Megger Primeon User manual

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Primeon
Compact, single-phase test van system
OPERATION AND MAINTENANCE
Issue: G (05/2023) - EN
Article number: 87350

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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.
This warranty does not cover wear parts, lamps, fuses, batteries and accumulators.
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.
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.
Since some states do not allow the exclusion or limitation of an implied warranty or of consequential
damage, the limitations of liability described above perhaps may not apply to you.

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Contents
1Safety and general information ............................................................................................5
1.1 Basic information......................................................................................................................5
1.2 General warnings and safety instructions ................................................................................7
2Technical description ............................................................................................................9
2.1 System description...................................................................................................................9
2.2 Technical data........................................................................................................................13
3Safety devices ......................................................................................................................24
4Setting up and connecting the test van.............................................................................26
4.1 Setting up and securing the test van......................................................................................26
4.2 Electrical connection ..............................................................................................................27
4.2.1 Connection equipment ...........................................................................................................28
4.2.2 Connection of the earth cable ................................................................................................29
4.2.3 Connecting the reference earth (F-U monitoring) ..................................................................30
4.2.4 Connection to the test object .................................................................................................31
4.2.4.1 Using the HV connection cable ..............................................................................................31
4.2.4.2 Using the three-phase LV connection cable (optional) ..........................................................37
4.2.5 Establishing the mains supply................................................................................................38
4.2.5.1 Connection to mains supply ...................................................................................................38
4.2.5.2 Operation via generator or battery power supply (optional)...................................................39
4.2.6 Connection of the external safety device ...............................................................................40
4.3 Switching on the test van .......................................................................................................42
5Operation of the test van.....................................................................................................43
5.1 Operating unit.........................................................................................................................43
5.2 Other operating and connecting elements in the control area...............................................45
5.3 Switch on................................................................................................................................46
5.4 Resolving signalled problems ................................................................................................47
5.5 Operation ...............................................................................................................................49
6Work after completion of the measurement job ...............................................................50
7IT accessories and connectivity.........................................................................................52
7.1 Use of USB accessories ........................................................................................................52
7.2 Internet and GPS connectivity (optional) ...............................................................................53
8Troubleshooting...................................................................................................................56
8.1 Behaviour in the event of faults during normal operation ......................................................56
8.1.1 Check fuses ...........................................................................................................................56
8.1.2 Other possible fault causes....................................................................................................58
8.2 Behaviour in the event of continuous faults ...........................................................................59
9Care and maintenance.........................................................................................................60
9.1 Testing and maintenance measures to be carried out by the operator .................................60
9.2 Required maintenance by a service workshop ......................................................................60

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1 Safety and general information
1.1 Basic information
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!
Signal words and symbols used
The following signal words and symbols are used in this manual and on the product itself:
Signal word /
symbol
Description
DANGER Indicates a potential hazard which will result in death or serious injury if not
avoided.
WARNING Indicates a potential hazard which may result in death or serious injury if not
avoided.
CAUTION Indicates a potential hazard which may result in moderate or minor injury if not
avoided.
NOTICE Indicates a potential hazard which may result in material damage if not
avoided.
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 to highlight important information and useful tips on the operation of the
device/system. Failure to observe may lead to unusable measurement results.
Serves as a reference to further information in other operating instructions.

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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
The system may only be installed and operated by an authorised electrician. DIN VDE 0104 (EN 50191),
DIN VDE 0105 (EN 50110) and the German accident prevention regulations (UVV) define an electrician
as someone whose knowledge, experience and familiarity with the applicable regulations enables him to
recognise potential hazards.
Anyone else must be kept away!
Electromagnetic radiation
This device is designed for industrial use. When used at home it could cause interference to other
equipment, such as the radio or television.
The interference level from the line complies with the limit curve B (living area), the radiation level
complies with the limit curve A (industrial area) according to EN 55011. Given that living areas are
sufficiently far away from the planned area of operation (industrial area), equipment in living areas will
not be impaired.

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1.2 General warnings and safety instructions
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.
Operation in traffic environment
To ensure safety for operators and traffic, the country-specific regulations must be observed.
Five 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. Earth and short-circuit
5. Cover up or bar-off neighbouring energised parts
Using cardiac pacemaker / defibrillator
Physical processes during operation of high voltage may endanger persons wearing
a cardiac pacemaker or defibrillator when near these high voltage facilities.
Fire fighting in electrical installations
■According to regulations, carbon dioxide (CO2)is required to be used as
extinguishing agent for fighting fire in electrical installations.
■Carbon dioxide is electrically non conductive and does not leave residues. It
is safe to be used in energized facilities as long as the minimum distances
are maintained. A CO2
fire extinguisher must be always available within
electrical installations.
■If, contrary to the regulations, any other extinguishing agent is used for fire
fighting, this may lead to damage at the electrical installation. Megger
disclaims any liability for consequential damage. Furthermore, when using a
powder extinguisher near high-voltage installations, there is a danger that the
operator of the fire extinguisher will get an electrical shock from a voltage arc-
over (due to the powder dust created).
■It is essential to observe the safety instruction on the extinguishing agent.
■Applicable is DIN VDE 0132.

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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
operating 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 Primeon generates a dangerous voltage up to 62 kV during the
measuring operation. This is fed into the test object via the HV connection
cable.
■The test system may not be operated without supervision.
■Never fail to use safety equipment or put it out of operation.
■Operation requires minimum two people whereas the second person must
be able to activate the emergency switch in case of danger.
■To prevent dangerous charge accumulation, earth all metal parts in the
vicinity of the high voltage equipment.
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.
Due to the increased formation of ozone, sufficient fresh air must be supplied to the
operating room during operation.
Objects should not be placed on or lent against the heater, nor pushed between the
heater and wall.
Do not cover the air exit or leave any combustible material in close vicinity to the
heater.
Peripheral devices
Please follow the safety instructions of the peripheral devices (e.g. heater) installed
in the system environment. For all peripheral devices provided by Megger, the
instructions manual is included in the scope of delivery. Megger is not liable for
damage to material or humans due to misuse of these devices.

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2 Technical description
2.1 System description
The Primeon is a cable testing system intended for installation in a van, trailer or container, the basis of
which is the STX 40 cable fault location system. The vehicle installation carried out by Megger itself or by
following clear specifications enables rapid transportation, eliminating interference when time is of critical
importance without having to unload the system from the vehicle at the deployment location. This is also
ensured by the connection and safety technology integrated into the vehicle, which offers the user the
familiar high degree of comfort and safety.
Optionally, the vehicle can also be equipped with powerful VLF testing technology and modern
diagnostic systems that enable standard-compliant cable testing and partial discharge diagnostics.
The system is operated almost exclusively by a central control unit (with integrated TDR module), which
is also responsible for the automatic storing and logging of test results. All system functions,
measurement results, operating instructions and error messages are shown on a single display.

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Features
The basic configuration with STX 40 makes the system suitable for the following measuring tasks:
■DC test/trip detection up to 40 kV
■Insulation test up to 20 kV
■Fault detection with proven HV pre-locating methods such as
■Arc Reflection Measurement (ARM), voltage decoupling (Decay) and
■Induced Current Elimination (ICE)
■Fault conversion by burning at the fault location with up to 850 mA
■Sheath test with up to 20 kV with automatic breakdown detection
■Pinpoint location of sheath faults according to the step voltage method with up to 20 kV
■Pinpoint fault location in surge mode with up to 2000 J
Depending on the add-on equipment, the following measurement and diagnostic applications are also
available as options:
■VLF test with cosine rectangular and/or sinusoidal voltage
■Burning at the fault location with simultaneous fault detection (ARM burning)
■Line and fault detection by means of audio frequency signal
■TanDelta loss factor measurement
■Partial discharge diagnostics
In addition to the mentioned measurement and diagnostic technologies, the system offers the following
features:
■Highest safety standards
■Intuitive operation via touch display
■Workflow-supported automation of typical measuring and testing processes
■High system stability thanks to the Linux® operating system
■TDR-Performance-Upgrade „TDR Unleashed“ for higher pulse amplitudes, more pulse width,
state-of-the-art interference and noise suppression technologies and "Signature Boost" for long
ranges
■Self-powered (optional)
■Integrated protocol software with cable database for instant reporting (optional)
■Wireless communication interfaces (4G, WiFi, GPS) (optional)
■Transfer and synchronisation of measurement and cable data via a cloud database (optional)
■Remote control of important pinpointing and line location methods via app (optional)
■TeamViewer remote access for support and demonstration purposes (optional)

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Equipment matrix
Basic system Optional
Test
Insulation test via HV cable
via LV cable
DC voltage test up to 40 kV
VLF test with cosine rectangular
voltage with TDM 4540 (up to 40 kVRMS)
with TDM 6260 (up to 60 kVRMS)
VLF test with sinusoidal voltage with TDM 45 (up to 45 kVpeak)
with TDM 62 (up to 62 kVpeak)
Test with trapezoidal AC voltage
(rectangular voltage) with TDM 45 (up to 45 kVpeak)
with TDM 62 (up to 62 kVpeak)
Sheath test up to 20 kV
Fault location
Pulse reflection measurement via HV cable
via LV cable
Pulse reflection measurement in
the event of intermittent errors
via HV cable
via LV cable
ARM Multishot (arc reflection
measurement) ■
DECAY method up to 40 kV
ICE current pulse method ■
ARM burning with burn unit 15 kV

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Basic system Optional
Fault conversion
Burning up to 20 kV
with burn unit 15 kV
Fault pinpointing
Surging 8/16/32 kV @
2000 J
4 kV with 1100 J
Audio frequency generator 200 W
Sheath fault pinpointing up to 20 kV
PD Pinpointing with PD-TX pulse transmitter and
three-phase LV connection cable
Diagnostics
Dielectric strength test with
simultaneous tan delta
measurement
with TDM +
internal or external TanDelta sensor
TanDelta step test
PD diagnostics with sinusoidal
voltage
TDM + partial discharge coupler
(PDS 60(-HP) or PDS 62-SIN)
PD diagnostics with cosine
rectangular voltage
TDM (TDM 4540 or TDM 6260) +
PD coupler PDS 60(-HP)
PD diagnostics with DAC voltage TDM (TDM 4540 or TDM 6260) +
PD coupler PDS 60(-HP)

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2.2 Technical data
Technical data for the additional measurement technology (e.g. PDS 60, Ferrolux
receiver) and for the peripheral devices (e.g. generator system) available for the test
van can be found in the respective operating instructions.
General data of the vehicle's technical equipment
Parameter Value
Mains voltage 230 V, 50 Hz or 120 V, 60 Hz
Connection via isolation transformer (minimum 3.6 kVA)
Generator / Battery 12 V battery with 12 Ah (e.g. for interior lighting and cable
drum motor)
Generator system (e.g. Voltstar) up to 8 kVA (optional)
Connection power 3.6 kVA (optional up to 5 kVA)
Connection equipment
■HV connection cable 50 or 80 m
■Power cord 50 m (incl. suitable isolation transformer and power supply
system NAS 16)
■Earth cable 50 m
■Reference earth connection
cable
10 m
■External safety device
connection cable
15 or 50 m
■Three-phase LV connection
cable (optional)
25 or 50 m

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Parameter Value
Safety
■Electrical safety according to DIN EN (IEC) 61010-1
■Safety and protective
equipment
The following conditions are monitored during operation:
■Earth loop monitoring (F-ohm)
■Monitoring for dangerous potential increases (F-U)
■Monitoring for rapid voltage rises
■Rear door switch
■Safety key switch
■Emergency off switch internal/external (EN 50191)
■Discharge Safe discharge even in the event of an emergency shutdown
or power failure by the discharge equipment of the respective
individual device.
■Supply voltage Overvoltage protection, undervoltage protection,
residual current circuit breaker
Wireless data communication via
optional 4G/GPS router
(only available for CU 15.6 FLPD
control unit)
Mobile data (GPRS/EDGE/3G/4G), Wi-Fi, GPS
Operating temperature -10 °C ... +50 °C
Storage temperature -20 °C ... +70 °C
Operating humidity 93% at 30 °C (non-condensing)

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Parameter Value
Operating altitude Depending on the operating altitude, the following limit values
must be considered when setting the voltage:
Umax refers to the maximum voltage of the respective voltage
source.
Technical data of the available control units
Parameter CU 10.1 FL CU 15.6 FL CU 15.6 FLPD
Processor NXP i.MX6Q
QuadCore 996MHz
NXP i.MX6Q
QuadCore 996MHz
Intel®Core i5-7300U
RAM 1 GB DDR3 1 GB DDR3 8 GB DDR4
Memory 4 GB NAND Flash 4 GB NAND Flash 256 GB SSD
Display 10.1 inch
1280 x 800 WXGA
15.6 inch
1920 x 1080 Full HD
15.6 inch
1920 x 1080 Full HD
Design Integrated or remote Remote Remote
USB USB 2.0 USB 2.0 USB 3.0
Operating system Linux® Linux® Linux®
Suitable for PD
diagnostics?
No No Yes
<5000
m 0.6 Umax
<4000
m 0.7 Umax
<3000
m 0.8 Umax
<2000
m Umax

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Technical data of the STX 40 fault location system
Parameter Value
Insulation test
■Measurement voltage 1 … 20 kV
■Measuring range 100 Ω … 650 MΩ
DC voltage test
■Test voltage 0 … 40 kV ±1.5 %
(adjustable in 0.1 kV increments)
■Leakage current measurement 0 … 1 A ±2 %
TDR module (time range reflectometer)
■Distance range (at v/2 = 80 m/μs) 20 m … 320 km (standard)
20 m … 1280 km („TDR Unleashed“)
■Pulse width 20 ns … 10 μs (standard)
20 ns … 30 μs („TDR Unleashed“)
■Pulse amplitude 100 V (standard)
250 V („TDR Unleashed“)
■Resolution 0.1 m at v/2 = 80 m/μs,
■Accuracy 0.1%
■Timebase accuracy <50 ppm
■Data rate 533 MHz
■Runtime setting As v/2 or NVP value
10 … 149.9 m/μs or 33 … 492 ft/μs
■Dynamic range 115 dB
■Output impedance 50 Ω
■Distance dependant
de-attenuation (ProRange)
+40 dB, adjustable

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Parameter Value
Surging
■Surge levels10 … 8/16/32 kV with 2000 J
0 … 4 kV with 1100 J (optional)
■Surge sequence Every 3 seconds at 32 kV
Adjustable between 3 … 10 seconds or
single surge
Prelocating methods
■ARM Multishot Reflectance measurement in an arc caused by a fault; 32
consecutive error patterns per measurement
■ICE Current decoupling from a travelling wave caused by a
fault
■DECAY Voltage decoupling from a travelling wave caused by a
fault
Burning with internal high voltage
source
Max. 850 mA in the 5 kV range
Max. 400 mA in the 10 kV range
Max. 200 mA in the 20 kV range
Max. 100 mA in the 40 kV range
Burning with 15 kV burn unit See the enclosed operating manual
Sheath test
■Output voltage 0 … 20 kV ±1.5 %
■Leakage current measurement 0 … 1 A ±2 %
Sheath fault pinpointing
■Output voltage 0 … 20 kV ±1.5 %
■Timing 0.5:1, 1:3, 1:4, 1:6
1If the system is supplied with 120 V AC input voltage, the output power is
limited to 1,600 W (in accordance with ANSI/NEMA 5)

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Technical data of the FLG 250 audio frequency generator (optional)
Parameter Value
Frequencies 0.491 kHz, 0.982 kHz, 8.440 kHz (customer-specific
frequencies are possible)
Output power 250 W
Technical data of the TDM 45/TDM 4540 test and diagnostic module (optional)
Parameter Value
Output voltage
■Sinusoidal 2 … 32 kVRMS/45 kVpeak
■Rectangular ±2 … ±45 kV
■Cosine rectangular
(TDM 4540 only)
±3 … ±40 kV
■DAC (damped AC)
(TDM 4540 only)
±3 … ±40 kV
Max. output current source 12 mARMS (at rated voltage)
Leakage current measurement (Rectangular, VLF-CR and DC operation)
■Display range 0 … 20 mA
■Resolution 10 μA

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Parameter Value
Frequency
■Sinusoidal/rectangular voltage 0.01 Hz … 0.1 Hz
■Cosine rectangular voltage
(TDM 4540 only)
0.1 Hz
■DAC voltage
(TDM 4540 only)
20 Hz … 500 Hz
Testable load capacity (See also the following diagrams)
■Sinusoidal voltage 0.6 μF at 45 kV/0.1 Hz
■Rectangular voltage 0.6 μF at 45 kV/0.1 Hz
■Cosine rectangular voltage/DAC
voltage (TDM 4540 only)
4.8 μF at 40 kV
■Maximum load capacity 10 μF at reduced voltages and frequencies
Tan delta measurement (optional)
■Measuring range 10-3 … 100
■Accuracy (at a load capacity
>20 nF)
1 x 10-3 or 1 %
■Resolution 1 x 10-4

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The following graph applies to tests with sinusoidal voltage and illustrates the dependence of the test
frequency on the capacity of the connected load and the set test voltage. If a test frequency cannot be
applied due to the capacity limits specified here, an automatic adjustment is made and the user is
informed about this condition.
In cosine rectangular or DAC mode (TDM 4540 only), the following load graph also applies2:
2Only valid between -25 and 45 °C. In the temperature range from 45 °C to 55°C, the
power is reduced to 80 % at 40 kV.
U/kV
C
load
/µF