Megger SPG 32-1750 User manual

Issue: 6 (11/2018) – EN
128312543
Operating Manual
SPG 32-1750 / 32-3500 /
Surgeflex 32

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 or should you need the help of an authorized
service station, 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 disclaims all responsibility for damage resulting
directly or indirectly from the delivery, supply, or use of this matter.

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.

I
Contents
Consultation with Megger ............................................................. 3
Terms of Warranty ......................................................................... 4
1Description .......................................................................... 4
1.1 General...................................................................................................4
1.2 Design ....................................................................................................4
1.3 Operation as a complete test- and fault location system Surgeflex 32...5
1.4 Function..................................................................................................6
1.4.1 Shock discharge generator.....................................................................6
1.4.2 Arc reflection method (ARM) ..................................................................7
1.4.3 Sheath fault location...............................................................................7
1.4.4 High voltage testing................................................................................8
1.5 Power Supply .........................................................................................8
1.6 Technical characteristics ........................................................................9
1.6.1 Shock discharge operation "SWG".........................................................9
1.6.2 Arc Reflection Method "ARM".................................................................9
1.6.3 Sheath fault location "MFO" ...................................................................9
1.6.4 High voltage testing "HPG"...................................................................10
1.6.5 General data:........................................................................................10
1.7 Scope of supply....................................................................................11
1.7.1 Standard accessories :.........................................................................11
1.7.2 Special accessories :............................................................................11
1.7.3 Racks and cable drums........................................................................11
2Operation and indication panel of the SPG 32................ 12
2.1 Connection panel .................................................................................14
3Safety ................................................................................. 15
3.1 Detachable-key switch..........................................................................15
3.2 Safety terms as per VDE 0104 (EN 50191)..........................................15
3.2.1 Mains connection .................................................................................15
3.2.2 Ready for operation..............................................................................15
3.2.3 Ready for switching on .........................................................................16
3.3 VDE regulations 0104 (EN 50191) .......................................................16
3.3.1 Non-steady test equipment ..................................................................16
3.3.2 Danger zone.........................................................................................16
3.3.3 Emergency-Off switch ..........................................................................16
4Putting into operation....................................................... 17
4.1 General attentions ................................................................................17
4.1.1 The five safety rules .............................................................................17
4.1.2 Connection diagram .............................................................................18
4.1.3 Earthing the instrument ........................................................................18
4.1.4 Connecting the high voltage lead to the instrument .............................19
4.1.5 Connecting the high voltage lead to the faulty cable ............................19
4.1.6 Cordoning off open cable ends ............................................................20

II
4.1.7 Connecting the voltage supply .............................................................20
4.2 Switching on .........................................................................................21
4.3 Function selection ................................................................................21
5Shock discharge operation .............................................. 22
5.1 Selection of the surge voltage ..............................................................22
5.2 Putting the shock discharge generator into operation ..........................23
5.2.1 Setting the impulse sequence ..............................................................23
5.2.2 Single pulse..........................................................................................23
5.2.3 Current coupling measurement ............................................................24
5.3 Switching the shock discharge generator off........................................24
5.4 Safety information for shock discharge operation ................................25
5.4.1 Fault location in plastic insulated cables ..............................................25
5.4.2 Working on open cable trenches..........................................................25
5.5 Disconnecting the leads .......................................................................25
6Shock discharge operation with arc generation (ARM) . 26
6.1 Connection mode for the arc reflection method (ARM) ........................26
6.2 Function: shock discharge operation with arc reflection (ARM)............26
6.3 Working with the short-term arc reflection method (ARM)....................27
6.4 Switching off the ARM-function ............................................................27
7Sheath fault location......................................................... 28
7.1 Sheath fault location operation.............................................................28
8High voltage testing.......................................................... 29
8.1 Working with the testing mode .............................................................29
8.2 Voltage coupling...................................................................................30
8.3 Switching off testing operation .............................................................30
9Malfunctions and error messages ................................... 31
9.1 Switch-on not possible ! .......................................................................31
9.2 Excess temperature .............................................................................31
9.3 Acoustic signal .....................................................................................32

III
List of figures
Figure 1 : Functional diagram of a shock discharge generator....6
Figure 2 : Functional diagram of the arc reflection method .........7
Figure 3 : Functional diagram of sheath fault location. ................7
Figure 4 : High voltage generation for the test branch 32 kV. .....8
Figure 5 : Operation and indication panel of the SPG 32 ..........12
Figure 6 : Connection panel SPG 32......................................... 14

4
1 Description
1.1 General
As a stand-alone device, the SPG 32 serves for cable fault
pinpointing by the acoustic method (surging), for sheat fault location
as per the DC step voltage method and for testing of cable
installations up to 32 kV DC.
1.2 Design
The SPG 32 is a fully enclosed, autonomous instrument and can be
operated without any accessory devices. For reasons of weight,
however, a transport vehicle of suitable size is required. In
conjunction with a cable drum rack, operation form the inside of a
cable test van is possible. Naturally, the unit can also be transported
directly to the test site by means of a small trolley. In this case, short
connection leads are sufficient and a cable drum rack is not
required.
All operating and indicating elements are mounted on the front
panel of the instrument, thus ensuring an easy operation.
The operating and indicating elements belonging to the safety
equipment are also situated on the front panel with the exception of
the detachable-key switch. All connections are made on the
connection panel at the rear of the instrument, thus isolating the
operator from the high voltage carrying output sockets.

5
1.3 Operation as a complete test- and fault location system
Surgeflex 32
Through the combination with an appropriate reflectometer (e.g.
T3060, Teleflex SX, Teleflex VX), the abilities and functions of the
SPG 32 are complemented by modern fault location methods,
without losing its mobility.
These Surgeflex 32 systems are mostly delivered hardwired on a
trolley or as in-vehicle installation. It is also possible to upgrade an
existing SPG 32 with a reflectometer. Please get in touch with the
local Megger-representation.

6
1.4 Function
The SPG 32 has several functions which are described hereunder.
It is to be noted that all these functions are accommodated in one
housing.
1.4.1 Shock discharge generator
Figure 1 shows the basic function of a shock discharge generator.
The impulse capacitor C (with voltage levels 8, 16 and 32 kV) which
is charged by the switchable high voltage power supply unit,
discharges into the faulty cable via the working spark gap AF. A
possible residual charge of the cable or the instrument is shunted
through the earthing spark gap EF when the instrument is switched
off.
Figure 1 : Functional diagram of a shock discharge generator.
AF = Working spark gap
E = Energy content in Joules or Ws
EF = Earthing spark gap
C = Impulse capacitor in µF
U = Voltage in kV
Lk = Linear coupler for impulse current measurement
The output of a shock discharge generator is determined by the
formula in figure 1.
Example for SPG 32-1750 (32 kV-level

C = 3,4
µ
F):
U = 32 kV E = 1750 Joule
U = 16 kV E = 437 Joule

7
1.4.2 Arc reflection method (ARM)
In the arc reflection method (ARM), the voltage coming from the
impulse capacitor C generates a flashover at the fault. The resulting
arc is maintained by the resistance R which enables a pulse
reflection measurement to be carried out during the arc duration.
Coupling of the reflectometer (Teleflex) is made via high voltage
proof capacitors. The setup of the arc reflection method is shown in
figure 2.
Figure 2 : Functional diagram of the arc reflection method
1.4.3 Sheath fault location
For the location of sheath faults in plastic insulated meedium and
high voltage cables, DC impulses are used which are fed in
between screen and earth. The current escapes at the sheath fault
and generates a voltage peak in the surrounding earth which is
pinpoint located by the step voltage method. In the operation mode
"MFO" (sheath fault location) the SPG 32 can be used as a supply
for sheath fault location. Figure 3 shows the basic function. Of
special importance is the series resistance R, which prevents the
full charging power of the impulse capacitor from reaching the point
of fault. This avoids a thermal overload at the fault.
Tr1
C
AF
EF
+
-
R
Figure 3 : Functional diagram of sheath fault location.

8
1.4.4 High voltage testing
For high voltage testing, a special high voltage source is installed in
the SPG 32, which is fed from the transformer Tr 1. This ensures,
that no capacitance is paralleled to the test object. The functional
diagram of this circuit is shown in figure 4.
Figure 4 : High voltage generation for the test branch 32 kV.
In case of a flash-over, the capacitively coupled reflectometer
(Teleflex) allows a pre-location of the flash-over location by means
of the recorded oscillating voltage curve (DECAY method).
1.5 Power Supply
For power supply of the SPG 32, a 230 V AC mains with a
frequency of 45 - 60 Hz is required. If a portable generator is used
for external current supply, it has to have an output power of at least
2 kVA due to the largely varying load on shock discharge operation.

9
1.6 Technical characteristics
1.6.1 Shock discharge operation "SWG"
a.
Output stage I.
0 – 8 kV
1750 Ws
3500 Ws (optional)
b.
Output stage II.
0 – 16 kV
1750 Ws or
3500 Ws (optional)
c.
Output stage III.
0 – 32 kV
1750 Ws or
3500 Ws (optional)
d
Optional output stage
0 – 4 kV
1200 Ws
e.
Impulse rate approx.
2.5 – 10 seconds
f.
Single impuls
triggered manually
g.
Short circuit current
0 – 8 kV
200 mA
0 – 16 kV
100 mA
0 – 32 kV
50 mA
1.6.2 Arc Reflection Method "ARM"
a.
Max. ignition voltage
32 kV
b.
Arc duration
1 – 10 ms
1.6.3 Sheath fault location "MFO"
a.
Output voltage
0 – 5 kV
b.
Output current
0 – 160 mA
c.
Pulsed output approx.
2.5 – 10 sec.
d.
Sheath fault location
0 – 5 V

10
1.6.4 High voltage testing "HPG"
a.
Output voltage
0 – 32 kV
b.
Test current
0 – 20 mA
1.6.5 General data:
a.
Weight
1750 J version
3500 J version
135 kg
173 kg
b.
Dimensions (WxDxH)
1750 J version
3500 J version
520 x 430 x 750 mm
520 x 700 x 750 mm
c.
Protection type
IP 21

11
1.7 Scope of supply
1.7.1 Standard accessories :
a.
Shock discharge, high voltage testing
and sheath fault location unit.
SPG
32
b.
Set of cables
consisting of
1. High voltage connection lead
HSK
20
2. Trigger cable for current coupling
VK
24
3. Connection lead arc reflection
method (ARM)
VK
24
4. Trigger cable arc reflection
method (ARM)
VK
24
5. Trigger cable for voltage coupling
VK
24
6. Mains connection lead
NKG
S
7. Earthing lead
EK
1
1.7.2 Special accessories :
c.
Isolation transformer
(2.000 or 2.500 VA)
GTV
d.
Emergency – Off switch
NAG
1
1.7.3 Racks and cable drums
Various racks for installation in a cable test van or for combination
with other measuring systems are available. A connection of
F - Ohm and FU safety equipment is possible.
For operation of the SPG from inside of a vehicle, different cable
drum systems can be offered.
Offers for racks (modules) and cable drums can be had on request.
For this purpose, we would require detailed information, e.g. about
the type of vehicle, payload space available and the required
lengths of cables.

12
2 Operation and indication panel of the SPG 32
Figure 5 : Operation and indication panel of the SPG 32
Legend on next page.

13
1. Multipurpose meter with % indication
200 mA for sheath fault location
20 mA for high voltage testing
250 V for arc reflection method (ARM) and shock discharge
operation
2. Variac for voltage setting
3. Rotary plug switch for coarse voltage selection
4 (optional) / 8 – 16 – 32kV.
4. kV-meter 0 – 8 – 16 – 32 kV
5. Pilot lamp : function short-term arc reflection ("ARM")
6. Pilot lamp : function shock discharge
7. Pilot lamp : function high voltage testing
8. Pilot lamp : function sheath fault location
9. Rotary switch for function selection
10. Switch current measuring range to 2 mA (MFO and HPG mode)
(for units with the optional 4 kV output stage, this switch is also
used to activate 4 kV surge voltage in SWG and ARM mode)
11. Timing pulse rate 2.5 - 10 s
12. Single impuls in shock discharge operation and overtemperature
indicator
13. High voltage "ON"
14. "ON" and mains supply indicator
15. "Off" (all functions)

14
2.1 Connection panel
Figure 6 : Connection panel SPG 32
1. High voltage terminal (output)
2. Trigger lead for current coupling
3. ARM connecting lead
4. Trigger lead ARM
5. Trigger lead for voltage coupling
6. Connection terminal for emergency off device
7. Mains fuse 10A
8. Mains fuse 10A
9. Fuse for control circuits 0.8 A
10. Socket : Mains connection 230 V AC
11. Socket : Protective earthing
12. Signal device for faulty operation
13. Detachable-key switch

15
3 Safety
The SPG 32 delivers a dangerous contact voltage of >1kV and must
hence only be operated by trained personnel. The following safety
measures have to be observed:
3.1 Detachable-key switch
For reasons of product liability, it must be made sure that test
instruments, which deliver a dangerous contact voltage cannot be
switched on unintentionally by unauthorized persons. The SPG 32
has a detachable-key switch, which has to be kept in safe keeping
by the responsible person. This detachablekey switch is situated on
the connection panel at the rear of the instrument (item 13).
3.2 Safety terms as per VDE 0104 (EN 50191)
3.2.1 Mains connection
Indicated by the white illuminated button (14). Mains voltage is con
nected. The instrument is not yet switched on. The white illuminated
button (14) lights continuously and cannot be switched off.
3.2.2 Ready for operation
Indicated by the green illuminated button (13). The instrument is
switched on, but no high voltage is present. The output is shorted
and earthed.
Using cardiac pacemaker
Physical processes during operation of high voltage may
endanger persons wearing a cardiac pacemaker when near
these high voltage facilities.

16
3.2.3 Ready for switching on
Indicated by the red illuminated button (15). The green illuminated
button (13) extinguishes. The instrument is switched on. High
voltage can be present ! Caution : DANGER.
Note: If the green illuminated push button (13) when depressed
extinguishes, but the red illuminated push button (15) does
not light up, the switching state "Ready for switching ON" is
also valid. DANGER !!
3.3 VDE regulations 0104 (EN 50191)
3.3.1 Non-steady test equipment
As per VDE 0104, the place of setting-up and connecting the
instrument, including the start end of the cable to be tested,
constitutes a non-steady test equipment and is considered a test rig
which is not protected against physical contact. The same goes for
the far end (or ends) of the cable under test.
3.3.2 Danger zone
Test rigs without protection against physical contact have to be
cordoned off, secured and marked with danger notices since they
constitute danger areas with different danger zones.
3.3.3 Emergency-Off switch
On principle, test rigs have to be fitted with an emergency-Off
switch. For the SPG 32, an emergency-Off switch NAG 1 is
available as an optional extra. It is connected to socket (6) on the
connection panel at the rear of the instrument. For the purpose of
operating the instrument with other emergency switching devices, a
dummy plug is mounted to the socket (6).