Megger Surgeflex 15 User manual

INSTRUCTION MANUAL
Portable Fault Locating System
Surgeflex 15 / Surgeflex 25
Issue: 2 (09/2014) – EN
128312416

2
INTENDED APPLICATION
The SFX 15/25 Fault Locating System is intended to be used for locating faults on primary
power cables. It must be operated by trained and certified Power Utility personnel in
accordance with all applicable federal, state, local and company regulations and safety
standards, including, but not limited to all standards describing the proper handling of High
Voltage.
WARRANTY
Products supplied by Megger are warranted against defects in material and workmanship for
a period of one year from the date of shipment. Megger will, at its option, repair or replace
any product, which proves to be defective during the warranty period, if it is returned to
Megger. Repairs necessitated by using the product for any but the intended application are
not covered by this warranty. Any repairs or modifications to a product must be performed
by Megger or an authorized serving agent, using original Megger spare parts only.
NO OTHER WARRANTIES ARE EXPRESSED OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE. MEGGER IS NOT LIABLE FOR CONSEQUENTIAL
DAMAGES.
Technical SUPPORT & ASSISTANCE
For assistance, contact your local Rep or
Megger
Service department
Dr. Herbert Iann Str. 6
Baunach, Germany
Tel: [phone])
Fax: [phone])
e-mail: [e-mail]
INITIAL INSPECTION
Megger products are carefully inspected and tested before shipping. Upon receipt, the
equipment should be checked against the packing list for any shortages and visually
inspected for damages. Immediately notify the carrier and Megger of any shipping damage.
Save all packing materials, which will be needed if a damage claim is filed.

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1.0 INTRODUCTION
Today’s state of the art URD fault locating method comprises four steps, which, when
implemented and followed correctly, provide for a safe and restoration time sensitive
process that also will eliminate or minimize any additional damage to the cable.
The four-step procedure will be applicable in the vast majority of typical URD faults:
- trace (locate) cable
- assess type of fault using an insulation tester
- prelocate fault, e.g. with the Arc Reflection Method (ARM)
- pinpoint exact location

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2.0 INTEGRATED SFX SERIES FAULT LOCATING SYSTEM
The SFX Series models locate efficiently high and low resistance as well as intermittent
cable faults on primary and, under certain circumstances, secondary power cables. Due to a
sequential safety interlock system it is not possible to inadvertently apply high voltage to the
cable under test.
The SFX Series models combine three modes of operation, with a maximum voltage of
either 15 or 25 kV in each mode (complete specifications for each model are listed in the
appendix):
- Arc Reflection Mode, ARM in combination with internally integrated filter
- Direct Thump Mode
- DC Highpot Mode (optional leakage current measurement)
The SFX Series Models use an electronically controlled feed back circuit to control the
voltage at the high voltage discharge contact, which is solenoid operated. This design
ensures optimum energy transfer from the impulse capacitor into the faulty cable. The surge
generator (SG 15/25) is under normal use maintenance free for many years.
The SFX Series Models automatically discharge the cable under test and their own internal
capacitor(s)
- when the power to the unit is turned off
- when "High Voltage" in any of the operating modes is switched off
- when the HV switch is pulled in order to change the mode of operation
The SFX Series Models contain a built-in ARM filter, which is essential in the application of
the Arc Reflection Method for fault locating. The filter isolates and protects the TDR from the
high voltage pulse produced by the surge generator and couples the low voltage, high
frequency TDR pulse onto the energized cable.
The TDR detects “opens” (cable end or fault) and “shorts”, cable splices and transformers
as well as any change in impedance in the cable under test. High resistance phase to
ground faults, also referred to as “pinhole faults” (typically higher than 200 ohms) do not
produce a detectable reflection on a TDR. By using the thumper in combination with the
TDR it is possible to detect this type of fault. The flashover, which is generated by the
thumper, converts the high resistance fault temporarily into a low resistance fault (several
Ohms), which can be detected by the TDR. The distance between the cable hook-up (start
marker) and the fault location (end marker) is displayed on the TDR screen.

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3.0 GENERAL SET UP INSTRUCTIONS
3.1 IMPORTANT NOTES
!!! WARNING !!!
DO NOT TEST-FIRE THE SFX SERIES FAULT LOCATING SYSTEM BEFORE PROPER
TEST SETUP. DANGER TO OPERATOR AND DAMAGE TO THE EQUIPMENT MAY
RESULT. TEST FIRING OF THE SFX SERIES FAULT LOCATING SYSTEM WILL VOID
WARRANTY.
ALWAYS operate the SFX Series Fault Locating System in a VERTICAL position.
Grounding and HV contacts both require a vertical orientation to ensure proper functioning
as well as a “Fail Safe Position” in case of an AC or DC power failure or if the unit is shut off.
In order to disconnect the SFX Series Fault Locating System from mains, unplug the power
outlet before you disconnect the mains cable from the device.
!!! SAFETY !!!
BEFORE CONNECTING THE SFX SERIES FAULT LOCATING SYSTEM TO THE CABLE
TO BE TESTED, BE SURE THAT THE CABLE HAS BEEN ISOLATED, TESTED AND
GROUNDED AT BOTH ENDS IN COMPLIANCE WITH ALL OSHA & COMPANY
PROCEDURES. ALWAYS LOCATE FAULT LOCATING SYSTEM OFF TO THE SIDE OF
THE CABLE PATH, NEVER ON TOP OF CABLE PATH !!
Fife 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.
Ventilation
The surge operation creates ozon. It is necessary to operate the instrument
under well ventilated condition to keep ozon levels below limit values for the
operator.

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3.2 POWER OPTIONS & FRONT PANEL LAYOUT
Fig.2 Typical SFX SERIES Configuration (Fully Self Contained System)
NOTE: Battery Charging Jack is on Rear Side of Instrument Enclosure!
FIG. 3 Front Panel Layout of the surge generator SG 15/25
1. unit can be operated from internal battery
(battery sufficient for a full day of typical URD
fault locating activities)
2. unit can be operated from an AC source
(115VAC / 3A, cable included with equipment,
only source for remote controlled truck mount
models)
HI DC HIPOT /
TIMER
MODE SWITCH
(PULL-TURN- PUSH)
"RADAR/ ARM"
"DIRECT THUMP/ HIPOT"
HV RANGE SWITCH, M
MODEL ONLY (PULL-TURN-
PUSH)
SINGLE SHOT BUTTON
(ARM MODE ONLY)
1. HV VOLTMETER (kV)
2. GREEN RANGE
BATTERY CHARGE OK
LEAKAGE CURRENT
METER
µ
A
(OPTIONAL)
CONTROLLER POWER
ON/OFF
GREEN "HV ON"
BUTTON
RED "HV OFF" BUTTON
3 CIRCUIT BREAKERS
"TDR" "CONTROL"
"ACCESSORY"
VOLTAGE CONTROL KNOB
BATTERY TEST BUTTON
POWER SWITCH
- DC OPERATION
- 115 VAC OPERATION
115 VAC AUXILLIARY OUTLET
115 VAC EXTERNAL POWER

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4. CONNECTING THE SFX SERIES UNIT
Connect the safety ground lead from the SFX Series unit (flexible copper braid) to a good
system ground, preferably the ground rod in the pad mount or at the base of the riser pole.
This grounding technique is called “single-point grounding”. Due to changing ground
conditions, locally driven grounds (in addition to the system ground) are no safe substitute
for single-point grounding and should not be permissible in place of properly installed
system grounds.
Connect the HV return lead to the cable sheath or concentric of the specific cable to be
tested. The resistance between the HV return (operational ground) and system ground
(safety ground) should be less than 5 ohms (Ohm meter check).
If the resistance is greater than 5 ohms, an additional ground cable should be
connected from the concentric directly to the system ground rod.
Connect the HV test lead to the phase conductor to be tested (optional elbow adapter or
vice grip).

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5. OPERATING THE SFX SERIES FAULT LOCATING SYSTEM
5.1 PRELOCATION PROCEDURE WITH TDR (ARM MODE)
After locating the cable path the SFX Series Fault Locating System is set up to the
side of it. After opening the front door the power switch on the front panel is put in
the "Battery Operation" position. The TDR is set up on top of the system. The 115
VAC power cable and the 2 coax cables are securely connected to the rear side of
the TDR.
For detailed information on the electrical connection between the TDR and
the surge generator SG 15/25, please refer to the operating manual of the
TDR.
1
Before making any connections make sure to observe the five safety rules
(see page 5).
2
Take the safety ground cable and make the connection to station ground.
3
Connect the High Voltage Output cable to the cable under test.
Connect the HV Return lead to the concentric neutral.
4
Put the System Mode Switch (upper) in the "RADAR/ARM" position (- PULL -
TURN - PUSH -).
5
Use the switch on the lower front panel to choose between battery and power
supply operation.
6
Push "CONTROLLER ON" button (upper control panel). Light will come on.
7
Put the voltage control knob fully counter-clockwise
8
Remove all grounding elbows or grounding jumpers
9
Use the TDR to record a reference trace and make the necessary
adjustments (gain, range, v/2) required for best representation of the trace.
Prepare the TDR for fault trace recording.
For detailed instructions on how to operate the TDR, please refer to
the operating manual of the TDR.
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Make sure everyone is in the clear!
11 Put lower HV switch on system in the required position
(- PULL - TURN - PUSH -). Best suited position depends on the voltage
required to ignite an arc at the fault location:
SFX 15:
<7.5 kV -> set range to 0 – 7.5 kV
>7.5 kV -> set range to 0 – 15 kV
SFX 25:
<12.5 kV -> set range to 0 – 12.5 kV
>12.5 kV -> set range to 0 – 25 kV
12
Push the green “HV ON" button on the front panel (red button will light up).
13
Use "Voltage" control knob to adjust the surge voltage (indictaed on the
voltmeter).
14
Push "SINGLE SHOT" button to trigger a shot.

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15
If no voltage flash-over took place, increase the surge voltage and trigger
another shot.
16
Push the red "HV OFF" button
17
Try to determine the fault distance by means of the two traces.
For detailed instructions on how to operate the TDR, please refer to
the operating manual of the TDR.
18
Pinpoint the fault (see next section).

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5.2 PINPOINTING PROCEDURE
After locating the cable path the SFX Series Fault Locating System is set up to the
side of it. After opening the front door the power switch on the front panel is put in
the "Battery Operation" position.
1 Before making any connections make sure the cable under test is de-
energized and grounded and system is off.
2
Take the safety ground cable and make the connection to the system ground.
3
Connect the High Voltage Output cable to the cable under test.
Connect the HV Return lead to the concentric neutral.
4
Put the System Mode Switch (upper) in the "DIRECT THUMP" position
(- PULL - TURN - PUSH -).
5 Use the switch on the lower front panel to choose between battery and power
supply operation.
6
Push "CONTROLLER ON" button (upper control panel). Light will come on.
7
Turn the voltage control knob fully counter-clockwise.
8
Remove all grounding elbows or grounding jumpers.
9
Put the "HIPOT / TIME" knob to the "6 SEC" position.
10
Make sure everyone is in the clear!
11
Put lower HV switch on system in the required position
(- PULL - TURN - PUSH -). Best suited position depends on the voltage
required to ignite an arc at the fault location:
SFX 15:
<7.5 kV -> set range to 0 – 7.5 kV
>7.5 kV -> set range to 0 – 15 kV
SFX 25:
<12.5 kV -> set range to 0 – 12.5 kV
>12.5 kV -> set range to 0 – 25 kV
12
Push the green “HV ON" button on the front panel (red button will light up).
Thumper starts cycling.
13 Adjust the "Voltage Control Knob" to bring up the required kV on the
voltmeter (each cycle should "SNAP" and the voltmeter should drop to almost
zero).
14
Pinpoint the fault using the Digiphone.
15
After pinpointing fault turn "Voltage Control Knob" fully counter-clockwise and
push red "HV OFF" button.
16
Cable under test is now discharged and grounded by system.

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5.3 LEAKAGE CURRENT MEASUREMENT (OPTIONAL)
IN CONJUNCTION WITH HIPOT TEST
The SFX Series Fault Locating System can be optionally equipped with a leakage
current meter. A digital Milli Amp meter with a LED backlight is installed right below
the voltmeter in the top panel of the system.
The current meter is active when the mode switch is switched to "DC HIPOT" and to
the higher of the two voltage ranges (‘0 - 15 kV’ or ‘0 - 25 kV’ respectively). Only in
the higher voltage range will the circuitry compensate for the leakage resulting from
the internal bleeding resistors, which are connected across the capacitors (safety
provision).
The meter has a resolution of 10 µA and a full range of 2 mA. If during the test the
DC voltage is lowered the meter will read negative till a steady state has been
reestablished.

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6.0 MAINTENANCE
The SFX Series system will need very little maintenance under normal operating
conditions. If not in use the system should be stored in an if possible dust free and
dry environment. Humidity (condensation) by itself or in combination with dust can
reduce critical distances within the equipment, which are necessary to maintain safe
high voltage performance.

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Appendix
Technical Specifications
THREE MODES OF OPERATION
0-15/0-25 kV ARC Reflection Mode (prelocate)
•0-15/0-25 kV DC Hipot
(current measurement optional)
•0-15/0-25kV Continuous thumping at 4-12
second intervals for pinpointing
•0-15/0-25 kV Surge Pulse Mode (optional)
(special prelocating method)
INTEGRATED FILTER SUPPORTS
•ARC Reflection Mode
•Surge Pulse Mode (optional)
THUMP (SURGE) ENERGY
1150 Joules
THUMP (SURGE) VOLTAGE
Adjustable from 0-7.5/ 0-15KV
Adjustable from 0-12.5/0-25kV
THUMP (SURGE) RATE
Adjustable between 4-12 seconds
(1150 Joules every 7 seconds)
DC HIPOT TEST
0-15 kV DC
0-25 kV DC
SUPPLY VOLTAGE
90 - 120 V 50/60 Hz (230V optional)
INPUT POWER
max. 700 VA
Fuse: 230 V slow blow 4 A / 250 V
117 V slow blow 4 A / 250 V
OPERATING TEMPERATURE:
-20 C to +40 C
GROUNDING CONNECTION / CABLE
Heavy duty brass stud / 50 ft of # 2 braided
copper wire with clear jacket
HV OUTPUT CABLE
50 ft of 50 kV output cable hardwired, male
MC connector at the cable end
POWER OUTLET, ACCESSORIES
115 VAC, for TDR or accessories (100 W)
Fuse: slow blow 4 A /250 V
BATTERY (optional):
Deep Cycle Marine Gel Cell Battery (built-in
inverter converts 12V battery power to 115
VAC (230 V optional) to operate the unit, TDR
and light duty accessories)
Fuse: 2x BUSS MDL 20 A
WEIGHT Approximately 240 lbs incl. TDR

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SPECIFICATIONS OF TIME DOMAIN REFLECTOMETER
For the specifications of the TDR, please refer to the respective operating manual.