Megger OCR15D User manual

1 Part Number 86826
Rev 1 Date 11/6/2019
User Manual
Model OCR15D
and
Model OCR50D
AUTOMATIC CIRCUIT RECLOSER
TEST SETS
It is essential that this instruction book be read thoroughly before putting the equipment in service.

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Revision History
Revision
ECN #
Date
1
33728
6 Nov 2019

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IMPORTANT
This manual, as well as the hardware and software described in it, is furnished under license and
may be used or copied only in accordance with the terms of such license. The content of this
manual is furnished for informational use only, is subject to change without notice. Megger
assumes no responsibility or liability for any errors or inaccuracies that may appear in this
manual.
The information and data in this User Manual are proprietary. The equipment described herein
may be protected by U.S. patents. Megger specifically reserves all rights to such proprietary
information as well as rights under any patent, none of which is waived by the submission of this
user manual.
Except as permitted by such license, no part of this publication may be reproduced, stored in a
retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording,
or otherwise, without the prior written permission of Megger.
Megger, the Megger logo are trademarks of Megger. All other trademarks are the property of
their respective owners.
Notice to U.S. government end users. The hardware, software and documentation are
“commercial items”, as that term is defined at 48 C.F.R. §2.101, consisting of “commercial
computer software” and “commercial computer software documentation,” as such terms are used
in 48 C.F.R. §12.212 or 48 C.F.R. §227.7202, as applicable. Consistent with 48 C.F.R. §12.212
or 48 C.F.R. §§227.7202-1 through 227.7202-4, as applicable, the commercial computer software
and commercial computer software documentation are being licensed to U.S. government end
users (1) only as commercial items and (2) with only those rights as are granted to all other end
users pursuant to the terms and conditions set forth in the Megger standard commercial
agreement for this software and hardware. Unpublished rights reserved under the copyright laws
of the United States. The recipient, if a Government agency, acknowledges that this manual and
the equipment described were procured with "Limited Rights" to technical data as described in
ASPR 9-203 (b).
The STVI includes an RTOS-resident computer program. This program belongs to Megger and
contains trade secret ideas and information of Megger.
Written and designed at Megger, 4271 Bronze Way, Dallas, Texas 75237.
__________________________
Printed in the USA.
2011 Megger, all rights reserved.

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SAFETY PRECAUTIONS
WARNING:
VOLTAGES GENERATED BY THIS INSTRUMENT CAN BE HAZARDOUS
This instrument has been designed for operator safety; however, no design can completely protect
against incorrect use. Electrical circuits are dangerous and can be lethal when lack of caution and
poor safety practices are used. There are several standard safety precautions that should be taken by
the operator. Where applicable, IEC safety markings have been placed on the instrument to notify
the operator to refer to the user manual for instructions on correct use or safety related topics. Refer
to the following table of symbols and definitions.
Symbol
Description
Direct Current
Alternating Current
Both direct and alternating current
Earth (ground) Terminal. There is a common chassis ground terminal located
on the front panel (see Front panel under Description of Controls.
Protective Conductor Terminal
Frame or Chassis Terminal
On (Supply)
Off (Supply)
Caution, risk of electric shock
Caution (refer to accompanying documents)
WARNING: Under no circumstances should the operator or technician attempt to open or
service any Megger instrument while connected to a power source. Lethal voltages are present
and may cause serious injury or death!

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SAFETY PRECAUTIONS (Continued)
The following are some specific safety related items associated with the OCR test
systems.
Read and understand all safety precautions and operation instructions before attempting
to use this unit.
This test set should only be operated by specifically trained technicians and engineers
familiar with this type of industrial electrical equipment.
The purpose of this equipment is limited to use as described in this instruction manual.
Should a situation arise that is not covered in the general or specific safety precaution
please contact Megger regional representative or Megger, Dallas Texas.
Safety is the responsibility of the user. Misuse of this equipment can be extremely
dangerous.
Always start with the main power OFF, before connecting the power source.
Make sure outputs are off before attempting to make test connections.
Never connect the test set to energized equipment.
Always use properly insulated test leads. The optional test leads are rated for
the continuous output ratings of the test system, and should be properly used
and cared for. DO NOT use cracked or broken test leads.
Always turn the test system off before disconnecting the power cord.
DO NOT attempt to use the unit without a safety ground connected.
DO NOT attempt to use the unit if the power cord ground prong is broken or
missing.
DO NOT use the test set in an explosive atmosphere.
The instrument must only be used by suitably trained and competent persons.
Observe all safety warnings marked on the equipment.
For safety related or other important topics, like the statement below, will be
notated with the adjoined symbol. Read the topic carefully as it may relate
either to the safe operation of the test system or the safety of the operator.
Under no circumstances should the operator put their hand or tools
inside the test system chassis area with the test system connected to a
power source. Lethal voltages are present and may cause serious
injury or death!

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This test set includes a resident computer program.
This program belongs to Megger and contains trade secret ideas and information of Megger.
To the extent this program contains ideas, Megger intends to protect and enforce it rights under state law.
To the extent the program is deemed to constitute a form of expression of an idea, Megger intends to
protect and enforce its rights under the Copyright Act of 1976. The Statutory Copyright notice has been
affixed hereto in the event that it is later determined that the program has been published within the
meaning of the Copyright Act of 1976.
It is essential that this instruction book be read thoroughly before putting the equipment in service.

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TABLE OF CONTENTS
I. General Description
II. Safety Precautions
III. Input Circuit
IV. Output Circuit
V. Description of Controls
VI. Test Procedures
A. Series Type Reclosers
1. Minimum Pick-up Test
2. Timing Test
B. Testing Vacuum Type Reclosers
C. Reclosers Requiring Line Voltage for Closing
D. Sectionalizers

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I. GENERAL DESCRIPTION
The Megger Model OCR15D and OCR50D are high current primary injection test
sets designed for testing automatic oil and vacuum circuit reclosers and other
current actuated devices. These units incorporate a variable high current ac output
with an impedance matching network to stabilize the output current. The unit
provides appropriate instrumentation and control circuitry to monitor contact
closure, opening and provide timing functions.
II. SAFETY PRECAUTIONS
WARNING
Potentially lethal voltages can be present on the output leads when the test
set is in operation. The operator is responsible for ensuring the safety of all
personnel during operations. While conducting tests, keep all personnel at a
safe distance from the test set and the device being tested.
CAUTION
For safety of the operator, it is absolutely essential that the test set be
properly and effectively grounded.

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III. INPUT CIRCUIT
INPUT VOLTAGE
OCR50D
Due to the output capability (50 kVA continuous for the OCR50D) as well as the
specific applications for which the test set was designed, the test set must be
powered by a 480 volt single-phase input service.
OCR15D
The Megger OCR15D (15 kVA continuous) is designed to operate from any of
several input voltages in order to accommodate the various voltages encountered
by users in the field. It is necessary to change the input terminal connections to
match the available input voltage. This change is made on a terminal board located
inside the right side access panel. The test set must be disconnected from the
supply source before attempting to change the terminals.
SELECTION OF INPUT LEADS
Due to the wide variation in individual user requirements with regard to wire sizes,
terminations and length of leads, all units are supplied with input socket and
matching plug only. The plug will accept a wide range of wire sizes more than
adequate for the duty required. The power source must have sufficient capacity,
and the input leads must be large enough to maintain RATED input voltage at the
INPUT terminals of the test set. Although the test set is designed to operate
satisfactorily at 95-105% of rated voltage, any drop in voltage below RATED at the
input terminals will result in a proportional decrease in the maximum available
output.
NOTE: To achieve published output currents, the rated input voltage must be
maintained at the test set terminals during the test.
When utilizing maximum output from the test set, the input line currents
may be as high as 400% of nameplate rating. The following table has
been prepared to aid in selecting the proper wire size for the input
leads. To use the table, refer to the following four steps:

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1. Determine the rated input current from the nameplate on the test set. Be sure
to choose the correct current for the input voltage being used.
2. Multiply this value by four.
3. Determine the length of input lead required. This is in circuit-feet, therefore it
is the one-way distance from the test set to the power source.
4. Select the proper wire size from the table using factors 2 and 3 above.
Input Lead Example:
Step 1 - 100 amperes (from nameplate)
Step 2 - 4 x 100 = 400 amperes
Step 3 - 60 ft. (distance from test to input power source.)
Step 4 - # 2 wire (from Chart)
For safety, a ground wire must be connected to the test set frame. The size
of this conductor should be not less than 1/2 the cross section of the
current carrying input leads (three-wire sizes less) and in no event smaller
than #10. An audible alarm is sounded if the test set is not properly
grounded.

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SELECTOR CHART FOR INPUT LEADS
LENGTH OF INPUT LEADS
DISTANCE FROM TEST SET TO POWER SOURCE
FOUR TIMES (4X)
RATED INPUT POWER 20 40 60 80 100 120 140 FEET
MINIMUM WIRE SIZE A. W. G.
50 8 8 8 8 8 8 8
75 8 8 8 8 8 8 6
100 8 8 8 8 6 6 4
125 8 8 8 6 6 4 4
150 8 8 8 6 4 4 2
175 8 8 6 4 4 2 2
200 8 8 6 4 4 2 2
225 8 8 6 4 2 2 1
250 8 6 4 4 2 2 1
275 8 6 4 2 2 1 1/0
300 8 6 4 2 2 1 1/0
325 8 6 4 2 1 1 2/0
350 8 4 2 2 1 1/0 2/0
375 8 4 2 2 1/0 2/0 2/0
400 8 4 2 1 1/0 2/0
425 8 4 2 1 1/0 2/0
450 8 4 2 1 2/0
475 6 4 2 1/0 2/0
500 6 4 2 1/0 2/0
525 6 2 1 1/0 2/0
550 6 2 1 1/0
575 6 2 1 2/0
600 6 2 1 2/0
THE WIRE SIZES IN THIS CHART WILL RESULT IN VOLTAGE DROPS OF 10
VOLTS OR LESS.

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IV. OUTPUT CIRCUIT
SELECTION OF OUTPUT TERMINAL
Several output terminals at various voltage and current ratings are provided to
adapt the OCR Test Set to a wide variety of test circuit impedances. The current
ratings shown on the output taps are the continuous duty ratings. The test set
works at peak efficiency when the outputs are used at 2 to 3 times their
continuous rating. In this way, finer adjustment can be obtained by making
maximum use of the variable autotransformer range and matching impedance
network. The LOW CURRENT terminals should be used when testing high
impedance devices where higher current terminals do not have sufficient voltage
to "push" the desired test current through the device. For example, to test a
recloser with a 50 amp coil rating at a test multiple of 5x (250 amperes), the
operator should use the 100A output tap (not the 250A tap). Only when the test
current exceeds 300A should the 250A tap be used.
SELECTION OF COMMON TERMINALS
The ammeter circuit of the OCR test set utilizes two current transducers to
measure both the very low and high currents available from this unit. For the
ammeter to correctly measure the output current of the test set, the proper
common terminal must be selected. For currents of 20 amperes and below,
COMMON 1 Terminal must be used; and, similarly, when test currents exceed 20
amperes, COMMON 2 Terminal must be used.
SELECTION OF MATCHING IMPEDANCE
The impedance matching network is incorporated to swamp-out the changing
impedance of the recloser. As the operating plunger moves through the coil of
the recloser the impedance increases. Experience has shown that the higher the
matching impedance on the primary of the output transformer, the less effect the
changing impedance of the recloser has on the output current. The limiting factor
is the available power of the test set. The more matching impedance, means
more power consumed by the test set and less available output current. To
select the appropriate matching impedance to conduct timing tests, first select
the appropriate output tap and common, i.e. for a test current of 200 amperes
use the 150V-100A tap (see SELECTION OF OUTPUT TERMINAL). The
appropriate matching impedance for a given recloser will be determined through
experience. Until such time, move the impedance tap selector switch to position
10. Rotate the Output Control wheel to the 90% position.

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Upon operation of the test set, in the momentary position, if the test current
indicated is too low, switch the LOAD COMPENSATOR Switch to position 11 and
repeat the procedure. Switching to position 11 decreased the matching
impedance and therefore allows more output test current. If the test current is
too high, switch the impedance tap selector switch to position 9 to increase the
matching impedance, thus reducing the output test current and repeat the
procedure. Fine adjustment of the current can be made with the Output Control
wheel.
It is suggested that the LOAD COMPENSATOR switch never be moved to
position # 15 during a recloser timing test. The lack of any matching impedance
could result in inaccurate results and possible damage to the test set.
OUTPUT CONNECTIONS
The testing of devices requires the use of test leads for connections between the
test set and the device being tested. The following information on the selection
of output leads will provide the user with a guide for choosing the proper tests
leads for this application.
Due to the voltage drop from the inductive reactance of the test circuit, a
significant loss of current will result for each inch of test lead. Therefore, when
choosing test leads, the length and size of lead chosen will determine the
maximum available test current. It is worthwhile to sacrifice cross section of test
leads for the sake of reducing length. Every inch of lead that can be eliminated
provides worthwhile increase in available test current. Heating is not a significant
problem in testing, even though the leads can become hot. The use of 4/0
welding or motion picture cable is convenient for constructing test leads.
Paralleling of sufficient cables provides higher test currents. Each cable can be
fitted with a compression lug on each end, then bolted to the output terminals of
the test set and the breaker.
The two cables between the test set and the device under test should be twisted
together or bundled with tape or cord to maintain the close proximity which
minimizes inductive reactance.

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V. DESCRIPTION OF CONTROLS
This section of the instruction manual describes the function of the various controls
located on the Megger Model OCR50D. The OCR15D is similar (no indicator
lamps or switch on the left side of the front panel). The majority of controls are
located on the touch sensitive control panel. The controls are easily accessed via
icons on the screen and provide for easy operation after a minimum of operator
familiarity. Figure 1 shows the location of the front controls.
Figure 1 –Front Panel Controls
Along the right side of the control panel are the:
Output Engizered Lamp –illuminates when the output is energized
Emergency Stop (ESTOP) Switch –pressing this button stops any testing
Adjustment Knob –this knob can take on various functions in the software.

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The external connections are located to the left of the touch panel.
The USB connectors provide the ability to: attach a USB thumb drive (for exporting
test reports or updating firmware/software), attach an external mouse or to attach
a USB keyboard.
The USB “B” connector (center connector) allows the user to connect an external
PC.
The switch at the bottom left is used to direct control to either the “onboard” (internal)
computer or a “remote” (external) computer.
The touch panel provides the main OCR control capability via the OCR application
in the PowerDB software. The OCR test set wakes to the OCR main screen when
powered up.
MICROPROCESSOR-CONTROLLED OPERATION
The microprocessor based control and instrumentation system ensures simple
operation and precise test results. The software automatically detects the minimum
pick-up current. It will signal when minimum pick-up is achieved and display the
magnitude of the pick-up current. The software records the current magnitude, trip
time and reclose times for each operation of the recloser. The software will also
indicate if the recloser took excessive shots to lock-out. Additionally, the software
will de-initiate the test set if the recloser is exceeding the allowed time to lock-out
and will indicate to the operator excess time to lock-out. The software is also
programmed to detect errors associated with operation of the test set or the device
under test.

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OCR Main Screen
Below is the OCR main test screen. The menu icons are shown across the top of the
screen.
Figure 2 –OCR Main Screen
The menu icons (across the top of the screen):
Connection Indicator –indicates the connection status of the controller
Configuration Screen –select frequency and software data logging
Clear Test Results –select to clear test result or clear all test results
Scale Selection –select full scale current (20A, 200A, 2kA, or 20kA –defaults to 200A)

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View Test Report –view the present test report
Add Test to Report –add the current test data and open the test report
File Operations –controls for saving/opening/deleting files
Nameplate Information –allows entry of pertinent nameplate information
Timer Setup –allows selection of timer control to follow current flow or a contact
Test Selection –allows the user to select a test to run
Help –online help
Configuration Screen
This menu item allows the user to set the OCR configuration parameters. Press the green check
button when finished.
Frequency - allows the user to toggle between 50/60 Hz system frequency:

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RMS Measurement Mode - allows selection of RMS measurement modes
The 120 Cycle RMS mode will use up to 120 cycles of data to determine the RMS
measurement. The 4 Cycle RMS mode will utilize the last 4 cycles of data for
calculations.
Display Versions –Displays the hardware and software version information:

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Adjust Screen Brightness - Allows the user to adjust screen brightness using
the black control knob to the right of the touch screen:
Logging -controls for enabling, clearing and copying the system
log files (to a USB stick):
Note that default is logging disabled. The user must enable logging to capture log files. It is
suggested that the log files be cleared prior to enabling the logging.
Log files are used for trouble-shooting and monitoring software operations. Log files may be
requested by support personnel to help address any issues.
“Enable logging” activates the software logging function.
“Clear log files” deletes the existing content of the log files.
“Copy log files” copies the log files to a USB stick.

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Restore Defaults –Restores parameters to factory settings:
Update Software –Allows for PowerDB software or OCR Firmware updates
and adding curve library updates:
Select Language –Allows for language selection