Megger HPG AC Series User manual

HPG XX-AC / HPG XX-H / HPG XX-D
High Voltage Test Sets
(Controlled by High Voltage Control Set HSW 3-2)
OPERATION MANUAL
Issue: A (11/2019) –EN
Artcle number: 128312070

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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, please contact:
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.
Megger Germany GmbH (Baunach) Megger Germany GmbH (Radeburg)
Dr.-Herbert-Iann-Str. 6
D - 96148 Baunach
Phone: +49 / 9544 / 68 – 0
Fax: +49 / 9544 / 22 73
Röderaue 41
D - 01471 Radeburg / Dresden
Phone: +49 / 35208 / 84 – 0
Fax: +49 / 35208 / 84 249
E-Mail: [e-mail]
http://www.sebakmt.com

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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.
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.

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Table of Contents
1Description.....................................................................................8
1.1 General............................................................................................8
1.2 Functions.........................................................................................8
1.3 High Voltage Test Configurations....................................................9
1.4 Technical Data ..............................................................................10
1.5 Scope of Delivery ..........................................................................11
2Operating Panel and Connection Panel ....................................12
3Test System Installations ...........................................................14
3.1 HPG XX-AC...................................................................................14
3.1.1 HPG 35-AC ...................................................................................15
3.1.2 HPG 58-AC ...................................................................................15
3.1.3 HPG 78-AC ...................................................................................15
3.2 HPG XX-H .....................................................................................16
3.2.1 HPG 50-H......................................................................................16
3.2.2 HPG 80-H......................................................................................16
3.2.3 HPG 110-H....................................................................................17
3.3 HPG XX-D .....................................................................................17
3.3.1 HPG 50-D......................................................................................18
3.3.2 HPG 80-D......................................................................................18
4Safety............................................................................................19
4.1 Key Switch.....................................................................................19
4.2 Safety Terms According to VDE 0104...........................................20
4.2.1 READY FOR MAINS CONNECTION ............................................20
4.2.2 READY FOR OPERATION ...........................................................20
4.2.3 READY FOR SWITCHING ON......................................................20
4.2.4 In Operation...................................................................................20
4.2.5 Portable Test Equipment...............................................................21
4.2.6 Forbidden Area..............................................................................21
4.2.7 Emergency Switching Off ..............................................................21
5Placing the Device.......................................................................22
6Connecting the Device................................................................23
6.1 Earthing .........................................................................................24
6.2 Connecting the Control Unit to the HV Transformer......................25
6.3 Connecting the System Earth to the Cable Under Test.................25
6.4 Connecting the HV Output to the Cable Under Test .....................25
6.4.1 Isolation of Open Cable Ends........................................................25

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6.5 Mains Connection..........................................................................25
7Startup..........................................................................................26
7.1 Switching On (Ready for Operation)..............................................26
7.2 Switching On (Ready for HV) ........................................................27
7.3 Selecting the Test Voltage.............................................................27
7.4 Voltage Measurement ...................................................................27
7.4.1 Voltage Measurement in Portable Installation...............................28
7.4.2 Voltage Measurement in Test Van Installation..............................29
7.5 Using the Timer .............................................................................29
7.6 Leakage Current Measurement.....................................................30
7.7 Limiting Resistance .......................................................................30
7.7.1 AC Testing.....................................................................................30
7.7.2 DC Testing ....................................................................................30
7.7.3 Note...............................................................................................31
7.7.4 Overtemperature ...........................................................................31
7.8 Switching Off .................................................................................31
8Disconnecting the Cable Under Test.........................................32

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List of Figures
Figure 1 : Operating panel............................................................. 12
Figure 2 : Connection panel .......................................................... 13
Figure 3 : HPG 35-AC, HPG 58-AC or HPG 78-AC installation .... 14
Figure 4 : HPG 50-H, HPG 80-H or HPG 110-H installation ......... 16
Figure 5 : HPG 50-D or HPG 80-D installation.............................. 17
Figure 5 : Safety advices (USA and Germany) ............................. 19
Figure 7 : Connection panel of the HTR........................................ 24
Figure 8 : Voltage measurement in portable installation ............... 28
Figure 9 : Direct voltage measurement ......................................... 29

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1 Description
1.1 General
The control unit HSW 3-2 is part of a complete high voltage test
system and is used to trigger the HV devices and to display
current and voltage.
The instrument disposes of some control elements and indicator
lamps for operation status indication.
The HSW 3-2 is either delivered as a stand-alone version for
portable operation or as table version for test van assembly.
The two versions differ in the position of the connection panel
which is either placed at the right side (stand-alone version) or at
the bottom of the device (test van version). A conversion from one
version to the other can be performed without any difficult.
1.2 Functions
a. Power supply unit
b. Variac with Zero limit switch
c. Meters for current and voltage measurement
d. Programmable timer with indication of the residual time
e. Operating elements with indicating lamps
f. Limiting resistance with fan
g. Safety circuit and indicating lamps acc. to VDE 0104

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1.3 High Voltage Test Configurations
The HSW 3-2 can be used as control unit for the following high
voltage test sets:
HPG 35-AC 0 – 35 kVRMS AC
HPG 58-AC 0 – 58 kVRMS AC
HPG 78-AC 0 – 78 kVRMS AC
HPG 50-H 0 – 50 kV DC (0 – 35 kVRMS AC)
HPG 80-H 0 – 80 kV DC (0 – 58 kVRMS AC)
HPG 110-H 0 – 110 kV DC (0 – 78 kVRMS AC)
HPG 50-D 0 – 100 kV DC (0 – 35 kVRMS AC)
HPG 80-D 0 – 150 kV DC (0 – 58 kVRMS AC)
CAUTION
Depending on the input voltage it is in some
cases
possible to generate a higher output voltage as the unit
has been design
ed for. This area is marked on the
scalar. NEVER exceed the maximum design output
voltage (as stated above)
as this could potentially
damage the system.

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1.4 Technical Data
a. Mains voltage: 230 V + 6 / - 10 %
b. Mains frequency: 45 – 60 Hz
c. Operating current: 16 A (max.)
d. Power rating: 3.5 kVA
e. Circuit breaker: 10 A
f. Output voltage: 0 – 250 V
g. Meter U: kV-Meter 0 … 60 kV
or 0 … 80 kV
or 0 … 110 kV
h. Meter I: mA-Meter 0.5 / 50 mA
i. Timer: 1 – 99 min
l. Operating temperature: - 20 bis + 550C
k. Storage temperature: - 40 bis + 850C
l. Protection class: IP 22
m. Weight HSW 3-2: 26 kg
n. Dimensions (L x B x T): 520 x 255 x 320 mm
p. Versions: stand-alone and table version

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1.5 Scope of Delivery
1. Control unit HSW 3-2
2. Cable set: VL 70
consists of:
2.1. NSP – lead (5 m) VSK 5
2.2. Mains cable (2.5 m) NKG S
2.3. Earth connection lead 5 m with clamp EK 1
2.4. Earth connection lead for transformator EK 1
2.5. Connection lead for system earth WK 1
3. Discharge rod depending on
system type
4. HV transformer with accessories depending on
system type
5. Manual
The HV test lead is not contained in the scope of delivery and has
to be ordered, if required (see below)!
Optional Accessories:
Emergency off switch NAG 1 810399
(with 5 m connection lead) NAG 1
Shielded HV test lead for DC tests:
5 m length 810003736
10 m length 820023906
Unshielded HV test lead for AC tests:
3 m length 2005029
5 m length 2004993
10 m length 2005030

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2 Operating Panel and Connection Panel
Figure 1 : Operating panel
1. Analog volt meter
2. Analog ampere meter
3. Rotary knob for variac adjustment
4. Rotary switch for limiting resistance
5. Pushbutton for test range selection
6. Rotary switch for selection of AC/DC operation
7. Rotary switch for timer
8. Key switch
9. Lighted pushbutton, green - HV ON
10. Lighted pushbutton, white – system ON
11. Lighted pushbutton, red – system OFF
12. Circuit breaker 10 A (therm./magnetic)
13. Control fuse M 0.8/250C
14. Circuit breaker 10 A (therm./magnetic)
15. Time programming keys
16. Digital indication of the residual test time

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Figure 2 : Connection panel
17. Socket for connection lead to the high voltage transformer
18. Socket for earthing lead
19. Socket for direct HV measurement
(optional for test van installations)
20. Label
21. Identification plate
22. Socket for connecting the emergency off switch
23. Mains connection 230 V AC

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3 Test System Installations
Since the HSW 3-2 control unit can be operated with several test
systems, the specific test system installations are described in the
following section.
3.1 HPG XX-AC
The 50 Hz alternating current is directly tapped on the output of
the cast resin-insulated transformer.
Figure 3 : HPG 35-AC, HPG 58-AC or HPG 78-AC installation
The test performance is only suitable for test objects with low
capacity and is limited as follows:
HPG 35-AC: 1.2 kVA (long-term operation)
3 kVA (short-term operation)
HPG 58-AC: 1.2 kVA (long-term operation)
2.5 kVA (short-term operation)
HPG 78-AC: 1.2 kVA (long-term operation)
2.5 kVA(short-term operation)
230 V (+6% / -10%)
45 – 60 Hz

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The HV transformer should be connected with the test object
using a direct connection (wire or bus bar). It is also possible to
connect them with a short cable connection (6 to 10 m). Longer
cable connections do not make sense, since the remaining test
performance would be too low.
3.1.1 HPG 35-AC
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 35-1
3. Cable set VL 70
4. Discharge rod EST 50
3.1.2 HPG 58-AC
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 58-1
3. Cable set VL 70
4. Discharge rod EST 100
3.1.3 HPG 78-AC
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 78-1
3. Cable set VL 70
4. Discharge rod EST 100

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3.2 HPG XX-H
Figure 4 : HPG 50-H, HPG 80-H or HPG 110-H installation
3.2.1 HPG 50-H
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 35-1
3. HV rectifier HGL 80
4. Cable set VL 70
5. Discharge rod EST 50
3.2.2 HPG 80-H
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 58-1
3. HV rectifier HGL 80
4. Cable set VL 70
5. Discharge rod EST 100
230 V (+6% / -10%)
45 – 60 Hz

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3.2.3 HPG 110-H
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 78-1
3. HV rectifier HGL 120
4. Cable set VL 70
5. Discharge rod EST 150
3.3 HPG XX-D
Figure 5 : HPG 50-D or HPG 80-D installation
230 V (+6% / -10%)
45 – 60 Hz
WA
DCS 140
VS
IS
HGL XX-R
HGL XX-D

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3.3.1 HPG 50-D
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 35-1
3. HV rectifier HGL 70-R
4. HV rectifier HGL 70-D
5. Voltage doubler capacitor DCS 140
6. AC voltage connection WA
7. Insulated support IS
8. Cable set VL 70
9. Connecting piece VS
10. Discharge rod EST 100
3.3.2 HPG 80-D
This test system consists of the following components:
1. Control unit HSW 3-2
2. HV transformer HTR 55-1
3. HV rectifier HGL 80-R
4. HV rectifier HGL 80-D
5. Voltage doubler capacitor DCS 140
6. AC voltage connection WA
7. Connecting piece VS
8. Insulated support IS
9. Cable set VL 70
10. Discharge rod EST 150

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4 Safety
Figure 6 : Safety advices (USA and Germany)
All HPG high voltage test sets generate dangerous contact
voltages > 1 kV. Hence, the Instrument must be operated by
specialists or personnel who have been trained or instructed in the
use of the instrument. The following safety precautions should be
adhered to:
4.1 Key Switch
On the basis of european product legal liability requirements and
according to VDE 104-10-89 Pos. 3.9.4., unauthorized switching
on of the instrument must not be possible. This is accomplished
by the provision of a key switch [8] located on the front panel. The
key has to be kept safe by the person responsible for the device.

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4.2 Safety Terms According to VDE 0104
The term in parentheses describes the position number within the
VDE 0104 (italic).
4.2.1 READY FOR MAINS CONNECTION
The white pilot lamp (10) indicates the presence of mains supply.
The pilot lamp (10) is permanently lit and cannot be switched off.
4.2.2 READY FOR OPERATION
(Pos. 3.15.2)
Indicated by the green pilot lamp (9). Instrument is On. No high
voltage can be generated. If the discharge module is used, the HV
output is earthed.
4.2.3 READY FOR SWITCHING ON
(Pos. 3.15.3)
Indicated by the red pilot lamp (11).
Instrument is on. The green luminous pushbutton is off. This state
can only took place if the variac (3) is in null position. Thus, no HV
can be generated.
Note: If the green push-button (9) is switched off and the red pilot
lamp (11) does not light up, the instrument is also ready for
switching on. Caution!
4.2.4 In Operation
(Pos. 3.15.4)
Indicated by the red pilot lamp (11). By rotating the rotary switch
(3), HV can be generated.