Megger BT 500-IS-1 User manual

Operating Manual
Cable Fault Burn-Down
Instrument
BT 500-IS-1
Issue: 03 (11/2017) – EN
128311400

Operating Manual BT 500-IS-1
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: uks[email protected]
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.

Operating Manual BT 500-IS-1
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 BT 500-IS-1
I
Table of Contents
1General Safety Instructions........................................................................... 1
1.1 General Notes .................................................................................................. 1
1.2 General Safety Instructions and Warnings....................................................... 3
2Description...................................................................................................... 6
2.1 General Introduction......................................................................................... 6
2.2 Functions.......................................................................................................... 8
2.3 Power Supply ................................................................................................... 8
2.4 Technical Specification..................................................................................... 9
2.5 Items Supplied................................................................................................ 10
2.6 Special Accessory Equipment........................................................................ 10
2.7 Front View ...................................................................................................... 11
3Safety Precautions ....................................................................................... 12
3.1 Rotary Key Switch [ 11 ] ................................................................................. 12
3.2 Operation Standby ......................................................................................... 12
3.3 Switching-On Standby.................................................................................... 12
3.4 Mains Standby................................................................................................ 13
3.5 Emergency-Off Switch.................................................................................... 13
3.6 Earth Connection (Protective Measures)........................................................ 14
3.7 Temperature Monitoring ................................................................................. 14
4Getting Started and Operation .................................................................... 15
4.1 Burning Down................................................................................................. 15
4.1.1 Preparation of Burning-Down ......................................................................... 17
4.1.2 Burning-Down................................................................................................. 18
4.1.3 Power Diagram of Fault Location ................................................................... 18
4.2 Sheath Fault Postlocation .............................................................................. 20
4.3 Sheath Fault Prelocation in Conjunction with MVG 5..................................... 21
4.4 Voltage Testing .............................................................................................. 23
4.4.1 Preparation of Voltage testing ........................................................................ 24
4.4.2 Voltage Testing .............................................................................................. 24
4.5 Switching Off .................................................................................................. 25
5Customer Service......................................................................................... 26

Operating Manual BT 500-IS-1
II
List of figures
Figure 1 : View of the BT 500-IS-1.....................................................6
Figure 2 : Type label 230 Volt version vs. 115 Volt version..............6
Figure 3 : Front View of BT 500-IS-1................................................11
Figure 4 : How to Connect the BT 500-IS-1 for Burning Down,
Mode Wire / Wire .............................................................15
Figure 5 : Power Diagram of Fault Location.....................................19
Figure 6 : Principle of Sheath Fault Postlocation .............................20
Figure 7 : Schematic Diagram of Sheath Fault Prelocation Using
MVG 5 and BT 500-IS-1 ..................................................21
Figure 8 : How to Connect the BT 500-IS-1 for Sheath Testing .......23

Operating Manual BT 500-IS-1
1
1 General Safety Instructions
1.1 General Notes
Safety precautions
This manual contains basic instructions for the
commissioning and operation of the device / system. For this
reason, it is important to ensure that the manual is always
available to the authorised and trained operator. He needs to
read the manual thoroughly. The manufacturer is not liable
for damage to material or humans due to non-observance of
the instructions and safety advices provided by this manual.
Locally applying regulations have to be observed!
Labelling of safety instructions
The following symbols are used on the product:
Symbol
Description
Serves to highlight warnings and safety
instructions.
As a warning label on the product it is used to
draw attention to potential hazards which have to
be avoided by reading the manual.
Serves to highlight warnings and safety
instructions that explicitly indicate the risk of an
electric shock.
Serves as a warning indicating that the marked
item can be hot and should not be touched without
taking care.
Serves to request the user of the equipment to
carefully read the user manual and adhere to the
instructions.
Protective Ground. This symbol identifies the
terminal which is intended for connection to an
external conductor for protection against electrical
shock in case of a fault, or the terminal of a
protective earth (ground) electrode.

Operating Manual BT 500-IS-1
2
Working with products from Megger
It is important to observe the generally applicable electrical
regulations of the country in which the device will be installed
and operated, as well as the current national accident
prevention regulations and internal company directives (work,
operating and safety regulations).
After working on the system, it must be voltage-free and
secured against reconnection as well as having been
discharged, earthed and short-circuited.
Use genuine accessories to ensure system safety and
reliable operation. The use of other parts is not permitted and
invalidates the warranty.
Operating staff
In its normal operation, the Cable Fault Burn-Down
Instrument BT 500-IS-1 generates a voltage >1 kV which is
dangerous to touch. The system may only be installed and
operated by an authorized electrician. An electrician is
defined as someone whose knowledge, experience and
familiarity with the applicable regulations enable him to
recognize potential hazards.
Anyone else must be kept away!
Declaration of Conformity (CE)
The product meets the following security requirements of the
European Council Directives:
•EMC Directive (2014/30/EC)
•Low Voltage Directive (2014/35/EC)
•RoHS Directive (2011/65/EU)

Operating Manual BT 500-IS-1
3
1.2 General Safety Instructions and Warnings
Intended application
The operating safety is only guaranteed if the delivered
system is used as intended. Incorrect use may result in
danger to the operator, to the system and the connected
equipment.
The thresholds listed in the technical data may not be
exceeded under any circumstances.
Behaviour at malfunction of normal operation
The equipment may only be used when working properly.
When irregularities or malfunctions appear that cannot be
solved consulting this manual, the equipment must
immediately be put out of operation and marked as not
functional. In this case inform the person in charge who
should inform the Megger service to resolve the problem. The
instrument may only be operated when the malfunction is
resolved.
Five safety rules
Always abide by the 5 rules of safety, in particular when
making or breaking connections:
The five safety rul
es must always be followed when working
with HV (High Voltage):
1. De-energize
2. Protect against re-energizing
3. Confirm absence of voltage
4. Earth and short-circuit
5. Cover up or bar-off neighboring energized parts
Using cardiac pacemaker
Physical processes duri
ng operation of high voltage
may endanger persons wearing a cardiac
pacemaker when near these high voltage facilities.

Operating Manual BT 500-IS-1
4
WARNING
Dangers when working with high voltage
Working on high voltage systems and equipment –
especially in non-stationary operation – requires
particular care and safety-conscious action on the
part of test personnel. VDE regulations 0104 on
setting up and operating electrical test systems, as
well as EN 50191 and national standards and
regulations must be strictly adhered to.
•The BT 500-IS-1 test system generates a
dangerous voltage of up to 2 kV DC.
•
The test system may not be operated without
supervision.
•Never fail to use safety equipment or put it
out of operation.
•To prevent dangerous charge accumulation,
earth all metal parts in the vicinity of the high
voltage equipment and the test object.
Observe all commonly applicable regulations regarding the
operation of devices which generate voltages that are
dangerous to touch (e.g. VDE and EN for Germany/Europe).
The user shall not position the equipment so that it is difficult
to operate it. Special attention shall be given to the safety-
relevant controls and functions.
The main power cord plug ultimately serves as the master
disconnect for the BT 500-IS-1 so must always remain
accessible and in case of a fault with the unit the plug should
be removed from the wall socket to de-energize the unit.

Operating Manual BT 500-IS-1
5
Non-Stationary Test Equipment
The site where the BT 500-IS-1 is put up and installed,
including the near end of the cable to be tested, is regarded
as a non-stationary test equipment (according to VDE
0104-10-89). It must be looked at as a test site without
forced protection against accidental contact. The same
applies to the end (or ends) of the connected test object.
High-Risk Area
Any test site without forced protection against accidental
contact must be sealed off, safeguarded and marked
accordingly, as it is regarded as a high-risk area with various
danger zones.

Operating Manual BT 500-IS-1
6
2 Description
2.1 General Introduction
Figure 1 : View of the BT 500-IS-1
Note: The BT 500-IS-1 is available for nominal mains supply
voltages of either 230 Vac or 115 Vac. The information
provided in the user documentation is valid for both versions
of the BT 500-IS-1 unless stated otherwise. In case of
differences, the text “230 Volt version” or “115 Volt version”
are used to differentiate. In case of doubt the version can be
determined by checking the supply voltage as provided on
the type label:
Figure 2 : Type label 230 Volt version vs. 115 Volt version

Operating Manual BT 500-IS-1
7
The Cable Fault Burn-Down Instrument BT 500-IS-1 is mainly
for converting (burning down) high-resistance cable faults in
signal, control and telecommunication cables.
Its voltage source is adjustable between 0 and 2 kV. It has a
balanced output, i. e. a faulty pair of wires can be connected
to its terminals in balanced (floating) circuit.
Optionally the instrument can be used in conjunction with
Sheath Fault Prelocating Device MVG 5 for prelocating
sheath faults. Sheath fault postlocation and line-to-earth fault
location can be carried out using the step voltage method by
combining the BT 500-IS-1 with an Earth Fault Locator (e.g.
ESG NT).
The BT 500-IS-1 may also be used for testing the withstand
voltage of telecommunication cables and cable sheaths
made of PVC or PE.

Operating Manual BT 500-IS-1
8
2.2 Functions
The output voltage of the device can be pre-set at ranges
500, 1000 and 2000 Volts (rotary switch [4]). Within the
preselected voltage range, voltage can be adjusted
continuously between approx. 0 Volt and the preselected full-
scale voltage by means of the rotary control [6]. There is yet
another rotary control for adjusting current between 10 % and
100 % of its maximum value.
The BT 500-IS-1 features voltage and current regulation to
prevent overload of the cable burn-down instrument at any
range. Whenever the cable fault suddenly turns into a short
circuit or shows low-resistance behavior, current is
automatically kept constant at the value preselected by
means of the rotary control. Voltage is also maintained,
however, so the ignited spark will not be interrupted. In this
manner burning-down can be carried out using a very small
current in order to reduce the risk of damage to adjoining
wires or cables as much as possible.
There are two analog meters for indicating output voltage
and output current.
When the instrument is switched off, a built-in automatic
discharge device drains residual charges and connects the
test object to earth.
2.3 Power Supply
The instrument is powered from the mains through the
supplied earthing-contact cable connected to socket [10].
Depending on the version of the instrument it accepts a
nominal mains voltage of 230 Vac or 115 Vac (50 or 60 Hz).
When the detachable-key switch [11] is switched from 0 to I,
the instrument changes over to the standby mode. Power
standby is signaled by the white LED [20].

Operating Manual BT 500-IS-1
9
2.4 Technical Specification
230 Volt version
115 Volt version
Installed load
700 VA
Mains connection
230 Vac (± 15%),
3 A, 50 Hz
115 Vac (± 15%),
6 A, 60 Hz
Maximum output current
1 A
Maximum output voltage
2 kV DC
DC output ranges
500 V / 1 A
1000 V / 0.5 A
2000 V / 0.25 A
Current regulator
switching controller 10 to 100%
Voltage regulator
switching controller 0.5 to 100%
Dimensions (H x W x D)
200 x 360 x 360 mm (without handles)
Weight
approx. 9 kg
Operating temperature
- 10° C .. + 50° C
Storage temperature
- 20° C .. + 60° C
Relative humidity
93% at 30 °C (non-condensing)
Integrated discharging
circuit
max. 600 J (max. 2 discharges / min)

Operating Manual BT 500-IS-1
10
2.5 Items Supplied
Cable Fault Burn-Down
Instrument
BT 500-IS-1
230 Volt version
BT 500-IS-1
115 Volt version
Cable set consisting of:
HV connect. lead 3.0 m
HSK 2-B
Tap-off clip black
AK 41-B
Tap-off clip red
AK 42-B
Earth lead
EK 7
Earth clip
AK 49-B
Mains lead
NKG 1
NKG 1-US
2.6 Special Accessory Equipment
230 Volt version 115 Volt version
Emergency-off switch NAG 1 for stand-
alone operation
(not available)
Emergency-off switch NAG 2 for operation
in conjunction with
MVG 5
(not available)
HV connection lead with
damping resistor
(stabilization of the arc for
conductors with a small
cross section)
BT 500-IS-1-DR

Operating Manual BT 500-IS-1
11
2.7 Front View
Figure 3 : Front View of BT 500-IS-1
1
Miniature fuse - replace blown
fuse by type as shown on the
front panel.
230 V version: M6,3 / 250C
115 V version: 10A/125V
Time-Delay (CSA/UL approved)
12
Emergency-Off socket
(not applicable for the 115 Volt
version)
2
Output socket
13
Lamp repeater – Indication of
dangerous contact voltage
3
Earth socket
14
Lamp repeater – Indication of
overtemperature
4
Rotary switch for voltage ranges
500 V, 1 kV, 2 kV
15
Lamp repeater – Switching-on
standby
5
Output voltage indicator
16
Push button HV – OFF
6
Rotary control for voltage
17
Push button Operation standby –
ON
7
Push-button switch for full-scale
sensitivities 10 µA or 1 mA
18
Push button HV – ON
8
Output current indicator
19
Push button Pulsed operation
9
Rotary control for current
20
Lamp repeater – Mains standby
10
Mains socket
21
Lamp repeater – Operation standby
11
Rotary key switch
22
Lamp repeater – Pulsed operation

Operating Manual BT 500-IS-1
12
3 Safety Precautions
3.1 Rotary Key Switch [ 11 ]
For reason of the European product liability and according to
VDE 104-10-89 pos. 3.9.4, the instrument must be protected
against any unauthorized start-up. To this effect, the BT 500-
IS-1 has on its front panel a rotary key switch [11] which
meets this requirement.
The instrument is at mains standby as soon as rotary switch
[11] is turned from 0 to I.
3.2 Operation Standby
Is indicated by the green lamp repeater [21]. The instrument
is switched on but does not generate any high voltage. Its
output is shorted and connected to earth.
3.3 Switching-On Standby
In line with safety standards (e.g. German VDE 0104-10-89
pos. 3.9.4.2.), two deliberate operations must be performed
to change over to switching-on standby. For the BT 500-IS-1,
the rotary control [6] must be turned down to zero (left stop!)
and the green push button [18] must be depressed. The red
lamp repeater [15] will light up and the green lamp repeater
[21] will go out. From now on the instrument must be
regarded as switched on. Any deliberate turning of the rotary
control [6] will generate high voltage.
If upon pressing the green push button [18] lamp repeater
[21] goes out without the red lamp repeater [15] lighting up,
this situation must also be regarded as: Switching-on
standby!! There is the risk of electric shock.
If the BT 500-IS-1 generates a DC voltage which is
dangerous to touch, the red LED [13] lights up.

Operating Manual BT 500-IS-1
13
3.4 Mains Standby
For enhancing safety, the BT 500-IS-1 is furthermore
equipped with another lamp repeater [20] the color of which
is white. This lamp indicates that the instrument is connected
to the mains. The instrument is not switched on, no auxiliary
circuits are activated.
3.5 Emergency-Off Switch
For the BT 500-IS-1, several emergency-off switches are
available as optional extras to be used depending on the
mode of operation. They can be connected to connector [12]
on the front panel of the instrument. This option is not
available for the 115 Volt version.

Operating Manual BT 500-IS-1
14
3.6 Earth Connection (Protective Measures)
Take the following protective measures or check them before
switching the instrument on:
Connection of earth socket [3] to earth (e. g. station
earth).
Use the supplied connecting lead with protective
contact.
Make end of connection lead and all ends of the test
object safe against any contact.
3.7 Temperature Monitoring
To protect the BT 500-IS-1 from being damaged due to
overheating, it is equipped with a temperature monitor. The
blue lamp repeater [14] will light up in case of
overtemperature and the instrument will shut down. After the
instrument has cooled down for a certain time period, the
instrument will return to mains standby.

Operating Manual BT 500-IS-1
15
4 Getting Started and Operation
When used as a stand-alone instrument, the BT 500-IS-1 can
be employed for burning down high-resistance faults as well
as for sheath testing and locating sheath faults on
telecommunication and power cables.
The BT 500-IS-1 can be used for sheath fault prelocation
only in conjunction with sheath fault prelocating instrument
MVG 5.
You may use your BT 500-IS-1 in horizontal or in vertical
position, as desired. The permissible on-time of the
instrument is 100 %.
The instrument changes over into mains standby as soon as
the key switch [11] is turned from 0 to I.
4.1 Burning Down
As a rule, the BT 500-IS-1 is connected to the test object in
floating circuit (wire – wire) for performing fault conversion
(burning down).
Both connecting terminals are floating, i. e. they are not
connected to the casing or protective terminal within the
instrument.
NKG 1
BT 500-IS-1
Figure 4 : How to Connect the BT 500-IS-1 for Burning Down, Mode
Wire / Wire