stop enables the keyboard.
Turn OFF the MegaPulse P tester.
Hold in the TRIGGER and NOR-REV buttons.
Turn ON the MegaPulse PF tester.
Wait until the display shows rESE.
Release the TRIGGER and NOR-REV buttons.