Megger 128311841 User manual

HV Tester 25 kV
128311841
Operating Manual

3
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, 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.

4
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.
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.
To register a claim under the provisions of this warranty, the customer has to
complain about the defect, in case of an immediately detectable fault within 10
days from the date of delivery.
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.

Operating Manual
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HV Tester 25 kV
Table of content
1GENERAL 1
1.1 Safety instructions 1
1.2 INDICATIONS USED IN THE DESCRIPTION 2
2TECHNICAL DESCRIPTION 3
2.1 Description of the set 3
2.1.1 Scope of supply 3
2.1.2 Use of the set 3
2.2 Design of the set 4
2.3 Function 4
2.4 Specifications 5
3PREPARATION FOR USE 7
3.1 Operating requirements 7
3.2 Power supply 7
3.2.1 Internal rechargeable battery 7
3.2.2 Mains 8
3.2.3 External battery 8
3.2.4 Maintenance procedure (internal battery) 8
3.3 Connecting the test equipment 9
4OPERATING INSTRUCTIONS 11
4.1 Controls and displays 11
4.2 OPERATING PROCEDURE 12
4.2.1 Performing measurements 12
4.2.2 Ending testing 13
4.2.3 Safety measures 13
5CARE, MAINTENANCE AND REPAIR 15

Operating Manual
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HV Tester 25 kV
Table of Figures:
Figure 1 HV Tester 25 kV 4
Figure 2 HV Tester 25 kV 9
Figure 3 Example for connecting HV Tester 25 kV 10
Figure 4 Front of the HV Tester 25 kV 11

Operating Manual
1
HV Tester 25 kV
1 GENERAL
The HV Tester is a generator of high direct voltages.
The insulation of cables, electrical plant and plant components can be
tested for electric strength with this set. The insulation resistance of
test objects can be determined by measuring current and voltage using
integrated measuring instruments.
Thanks to its small size and low weight, the HV Tester is portable and
can be used directly on site. The clear arrangement of controls and
displays makes the set comfortable to handle.
The set has an integrated rechargeable battery.
A special protective ground circuit ensures a high level of safety.
1.1 Safety instructions
All persons involved in the transport, installation, operation,
maintenance and repair of this system must have read this user manual
carefully.
The system and its accessories are in accordance with the current state
of safety technology at the time of delivery. Owing to the work
processes involved, however, there may be parts of the system and its
peripherals, which cannot be given optimum protection without an
unreasonable reduction in function and usability.
The following safety instructions must be complied with.
GENERAL INSTRUCTIONS
Work on this system and its peripherals must only be performed by
qualified and/or trained staff. Other persons must be kept away.
This user manual must be available for the supervisory, operating and
maintenance staff to refer to.
Improper use may endanger life and limb, the system and connected
equipment, as well as the efficient functioning of the system.
Always use correct tools in perfect condition.
Checks must be made to ensure that the relevant safety regulations are
being complied with.
Only operate the system if it is in technically perfect condition.
No non-original parts may be used for the system and its peripherals,
as the necessary safety will not be guaranteed. No mode of working,
which detracts from the safety of the system must be used.
The user is under an obligation to report any changes in the system to
the supervisor responsible without delay.

Operating Manual
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HV Tester 25 kV
ELECTROTECHNICAL INSTRUCTIONS
The system and all additional equipment must be connected properly.
The relevant DIN and VDE regulations must be complied with.
Maintenance work must only be carried out when the system is
switched off (dead) and then only by qualified and/or trained staff.
1.2 INDICATIONS USED IN THE DESCRIPTION
Important instructions concerning personal protection, work safety and
technical safety are indicated as follows:
WARNING: Warning indicates work and operating procedures,
which must be complied with in full to exclude the
possibility of persons being put at risk. This includes
instructions concerning particular dangers when
handling the system.
ATTENTION: Attention indicates work and operating procedures,
which must be complied with in full to prevent the
system/peripherals from being damaged or destroyed.
N.B.: N.B. indicates special technical requirements to which
the user must pay particular attention when using the
system.

Operating Manual
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HV Tester 25 kV
2 TECHNICAL DESCRIPTION
2.1 Description of the set
2.1.1 Scope of supply
The scope of supply includes the following:
Item
Description
00001
HV Tester 25 kV with built in
batteries and softcase
00002
Mains connecting cable
00003
Connecting cable for external
battery
00004
Protective ground cable
(green/yellow)
00005
Operation ground cable (black)
00006
HV- connecting cable
(shielded) incl. clamp
00007
User manual /Service pack
00008
Packing
Table 1 Scope of supply
2.1.2 Use of the set
The HV Tester 25 kV is used for electrical testing of power cables and
plant with direct voltage:
Areas of application include:
Reclosing control after repairs and work on power cables, etc.
Testing newly laid cables before initial use
Testing disconnected cables
Testing electrical equipment
CAUTION: Owing to the high voltages, which occur, special safety
measures are required. These are explained in chapter 1.1on page 1.

Operating Manual
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HV Tester 25 kV
2.2 Design of the set
The compact HV Tester 25 kV is very portable thanks to its small size
and low weight and can be used directly on-site. State-of-the-art
technique and clearly designed operation panel for easy application.
The control and display elements as well as the high-voltage outlet are
arranged on the control panel.
A timer is provided for pre-selecting the testing time.
Figure 1 HV Tester 25 kV
2.3 Function
Before the set can be used, the HV Tester 25 kV has to be grounded
properly.
When the high-voltage adjuster is set to zero and the timer works, the
test voltage can be switched on at the press of a button and increased
continuously between 0 V and the nominal voltage.
The condition of the test object with regard to electric strength and
insulation quality can be determined from the values for test voltage and
leakage current displayed on the operation unit.
After testing, the object under test is discharged through the built-in
discharging facility.

Operating Manual
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HV Tester 25 kV
2.4 Specifications
Power supply mains 115 or 230 V AC
built-in rechargeable batteries
external DC voltage 11-15 V
Power consumption 120 W max
DC output voltage 0...25 kV
(negative polarity,
infinitely variable)
Output current 1.5 mA
Short-circuit current 1.6 mA ±0.1 mA
Voltage measuring range 0 - 30 kV
Current measuring range 0 – 0.2 mA and 0 - 2 mA
Discharge energy 3000 J max.
Operating time at full load
with built-in batteries approx. 45 min
Operating temperature -25°C to + 55 °C
Output short circuit and open circuit proof
Weight incl. batteries approx. 13.5 kg
Dimensions (W x H x D) 467 mm x 167 mm x 284 mm

Operating Manual
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HV Tester 25 kV

Operating Manual
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HV Tester 25 kV
3 PREPARATION FOR USE
3.1 Operating requirements
The carrying handle of HV Tester 25 kV can be adjusted by exerting
gentle sideways pressure on the buttons on either side in the joint area.
WARNING: The clearance between the high-voltage unit and
grounded or live parts as stipulated in DIN VDE 0104 must
be complied with.
CAUTION: Warning notices reading
DANGER!
HIGH - VOLTAGE
When the equipment is set up in the field, it must be placed outside the
cable trench and protected against dirt and moisture.
The HV Tester should be set up inside the cordon at a distance of
approx. 3 m from the high-voltage, preferably at operating height.
3.2 Power supply
3.2.1 Internal rechargeable battery
The set has an integrated rechargeable battery. This supplies power
when the "Mains" key switch is actuated.
The mains and external battery, if connected, take precedence,
however, and cause the internal battery to be switched off.
If the voltage is to low, the colour of the LED [13] p. 11 changes from
green to red. The high voltage will then be switched off after
approximately 10 minutes.

Operating Manual
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HV Tester 25 kV
3.2.2 Mains
If the set is connected to the mains, the external DC voltage and
internal battery are switched off (signalled by the green LED [11] p. 11).
Mains operation is accompanied by recharging / floating operation of
the internal battery.
The set is switched on with the "Mains" key switch, which is signalled by
the white standby indicator [4] p. 11.
The HV Tester 25 kV has a monitoring circuit which switches the high
voltage off if the voltage is to low.
The set remains connected to the mains even once the "Mains" key
switch has been turned off, allowing recharging / floating operation of
the internal battery.
CAUTION: Take care of the voltage selector switch [1], p. 9!
3.2.3 External battery
The external DC voltage must be in the 11-15 V range. This is indicated
by the green LED [12] p. 11. If the voltage is to low, the colour changes
to red. The high voltage will then be switched off after approximately
10 minutes.
3.2.4 Maintenance procedure (internal battery)
To charge the internal battery connect the mains supply to the HV
Tester (LED [11] p.11 lights up).
The 'Mains' key switch doesn't have to be switched on.
It takes approx. 10 hours to fully charge the internal battery from low
battery level.
The current is changed automatically between recharging / floating
operation of the internal rechargeable battery.

Operating Manual
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HV Tester 25 kV
3.3 Connecting the test equipment
The connecting cable is in the front of the carrying case.
1 2 3
7 6 5 4
1 Voltage selector
2 Power supply
3 Fuse (1.25 A slow for 115 V and 230 V)
4 Connector for external battery
5 Station ground
6 HV connector
7 Protective conductor terminal
Figure 2 HV Tester 25 kV

Operating Manual
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HV Tester 25 kV
Before the test equipment is connected, safe isolation from supply must
be established and safeguarded in accordance with DIN VDE 0105.
The requirements of DIN VDE 0104 and DIN VDE 0105 must be
complied with. The test equipment should be connected in the following
order:
1. Ground and short-circuit the conductor of the test object that is not
going to be tested (connect to station ground or auxiliary ground
point). In the case of ungrounded test objects, the tester can only
be used if an auxiliary ground is provided.
2. Establish a conductive connection between the station/auxiliary
ground and the ground terminal [5] of the HV Tester 25 kV.
3. In the case of mains operation the ground safety circuit checks
whether the protective ground (protective conductor terminal [7])
and station ground have the same potential. The yellow lamp
indicates that the potential is the same. If the lamp does not light
up, the potential of the station ground must be checked and a
connection established between the protective ground terminal
and the station ground. The housing of the HV Tester has the
same potential as the protective ground terminal.
4. In the case of internal or external batteries establish a
conductive connection between the protective conductor terminal
[7] and station ground.
5. Connect the high-voltage terminal [6] to the test object.
power supply
operational ground protective ground
Figure 3 Example for connecting HV Tester 25 kV

Operating Manual
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HV Tester 25 kV
4 OPERATING INSTRUCTIONS
4.1 Controls and displays
The controls and displays needed to operate the HV Tester are on the
front of the operation unit.
1 2 3 4
13 12 11 10 9
Figure 4 Front of the HV Tester 25 kV
The following tables explain the controls:
Item
Description
Remarks
1
Ammeter
Displays the current flowing through the
test object
2
Voltmeter
Displays the voltage connected to the
test object
3
HV adjuster
Adjuster for the high-voltage with forced
zero position
4
"Unit on" lamp
Lights up white when the unit is
switched on with the mains switch [8]
5
"Ground
terminal" lamp
Lights up yellow when the HV Tester is
grounded properly
6
Illuminated
"HV on" button
Green lit button for switching on the high
voltage
7
Illuminated
"HV off" button
Illuminated button for switching off the
high voltage (lights up when the high-
voltage is switched on)
8
Mains key switch
9
Timer
10
"Current
measuring range"
selector switch
Switches between the current
measuring ranges or 'AUTO'
11-13
LED's
for Power supply, internal batteries and
external batteries
Table 2 Controls and displays (part 2)
5
6
7
8

Operating Manual
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HV Tester 25 kV
4.2 OPERATING PROCEDURE
4.2.1 Performing measurements
When the mains key switch is turned on, the white pilot lamp (Figure 4
p. 11 [4]) lights up. If the equipment is grounded properly, the yellow
pilot lamp also lights up.
If this does not happen, the HV Tester still has to be grounded
(protective conductor terminal).
This pilot lamp [5] signals proper connection of the station and
protective grounds independently of the high voltage being connected.
The equipment will only work when both lamps are lit and the timer is in
action.
The illuminated green "HV on" [6] button switches the high voltage on
if the HV adjuster [3] in zero position at left stop (second switching
operation, interlock, forced zero position).
Tip: If you want to select testing times shorter than 5 min, turn the
rotary knob of the timer first beyond the position "5" and then to
the desired time.
The red illuminated "HV off" [7] button lights up at the same time,
indicating that the "high voltage is switched on".
The test voltage can now be set by slowly turning the adjuster
anticlockwise. While doing this, remember to follow the increase in
voltage and current on the instruments.
The output current can be measured in two measuring ranges (0.2 mA,
2 mA), which can be set using a selector switch [10].
In the central switch position (Auto), the measuring range is changed
automatically.
The relevant LED indicates the selected measuring range.
N.B.: The end stage of the HV Tester is secured against thermal
overload by a reverse voltage divider. In case of overload (e.g.,
short-circuit at the output), the output current is reduced to a
value of about 0,5 mA.

Operating Manual
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HV Tester 25 kV
4.2.2 Ending testing
Once testing is complete, turn the voltage down and switch the
equipment off ("HV off" Figure 4 p. 11 [7]).
When the test time expires, the high voltage is switched off
automatically by the timer and the discharge device is activated. The
discharge process of the test object can be followed on the measuring
instrument.
ATTENTION: After four discharge processes at a maximum, a
break of about 30 minutes shall be taken.
Once the displayed high-voltage reading has dropped to 0, the test
object can be grounded and the HV Tester disconnected.
Finally ground/short-circuit the test object yourself.
WARNING: The high-voltage connector must not be plugged in /
unplugged when live.
In an emergency, the high voltage must be switched off by a second
operator pressing the red "HV off" button.
4.2.3 Safety measures
The set must only be operated by electricians in accordance with DIN
VDE 1005. It must only be operated in areas, which have been secured
and/or cordoned off and marked in accordance with DIN VDE 0104 and
DIN VDE 0105.
In an emergency, the high voltage must be switched off and grounded
by a second operator pressing the red "HV off" button.
N.B.: Never put equipment with moisture condensation into
operation.
Please also follow the safety instructions in chapter 1.
Reliable grounding of the HV Tester is always necessary in addition to
adequate protection against electric shock.
CAUTION: Care must be taken during testing that the far end is
also reliably protected against electric shock.
Be aware that residual charges may still be present after discharge in
the case of capacitive tests.
WARNING: Parallel cables may also still be charged after testing.

Operating Manual
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HV Tester 25 kV