Megger Surgeflex 8-1000 User manual

Mess
- und Ortungstechnik
Measuring and Locating Technologies
Elektrizitätsnetze
Power Networks
Kommunikationsnetze
Communication Networks
Rohrleitungsnetze
Water Networks
Abwassernetze
Sewer Systems
Leitung
sortung
Line Locating
Issue: 05 (07/2014) –
EN
Article number:
128312422
Operating Manual
Low voltage fault location system
Surgeflex 8-1000

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Consultation with Megger
The present system manual has been designed as an operating guide and for reference.
It is meant to answer your questions and solve your problems in as fast and easy a way
as possible. Please start with referring to this manual should any trouble occur.
In doing so, make use of the table of contents and read the relevant paragraph with great
attention. Furthermore, check all terminals and connections of the instruments involved.
Should any question remain unanswered or should you need the help of an authorized
service station, please contact:
Megger Limited
Seba Dynatronic
Mess- und Ortungstechnik GmbH
Archcliffe Road
Kent CT17 9EN
T: [phone]
F: [phone]
E: [e-mail]
Dr.-Herbert-Iann-Str. 6
D - 96148 Baunach
T: [phone] – 0
F: [phone]
E: [e-mail]
Hagenuk KMT
Kabelmesstechnik GmbH
Megger USA
Röderaue 41
D - 01471 Radeburg / Dresden
T: [phone] – 0
F: [phone]
E: [e-mail]
Valley Forge Corporate Centre
2621 Van Buren Avenue
Norristown, PA 19403 USA
T: [phone]
F: [phone]
Megger
All rights reserved. No part of this handbook may be copied by photographic or other means unless Megger have
before-hand declared their consent in writing. The content of this handbook is subject to change without notice.
Megger cannot be made liable for technical or printing errors or shortcomings of this handbook. Megger also disclaim
all responsibility for damage resulting directly or indirectly from the delivery, supply, or use of this matter.

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Terms of Warranty
Megger accept responsibility for a claim under warranty brought forward by a customer
for a product sold by Megger under the terms stated below.
Megger warrant that at the time of delivery Megger products are free from manufacturing
or material defects which might considerably reduce their value or usability. This
warranty does not apply to faults in the software supplied. During the period of warranty,
Megger agree to repair faulty parts or replace them with new parts or parts as new (with
the same usability and life as new parts) according to their choice.
This warranty does not cover wear parts, lamps, fuses, batteries and accumulators.
Megger reject all further claims under warranty, in particular those from consequential
damage. Each component and product replaced in accordance with this warranty
becomes the property of Megger.
All warranty claims versus Megger are hereby limited to a period of 12 months from the
date of delivery. Each component supplied by Megger within the context of warranty will
also be covered by this warranty for the remaining period of time but for 90 days at least.
Each measure to remedy a claim under warranty shall exclusively be carried out by
Megger or an authorized service station.
This warranty does not apply to any fault or damage caused by exposing a product to
conditions not in accordance with this specification, by storing, transporting, or using it
improperly, or having it serviced or installed by a workshop not authorized by Megger. All
responsibility is disclaimed for damage due to wear, will of God, or connection to foreign
components.
For damage resulting from a violation of their duty to repair or re-supply items, Megger
can be made liable only in case of severe negligence or intention. Any liability for slight
negligence is disclaimed.
Since some states do not allow the exclusion or limitation of an implied warranty or of
consequential damage, the limitations of liability described above perhaps may not apply
to you.

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Table of contents
1. INTENDED APPLICATION .......................................................... 9
2. TECHNICAL DESCRIPTION...................................................... 11
2.1 Technical Data...............................................................................................11
2.2 Scope of delivery ...........................................................................................11
3. SAFETY PRECAUTIONS........................................................... 12
3.1 General safety measures ..............................................................................12
3.2 Connection rules............................................................................................13
3.3 Safety Device (optional).................................................................................15
3.4 Danger during the surging .............................................................................16
3.5 Circuit breaker (optional) ...............................................................................17
4. PROCESSING OF THE MEASUREMENTS............................... 18
4.1 Measurements with the base system Surgeflex 8-1000 ................................18
4.1.1 Testing and Burning ......................................................................................18
4.1.2 Pulse reflection measurement .......................................................................19
4.1.3. Surge Prelocation (ICE).................................................................................20
4.1.4 Arc Reflection Prelocation ARM ....................................................................21
4.2 Surge Pinpointing ..........................................................................................22
5. MAINTENANCE ......................................................................... 23
6. STORAGE AND TRANSPORT .................................................. 24

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1. Intended Application
The low voltage fault location system Surgeflex 8-1000 is a modular
component system for the handling of different tasks in the cable measuring
technologies specially for the low voltage network.
Surgeflex 8-1000 consists of a powerful base system, which can be extended
by additional units to an universal test system.
The base system consists of the Surge Unit 2/4/8 kV, the Arc Reflection
Adapter ARM Unit 8 kV and a powerful reflectometer (Teleflex SX or Teleflex
T3060). All units are mounted in a solid chassis and easily movable. By simple
changing of the connection cables, the unit is prepared for the different tasks.
According to the requirements, the units can be removed from the chassis and
used separately. The basic system permits the following operational modes:
-DC-testing up to 8 kV
-Prelocating
Reflection measurement
ARM measurement (Arc Reflection Method)
Impulse Current Method 2 / 4 / 8 kV
-Burning (Fault conditioning)
-Pinpointing
Distance and acoustic measurement
Sheat fault locating
By the installation of the following additional components, the
Surgeflex 8-1000 system can be extended:
-Pinpointing receiver Digiphone
-Audio frequency cable tracer and faultlocater Ferrolux family
-Earth fault locating receiver ESG

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2. Technical Description
2.1 Technical Data
Dimensions (W x H x D) 660 mm x 1050 mm x 700 mm
Weight appr. 100 kg
Supply 230 V ±10 %, 50/60 Hz (110 V optional)
Power consumption appr. 2 kVA
Operating termperature −15°C ... +45°C
Storage temperature −20 °C … 70°C
Protection class I
Protection rating IP21
Circuit breaker (isolating
transformer) (optional)
9 A
The detailed technical data are available from the operating manual of the
surge generator Surge Unit 2/4/8 kV and the reflectometer.
2.2 Scope of delivery
Surgeflex 8-1000 consists of the following components:
Amount Description
1 Surge Unit 2/4/8 kV
1 ARM Unit 8 kV
1 Teleflex SX or Teleflex T3060
1 Rolling Frame
1 Isolating transformer (optional)
1 Safety device (optional)
1 User Manual
1 Cable set

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3. Safety precautions
3.1 General safety measures
Five safety rules
The five safety rules must always be followed when working with HV
(High Voltage):
1. De-energise
2. Protect against re-energising
3. Confirm absence of voltage
4. Ground and short-circuit
5. Cover up or bar-off neighbouring energised parts
Wear Ear Protection
Surge operation can cause high and sudden noise levels.
It is strongly recommended to wear hearing protection
during surge operation. Keep in mind that this will limit the
operators awareness for ambient dangers.
•Ensure that there are no unsecured components with life voltage in the
close vicinity of the Surgeflex 8-1000, which could come into contact
with you or the system. Secure any possible component by the correct
covering procedure. If this is impossible due to technical reasons,
disconnect them from any voltage or cause the according responsible
manager or technician to arrange this before continuing. Observe the
correct execution of this task.
•Perform a control measurement with appropriate test equipment.
Ensure the correct functionality of this tester with a test or a
measurement on a known reference voltage.
•Select a location for the Surgeflex 8-1000which suits the weight and
dimension of the system and which provides a safe stand.
•Ensure also that the pace selected for the Surgeflex 8-1000 does not
affect the function of any other components or systems. If the use of
the Surgeflex 8-1000 requires modifications to other systems or
system components, it must be ensured that these modifications are
removed after the work is completed. Observe the special requirements
of this system. Obtain the correct permission from the authorised
personnel to do so before conducting any work.
This applies especially to any interference with safety appliances
and safety regulations.

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•The Surgeflex 8-1000 generates during its operational procedure
dangerous voltages up to 8 kV. These voltages are fed via the HV
cable into the test object. The high voltage connector must not be
touched or disconnected during HV operation.
•The test object must be protected against contact by applying
protective devices as covers, safety chains etc. which ensure the
danger zone cannot be reached.
•By according earthing and disconnection it must be guaranteed that the
dangerous voltages cannot access any unprotected location or
technical installation.
•During the operation of the Surgeflex 8-1000 a second person must be
present in sight and calling distance. This person must be able to
recognise eventual dangerous situations and to operate the emergency
off procedures.
•The Surgeflex 8-1000 must not be operated unattended.
•To prevent dangerous charges, all metallic objects in the vicinity of the
Surgeflex 8-1000 must be constantly earthed.
•All unused phases and cables must be shorted and earthed.
3.2 Connection rules
•Protective and operational earth must be connected in such a way, that
no dangerous step voltage or potential can build up between Protective
earth (PE) and Neutral (N).
•Protective earth connection in TN-Networks:
Connect the earth cable of the Surgeflex 8-1000 at the earth
connection point of the neutral (N). If this is impossible it must be
connected to a protective earth terminal which has the shortest
connection to this point.
•Protective earth connection in TT-Networks:
The operational conditions in these nets different and therefore not
applicable to a general rule. The operator of the system must avoid
dangerous and critical conditions by appropriate measures adapted to
the local rules.
•The operational earth of the Surgeflex 8-1000 (screen of the HV
connection cable) must be always connected to the earthed screen of
the test object, of this is not possible at the connection lead to the
station earth.
•Unused lines of the test object must be connected directly to the
operational earth.
•If test object and supply net are connected to different no with each
other connected earthing systems, it must be ensured that during the
operation of the Surgeflex 8-1000 the potential equalisation is
maintained with a connection cable of at least 16 mm² Cu diameter.
•The operation of the Surgeflex 8-1000 is only permitted with a correct
connected earth cable, since only this guarantees the correct protection
from high voltage when operation and contacting the system.

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Connection sequence:
1. Connect the yellow/green earthing wire to an appropriate foundation earth
electrode (station earth).
2. Connect to the object under test (see connection examples in section 4.1.).
3. Make sure to attach the dummy plug to the HV output of the ARM Unit 8 kV
which is not in use (ARM out or HV out)!
The connection cables of the Surgeflex 8-1000 are only to be
connected or disconnected from the test object, if this is visibly
shorted and earthed at the connection point with an approved device
in accordance with DIN VDE 0105.
4. Mark off test area according to EN 50191.
5. Connect the system to mains power.
ATTENTION
The wiring between the individual components of the
Surgeflex 8-1000 is equally appropriate for all operating
modes and should not be changed at any time!

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3.3 Safety Device (optional)
Using the safety device, the power supply to the Surge Unit 2/4/8 kV can be
disrupted or blocked with the EMERGENCY OFF switch and the key switch.
Furthermore, the status of the system is made clearly visible with the help of
two signal lights.
Part Description
Red signal light
Lights up when the system is supplied with mains voltage. Voltage
may be present at the HV output! The connected object under test
is to be regarded as live!
Green signal light
Lights up if the mains supply has been disrupted by the
EMERGENCY OFF switch or the key switch. No voltage is present
at the HV output!
"HV-Interlock" key switch
High voltage generation possible
High voltage generation locked. Pulse reflection
measurements with the reflectometer can be carried out.
In the locked state, the key can be removed and the system can thus
be protected against unauthorised high-voltage operation.
EMERGENCY OFF switch

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3.4 Danger during the surging
In the classic lead sheath cables with steel armour, the sheath and armour are
also used as earth. By this large surface earthing and the involved shifting of
the earth potential directly to the fault location, dangerous voltage potential
may build up.
Plastic insulated cables have no insulated screen. The screen consists of a
semiconducting layer and a relatively wide meshed copper screen. The
earthing is done at the earth terminals at both ends of the cable in the station.
With a cable fault it is common to have also a damage of the outer screen,
resulting in a return of the surge current via the earth to the station earthing
point. At the fault location as well as at the station earthing points hazardous
potentials are possible.
Since the Surgeflex 8-1000 is directly connected to the station earth, it is
possible to have dangerous contact voltages, if the earth transit resistance of
the station earth exceeds more than 2 Ω.
With the transit resistance being lower than 2 Ω, a danger to the operator by
a too high voltage over time ratio becomes relatively unlikely.
Is the location of the directly on top of the fault, the danger increases
excessively due to high and dangerous voltage potentials.
Safety measures:
1. Surgeflex 8-1000 may only be connected to earth points whose
resistance is lower than 2 Ω.
2. Surgeflex 8-1000 shall not be placed on the trace of the faulty cable.

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3.5 Circuit breaker (optional)
The mains circuit of the Surgeflex 8-1000 is secured against overcurrent by a
circuit breaker (optional). If the system suddenly switches off or cannot be
switched on despite an existing mains connection, it should be checked
whether the breaker has been tripped.
The system can be restarted after the the breaker switch has been pushed in
again.
If the circuit breaker cannot be switched on again or continues to trip, please
get in touch with the Megger service department in order to have the fault
resolved.

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4. Processing of the measurements
The setup of the test set must be done in accordance with the regulations
described in topic 3.
4.1 Measurements with the base system Surgeflex 8-1000
4.1.1 Testing and Burning
With the Surge Unit you are able to test and burn for 2 min.
For the testing and burning the reflectometer is not required.
Test Setup:
The Surge Unit 2/4/8 kV should be set-up in accordance with the associated
operating manual and a test or a burning process should be initiated.
Surge Unit
2/4/8 kV
Reflectometer
ARM Unit 8 kV
HV out
ARM out
230 V, 50/60 Hz

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4.1.2 Pulse reflection measurement
You need only the reflectometer for the reflection measurement.
Test Setup:
Operational steps:
−Start up the reflectometer according to the instructions of the associated
operating manual and carry out a pulse reflection measurement.
Surge Unit
2/4/8 kV Reflectometer
IN1 / Signal IN2
ARM Unit 8 kV
HV out
ARM out
230 V, 50/60 Hz

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4.1.3. Surge Prelocation (ICE)
Test Setup:
Operational steps:
−Start up the reflectometer according to the instructions of the associated
operating manual and prepare for recording the current curve in operating
mode ICE.
−Start up the Surge Unit 2/4/8 kV according to the instructions of the
associated operating manual and trigger a single shot.
−Determine the fault distance on the reflectometer.
ATTENTION
For the Surge Prelocation (ICE) you have to use only the „HV
out“ output.
It is forbidden to use the „ ARM out“ output.
Surge Unit
2/4/8 kV Reflectometer
U/I / ICE
ARM Unit 8 kV
HV out
ARM out
230 V, 50/60 Hz