Megger Surgeflex 12 User manual

Issue: 1 (10/2015) – EN
84983
Operating Manual
SPG 12-1100 / 16-2000 /
Surgeflex 12 / 16
Mess- und Ortungstechnik
Measuring and Locating Technologies
Leitungsortung
Line Locating
Rohrleitungsnetze
Water Networks
Kommunikationsnetze
Communication Networks
Elektrizitätsnetze
Power Networks

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 Lifting and carrying .................................................................................4
1.3 Design ....................................................................................................4
1.4 Operation as a complete test- and fault location system Surgeflex........5
1.5 Function..................................................................................................6
1.5.1 Shock discharge generator.....................................................................6
1.5.2 Arc reflection method (ARM) ..................................................................8
1.5.3Sheath fault location...............................................................................8
1.5.4 High voltage testing up to 17 kV (SPG 12) or 24 kV (SPG 16)...............9
1.6 Power Supply .........................................................................................9
1.7 Technical characteristics SPG 12.........................................................10
1.7.1 Shock discharge operation "SWG".......................................................10
1.7.2 Arc Reflection Method "ARM"...............................................................10
1.7.3 Sheath fault location "MFO" .................................................................10
1.7.4 High voltage testing "HPG"...................................................................10
1.7.5 General data:........................................................................................10
1.8 Technical characteristics SPG 16.........................................................11
1.8.1 Shock discharge operation "SWG".......................................................11
1.8.2 Arc Reflection Method "ARM"...............................................................11
1.8.3 Sheath fault location "MFO" .................................................................11
1.8.4 High voltage testing "HPG"...................................................................11
1.8.5 General data:........................................................................................11
1.9 Scope of supply....................................................................................12
1.9.1 Standard accessories:..........................................................................12
1.9.2 Special accessories:.............................................................................12
1.9.3 Racks and cable drums........................................................................12
2Operation and indication panel of the SPG 12/16........... 13
2.1 Connection panel .................................................................................15
3Safety ................................................................................. 16
3.1 Detachable-key switch..........................................................................16
3.2 Safety terms as per VDE 0104 (EN 50191)..........................................16
3.2.1 Mains connection .................................................................................16
3.2.2 Ready for operation..............................................................................16
3.2.3 Ready for switching on .........................................................................17
3.3 VDE regulations 0104 (EN 50191) .......................................................17
3.3.1 Non-steady test equipment ..................................................................17
3.3.2 Danger zone.........................................................................................17
3.3.3 Emergency-Off switch ..........................................................................17
4Putting into operation....................................................... 18

II
4.1 General attentions ................................................................................18
4.1.1 The five safety rules .............................................................................18
4.1.2 Connection diagram .............................................................................19
4.1.3 Earthing the instrument ........................................................................19
4.1.4 Connecting the high voltage lead to the instrument .............................19
4.1.5 Connecting the high voltage lead to the faulty cable ............................20
4.1.6 Cordoning off open cable ends ............................................................21
4.1.7Connecting the voltage supply .............................................................21
4.2 Switching on .........................................................................................22
4.3 Function selection ................................................................................22
5Shock discharge operation .............................................. 23
5.1 Selection of the surge voltage ..............................................................23
5.2 Putting the shock discharge generator into operation ..........................24
5.2.1 Setting the impulse sequence ..............................................................24
5.2.2 Single pulse..........................................................................................24
5.2.3 Current coupling measurement ............................................................25
5.3 Switching the shock discharge generator off........................................25
5.4 Safety information for shock discharge operation ................................26
5.4.1 Fault location in plastic insulated cables ..............................................26
5.4.2 Working on open cable trenches..........................................................26
5.5 Disconnecting the leads .......................................................................26
6Shock discharge operation with arc generation (ARM) . 27
6.1 Connection mode for the arc reflection method (ARM) ........................27
6.2 Function: shock discharge operation with arc reflection (ARM)............27
6.3 Working with the short-term arc reflection method (ARM)....................28
6.4 Switching off the ARM-function ............................................................28
7Sheath fault location......................................................... 29
7.1 Sheath fault location operation.............................................................29
8High voltage testing.......................................................... 30
8.1 Working with the testing mode .............................................................30
8.2 Voltage coupling...................................................................................31
8.3 Switching off testing operation .............................................................31
9Malfunctions and error messages ................................... 32
9.1 Switch-on not possible ! .......................................................................32
9.2Excess temperature .............................................................................32
9.3 Acoustic signal .....................................................................................33

III
List of figures
Figure 1 : Functional diagram of a shock discharge generator....6
Figure 2 : Functional diagram of the arc reflection method .........8
Figure 3 : Functional diagram of sheath fault location. ................8
Figure 4 : High voltage generation for the test branch.................9
Figure 5 : Operation and indication panel of the SPG 16 ..........13
Figure 6 : Connection panel ...................................................... 15

4
1 Description
1.1 General
As a stand-alone device, the SPG 12/16 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 17 or 24 kV DC respectively.
1.2 Lifting and carrying
The device must only be lifted and carried using the handles
provided on the side. The handles mounted on the front panel
cannot withstand the forces caused by lifting the device and could
break or tear off as a result.
1.3 Design
The SPG 12/16 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
1.4 Operation as a complete test- and fault location system
Surgeflex
Through the combination with an appropriate reflectometer (e.g.
T3060, Teleflex SX, Teleflex VX), the abilities and functions of the
SPG 12/16 are complemented by modern fault location methods,
without losing its mobility.
These Surgeflex 12/16 systems are mostly delivered hardwired on a
trolley or as in-vehicle installation. It is also possible to upgrade an
existing SPG 12/16 with a reflectometer. Please get in touch with
the local Megger-representation.

6
1.5 Function
The SPG 12/16 has several functions which are described
hereunder. It is to be noted that all these functions are
accommodated in one housing.
1.5.1 Shock discharge generator
Figure 1 shows the basic function of a shock discharge generator.
The impulse capacitor C (with voltage levels 3, 6, 12 kV or 4, 8,
16 kV respectively) 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

7
The output of a shock discharge generator is determined by the
formula in figure 1.
Example for SPG 16-2000 (16 kV-level C = 15,6 µF):
U = 16 kV E = 2000 Joule
U = 8 kV

E = 500 Joule
Example for SPG 12-1100 (12 kV-level C = 15,6 µF):
U = 12 kV E = 1100 Joule
U = 6 kV

E = 275 Joule

8
1.5.2 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
1.5.3 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 12/16 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.

9
1.5.4 High voltage testing up to 17 kV (SPG 12) or 24 kV (SPG 16)
For high voltage testing, a special high voltage source is installed in
the SPG 12/16, which is fed from the transformer Tr 2. This
ensures, that no capacitance is paralleled to the test object. The
functional diagram of this circuit is shown in figure 4.
Tr2
TDR Teleflex
Figure 4 : High voltage generation for the test branch.
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).
1.6 Power Supply
For power supply of the SPG 12/16, 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.

10
1.7 Technical characteristics SPG 12
1.7.1 Shock discharge operation "SWG"
a.
Output stage I.
0 – 3 kV
1100 Ws
b.
Output stage II.
0 – 6 kV
1100 Ws
c.
Output stage III.
0 – 12 kV
1100 Ws
d.
Impulse rate approx.
2.5 – 10 seconds
e.
Single impuls
triggered manually
f.
Short circuit current
0 – 3 kV
400 mA
0 – 6 kV
200 mA
0 – 12 kV
100 mA
1.7.2 Arc Reflection Method "ARM"
a.
Max. ignition voltage
12 kV
b.
Arc duration
1 – 10 ms
1.7.3 Sheath fault location "MFO"
a.
Output voltage
0 – 5 kV
b.
Output current
0 – 120 mA
c.
Pulsed output approx.
2.5 – 10 sec.
d.
Sheath fault location
0 – 5 V
1.7.4 High voltage testing "HPG"
a.
Output voltage
0 – 17 kV
b.
Test current
0 – 1 mA
1.7.5 General data:
a.
Weight
135 kg
b.
Dimensions (WxDxH)
520 x 430 x 750 mm
c.
Protection type
IP 20

11
1.8 Technical characteristics SPG 16
1.8.1 Shock discharge operation "SWG"
a.
Output stage I.
0 – 4 kV
2000 Ws
b.
Output stage II.
0 – 8 kV
2000 Ws
c.
Output stage III.
0 – 16 kV
2000 Ws
d.
Impulse rate approx.
2.5 – 10 seconds
e.
Single impuls
triggered manually
f.
Short circuit current
0 – 4 kV
400 mA
0 – 8 kV
200 mA
0 – 16 kV
100 mA
1.8.2 Arc Reflection Method "ARM"
a.
Max. ignition voltage
16 kV
b.
Arc duration
1 – 10 ms
1.8.3 Sheath fault location "MFO"
a.
Output voltage
0 – 5 kV
b.
Output current
0 – 120 mA
c.
Pulsed output approx.
2.5 – 10 sec.
d.
Sheath fault location
0 – 5 V
1.8.4 High voltage testing "HPG"
a.
Output voltage
0 – 24 kV
b.
Test current
0 – 1,4 mA
1.8.5 General data:
a.
Weight
135 kg
b.
Dimensions (WxDxH)
520 x 430 x 750 mm
c.
Protection type
IP 20

12
1.9 Scope of supply
1.9.1 Standard accessories:
a.
Shock discharge, high voltage testing
and sheath fault location unit.
SPG
12/16
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
1.9.2 Special accessories:
a.
Isolation transformer
(2.000 or 2.500 VA)
GTV
b.
Emergency – Off switch
NAG
1
c.
Internal F-Ohm safety device
1.9.3 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 12/16 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.

13
2 Operation and indication panel of the SPG 12/16
Figure 5 : Operation and indication panel of the SPG 16
Legend on next page.

14
1. Multipurpose meter with % indication 200 mA for sheath fault
location 2 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
3 – 6 – 12 kV (SPG 12) or
4 – 8 – 16 kV (SPG 16)
4. kV-meter (scale depends on model)
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 for test current 2 mA - 0.2 mA (MFO and HPG 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)
16. Circuit breaker 6 A

15
2.1 Connection panel
Figure 6 : Connection panel
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 10 A
8. Mains fuse 10 A
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
14. Operational earth connection (only relevant when installed in a
test van)
15. Protected 14.5 VDC power output for TFX SX

16
3 Safety
The SPG 12/16 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 12/16 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.