Megger VLF CR-28 User manual

VLF Test System
VLF CR−
28 kV
Date of issue: 05 (01/2010) - EN
Operating Manual
Subject No.: 128312950
Mess- und Ortungstechnik
Measuring and Locating Technologies
Leitungsortung
Line Locating
Rohrleitungsnetze
Water Networks
Kommunikationsnetze
Communication Networks
Elektrizitätsnetze
Power Networks

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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 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 disclaim all responsibility for damage resulting directly or indirectly from the
delivery, supply, or use of this matter.

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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 de-
fects 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 author-
ized 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
1. GENERAL INTRODUCTION.................................................. 1-8
1.1 Safety Precautions................................................................................. 1-9
1.1.1 General Safety Precautions................................................................... 1-10
1.1.2 Supplementary Guidelines..................................................................... 1-11
1.1.3 Danger Due To Returning Voltage From Space Charge ....................... 1-11
1.1.4 General Rules for Dealing with High Voltage......................................... 1-13
2. TECHNICAL DESCRIPTION ............................................... 2-14
2.1 Technical Specification....................................................................... 2-14
2.1.1 VLF Test System 28 kV ......................................................................... 2-14
2.2 Description of the VLF Test System................................................... 2-15
2.3 Description of components of the VLF Test System 28 kV.............. 2-18
2.3.1 Operating module .................................................................................. 2-18
2.3.2 Display of the Operating module............................................................ 2-19
2.3.3 VLF Test System as a whole ................................................................. 2-20
2.3.4 Protection covers of the modules .......................................................... 2-22
3. DESCRIPTION OF THE TEST METHOD ............................ 3-23
4. SETTING-UP OPERATION ................................................. 4-24
4.1 Safety Precautions............................................................................... 4-24
4.2 Electrical Connection of the VLF Test System.................................. 4-26
4.2.1 General Rules for Making Connections ................................................. 4-26
4.2.2 Connecting the Earth Cable................................................................... 4-26
4.2.3 Connecting the Test Object ................................................................... 4-26
4.2.4 Connecting the Mains Cable.................................................................. 4-26
5. EXECUTION OF TESTS ...................................................... 5-27
5.1 VLF / DC Test ....................................................................................... 5-27
5.2 Sheath Fault Location (SFL) ............................................................... 5-29
5.3 Starting the Test / Location................................................................. 5-29

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6. ADDITIONAL FUNCTIONS ..................................................6-32
6.1 Adjustment of Language ..................................................................... 6-32
6.2 Viewing the System Information......................................................... 6-32
6.3 Viewing / Setting the System Parameters.......................................... 6-33
6.4 Entering / Changing the Administrator Password ............................ 6-34
6.5 Returning to the start menu ................................................................ 6-35
7. Optional Features ...............................................................7-36
7.1 Detection of Breakdown and Short Circuit........................................ 7-36
7.2 Measurement of Leakage Current ...................................................... 7-36
7.3 Internal Protocol Printout.................................................................... 7-37
7.4 Using a SystemCard ............................................................................ 7-39
7.4.1 Purpose of a SystemCard...................................................................... 7-39
7.4.2 Preparing a SystemCard........................................................................ 7-40
7.4.3 Logging to SystemCard ......................................................................... 7-41
7.4.4 Operating the Test System with a SystemCard ..................................... 7-43
7.5 Function User Setup / User Level....................................................... 7-44
7.6 Re-Setting the System Settings / Deleting the Print Templates....... 7-45
7.7 Adjustment of the System Timer ........................................................ 7-46
8. Maintenance and Troubleshooting....................................8-47
8.1 How to Exchange the Paper Roll or Ink Ribbon of the Printer......... 8-47
8.2 Replacing the Battery of the System Clock ....................................... 8-48
8.3 Connecting Cables, HV Couplings ..................................................... 8-49
8.4 Operational and Error Messages........................................................ 8-49
8.4.1 Classification of Messages .................................................................... 8-49
8.4.2 Operational Messages about State of System....................................... 8-50
8.4.3 Operational Messages about Switching Conditions............................... 8-53
8.4.4 Error Messages and Warnings .............................................................. 8-55

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INDEX OF FIGURES
Fig 1: Representation of the test voltage characteristics (Device option Plus) 2-17
Fig 2: voltage waveform during polarity inversion ............................................ 2-17
Fig 3: Operating module, Front View ............................................................... 2-18
Fig 4: Display of the Operating module............................................................ 2-19
Fig 5: Connections at the right hand side of the VLF Test System.................. 2-20
Fig 6: Connectors on the rear of the VLF Test System.................................... 2-21
Fig 7: Protection cover of the Operating module (optional available also for HV-
module).................................................................................................. 2-22
Fig 8: Connection of the test object ................................................................. 4-26
Fig 9: Start menu ............................................................................................. 5-27
Fig 10: Selection of the operation mode............................................................ 5-27
Fig 11: Selection of the test voltage................................................................... 5-28
Fig 12: Selection of the test time ....................................................................... 5-28
Fig 13: Selection of the pulse rate ..................................................................... 5-29
Fig 14: HV on.................................................................................................... 5-29
Fig 15: Cable test............................................................................................... 5-30
Fig 16: Start menu after the test has been finished........................................... 5-31
Fig 17: User Setup: Language........................................................................... 6-32
Fig 18: Setup: System Informationen ................................................................ 6-32
Fig 19: Setup: Parameters................................................................................. 6-33
Fig 20: Setup: Enter password .......................................................................... 6-34
Fig 21: Setup: Entered password ok.................................................................. 6-34
Fig 22: Setup: Enter new password ................................................................... 6-35
Fig 23: Setup: New password stored ................................................................. 6-35
Fig 24: Setup: Return to start menu................................................................... 6-35
Fig 25: Breakdown detection ............................................................................. 7-36
Fig 26: Setup: Protocol Printout Off ................................................................... 7-37
Fig 27: Setup: Protocol Printout Standard ......................................................... 7-37
Fig 28: Setup: Protocol Off ................................................................................ 7-41
Fig 29: Setup: Protocol Extended ...................................................................... 7-41
Fig 30: Start menu with SystemCard inserted ................................................... 7-43
Fig 31: Start menu after new system settings have been stored ....................... 7-43
Fig 32: Setup: User Profile................................................................................. 7-44
Fig 33: Setup, Memory ...................................................................................... 7-45
Fig 34: Setup Date / Time.................................................................................. 7-46
Fig 35: Setup Date / Time: adjusting the day of the week ................................. 7-46
Fig 36: Setup Date / Time: adjusting the minutes.............................................. 7-46
Fig 37: Setup Date / Time: Saving by F1........................................................... 7-46
Fig 38: Unscrewing the printer front cover ............... Fig 39: Removing the front cover 8-47
Fig 40: Removing the ribbon cartridge............... Fig 41: Inserting the ribbon cartridge 8-47
Fig 42: Inserting paper roll into the printer.......................................................... 8-48
Fig 43: Paper feed button................................................................................... 8-48

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1. GENERAL INTRODUCTION
The VLF Test System shall be used for the stated field of application in cable diagnosis
only. Any other application is strictly forbidden! Megger cannot be made liable for any
damage to persons or matter caused by using the system for some other application.
This is why we advise you to absolutely abide by the safety precautions given in
chapter1 whenever you use the VLF Test Systems.
Each person involved in the assembly, operation, maintenance, and repair of the VLF
Test Systems is required to have read this handbook carefully.
Only trained and/or instructed staff are permitted to deal with the VLF Test System and
its periphery. Other persons have to stay away.
This handbook must be available to the supervising, operating, and maintenance staff
for reference.
Never use foreign components on the VLF Test System and its periphery, otherwise the
safety of the system is jeopardised.
The user is obliged to immediately report any occurring change in the system to the
supervisor in charge.
The operator is obliged to immediately shut down the system should any fault occur
that might pose a threat to the staff. The system is permitted to be switched on again
only after the fault has been eliminated.
The VLF Test System and all its supplementary equipment has to be connected and
operated according to instructions. All relevant standards (DIN, VDE) shall be met. Any
repair or maintenance operation may be carried out only after all circuits have been
shut down (are in a dead state) and only by an electrical expert. A person is regarded
an electrical expert if due to his or her practical training, knowledge, and experience as
well as knowledge of the relevant standards he or she is able to assess the operation to
be carried out and detect every possible risk.
Attention!
The VLF Test System 28 kV is a upright device and has to be only transported
and operated in upright position.

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1.1 Safety Precautions
Each person involved in the assembly, maintenance, and repair of this system is
required to have read this manual carefully.
At the time of supply, this system and its supplementary equipment are in line with the
state of the art in safety control. Due to the operating procedures there may be parts
and places of the system and its peripherals, however, which cannot be protected
properly without unreasonably interfering with their function and control. This is why
comprehensive personal experience in safety matters is absolutely vital for the
protection of both staff and equipment.
This is why we advise you to abide by the following safety precautions!
GENERAL INSTRUCTIONS
Only trained or instructed staff are permitted to deal with this system and its
peripherals. Any other persons shall be kept away from it.
This manual shall be available to the supervising, operating, and maintenance staff for
reference.
Improper use may constitute a high risk of damage to the life and health of the operator
as well as the system and the equipment connected to it (UVV). Use the system
exclusively for the purpose it has been designed for by its manufacturer.
Always use the appropriate tools for each operation on and for running the system and
keep your tools in good condition.
Permanently supervise that during operation and maintenance all safety precautions
are obeyed.
This system is allowed to be run by authorised persons with sufficient expertise only.
Operate the system and its pertaining peripherals only when they are in good working
order.
Never use foreign components on the system and its peripherals, otherwise the safety
of the system and its environment is not ensured. Refrain from any operation which
might jeopardise the safety of the system.
The user is obliged to immediately report any arising change in the system to the
supervisor in charge.
The operator is obliged to immediately shut down the system whenever a fault occurs
which may be safety risk to the staff. The system is permitted to be switched on again
only after the fault has been remedied.
Attention! Owing to the physical processes which take place within the high-
voltage system, each person wearing a pacemaker is in potential
danger when getting close to it.

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ELECTROTECHNICAL INSTRUCTIONS
The system and all its peripherals shall be connected according to instructions. All
relevant standards such DIN and VDE respectively, have to be met.
Any repair or maintenance operation may be carried out only after all circuit have been
shut down (are in a dead state) and only by an electrical expert according to UVV. A
person is regarded an electrical expert to UVV (Prevention of Accidents Regulation) if
due to his or her practical training, knowledge, and experience he or she is able to
clearly understand the operation to be carried out and detect any possible risk.
1.1.1 General Safety Precautions
Abide by the relevant Accident Prevention Regulations in the first place when you carry
out maintenance and repair operations.
Mark all components before you start any repair operation.
Always use new sealing and locking elements when you re-assemble fittings and
devices.
Leave all screw joints dry when assembling them (do not lubricate!).
Only trained staff are permitted to carry out maintenance and repair work.
Check the system for functionality whenever you have finished maintenance and repair
operations; this has to be particularly accepted in the case of existent safety equipment.
De-energise the system and make the site safe.
Before starting any operation on electrical units: De-energise all components you are
going to work on.
This applies even in the event that the repair seems to be marginal.
Make the place(s) of disconnection safe against any unintentional circuit reclosing.
After de-energising the system, before starting any work on the site: Check all
components of the system for all-pole disconnection.
Do so using a circuit tester or meter the functionality of which has been tested on a live
member of the system a short time before using it.
Fuses
It is absolutely inadmissible to patch or bridge a fuse or to use a patched fuse.
When replacing a fuse: Always use a fuse of identical or lower current rating and
characteristic (slow, fast, superfast action).
Never unscrew or pull out a fuse while it is under load. It is inadmissible to use a fuse
for switching a circuit.
Further important safety instructions:
- High-voltage installations has to be only operated in rooms with
protection according to regulations or behind appropriate barriers.
Never bypass nor render inactive any safety device.

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- At least two persons must be present whenever a high-voltage
installation is in operation. The second person shall be able to
recognise any risk and, in case of emergency, immediately actuate the
emergency-shutdown.
1.1.2 Supplementary Guidelines
The following guidelines which can not be directly derived from the instructions should
be added to the above mentioned regulations.
- Always connect all metal parts in the vicinity of a high-voltage
installation to earth in order to avoid dangerous charging. Particularly
great attention should be paid to non-stationary (mobile) operation.
- Open a circuit only when you are absolutely sure it does not carry any
current or voltage (danger of arcs).
- High-voltage testing and burning devices are short-circuit-proof. This
involves the danger of the voltage running up as soon as the short-
circuit is removed. Connect a bleeder in parallel to the meter (e. g., a
90 V glow-type bleeder) when making a short-circuit test.
- Even after circuits have been properly disconnected and discharged,
you are permitted to contact components which had been under voltage
and disconnect any measuring or test equipment only after the
installation has been visibly earthed and shorted by an appropriate
device.
1.1.3 Danger Due To Returning Voltage From Space Charge
- Remove earth connection and short circuit only when the object under
test is going to be put into operation again.
- As a basic principle capacitors and cables which are out of operation
must be earthed and shorted!
Attention! The test object has to be connected to earth and shorted after terminating
of the test.
You are not excused from this duty even the complete discharge by the
internal discharging unit and the zero positioning of the residual voltage
(Fig 3, item 2) have been performed.
In the case of an incomplete discharge of the test object the complete
discharging must be carried out by a suitable discharge rod.

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Attention! The HV module of the VLF Test System 28 kV contains electrical energy
storage devices also. These devices are discharged in the same way like
the test object by the internal discharging unit of the test device. To avoid
the re-charging by space charges the HV module has to be immediately
equipped by means of the provided shorting device (Fig 8) after
disconnection of the both components HV module and Operating module.
The shorting device has to be remained at the HV module even in the
case of transportation and storage and may not be removed until the
Operating module had been put on.
Instructions How to Handle Fixed and Flexible Cables and Leads
Do not use mains cables and their fixtures for attaching, fixing, or hanging up devices,
clothes, etc.
Make sure that the cables are not bent while being disconnected. Prevent any moisture
from infiltrating into the cable ends. Affix an appropriate moisture shelter, if need be.
Do not expose flexible leads to excessive tensile force while in operation or during
transport. In particular, make sure that the instruments are not hung by their leads and
that plugs are not pulled out of sockets by their leads.
How to Deal With Connectors and Cable Accessories
Connect every electrical removable appliances only by the connectors (plug, socket)
intended for this purpose.
Do not use any adapter or plug which matches a socket for some other voltage.
Use appropriate lock washers and spring washer to make every cable connecting ter-
minal safe against becoming detached.
When re-connecting a cable to a device or installation: Make sure that the cable shield
is connected to earth (by an earthing cone) and the cable inlet is sealed (in accordance
with the enclosure protection of the connected device).
As a rule, such installations contain a great number of connecting leads to the compo-
nents of the system and between individual components. Never misuse a connecting
lead, which is not insulated for operation under medium of high voltage, for making an
HV connection. Do not use patch cords for making HV connections. There might be
discharges between such a lead and other system components which would immedi-
ately destroy the insulating capacity of this lead and so do away with its safety.
Use only cables and connectors intended for application under high voltage
(HV cables or leads without insulation)!

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1.1.4 General Rules for Dealing with High Voltage
Dealing with high voltage and related equipment requires utmost care. This applies in
particular to cases of non-stationary (mobile) operation, i.e. such instances where there
is no special room which is permanently furnished with the appropriate safety equip-
ment to provide for safety from the start.
Absolutely abide by the VDE directive 0104 "Installation and operation of electrical test
systems" or relevant IEC standards, respectively.

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2. TECHNICAL DESCRIPTION
2.1 Technical Specification
2.1.1 VLF Test System 28 kV
Output voltage, DC 2 ... 28 kV
Output current source 12 mA
Range of indication,
Leakage current measurement 0 ... 12 mA
Resolution of indication 10 µA
Output voltage, VLF 2 ... 28 kV
Frequency 0.1 Hz
Waveform rectangular cosine
Cable capacitance to be tested
VLF Test System 28 kV Plus 4,6 µF (for full operating temperature
range)
5 µF (at common temperatures
(≤20° C) and with limited accuracy of
the measured leakage current values)
Sheath fault location voltage 2 ... 10 kV
Pulse rate for sheath fault location 4 s 1:3
4 s 1:5
6 s 1:5
6 s 1:9
Discharging unit integrated, 4.6 µF per 5 s
Supply voltage 230 V ±10 %, 50 ... 60 Hz
Option 120 V ±10 %, 60 Hz
Power consumption 500 VA at maximum
Operating temperature range -20 °C ... +50 °C
Operating humidity 30 °C, 93 % rel. humidity
Storage temperature range -40 °C ... +70 °C
Protection class I to DIN VDE 0140 T.1
Enclosure protection IP 20 to EN 60529
Dimensions (W x H x D) ca. 550 x 800 x 420 mm
Weights (according to stage of expansion) ca. 25 kg + 25 kg
incl cover and accessories

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Accessory equipment Mains connecting cable 2.5 m
Earth connecting cable 5 m
HV connecting cable 5 m
Phase clip
Terminal clip for earth connection
Protection cover for operating module
Instruction manual
Equipment case
OWTS connection cable (optional)
Optional equipment Detection of breakdown
Leakage current measurement
Logging
Printout (Protocol printing)
OWTS mode
2.2 Description of the VLF Test System
Based on comprehensive scientific research, relevant DIN and VDE standards which
we recommend to your attention, and more than 10 years of practical experience on
more than 300 VLF Test Systems, we can today take it for granted that the 0.1 Hz VLF
method for testing cables with plastics insulation outclasses any other test method
using DC voltage or power-frequency AC voltage as used so far.
A 0.1 Hz VLF Test System is required to meet the following demands:
•The repetition rate has to be so slow, that the power set free in any TE
channel that may already exist (TE = Teilentladung, partial discharge) is
small enough not to cause further erosion and so increase gas
pressure.
•The inversion of polarity, on the one hand, must be slow enough to
exclude any transients caused by travelling waves. On the other, it must
be fast enough that any space charge at the tip of a TE channel from
where it grows in the direction of the opposite electrode is preserved.
A system that meets these requirements has to supply a 0.1 Hz oscillation, with the
inversion of polarity taking place within the time duration of a 50 Hz half-wave.
Another vital characteristic to be considered when designing this system was to ensure
simple on-site testing by
−small dimensions,
−light weight, and
−low power consumption.
Every cycle starts with a charging phase in which the test object as well as the back-up
capacitor switched in parallel are charged from a DC source until the desired test
voltage is reached.
After a period of 5 seconds, the voltage source will be disconnected from the
system by S1(S2) and via R1(R2) discharged.

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Subsequently, V1 initiates the desired inversion process through inductor L1.
The test object changes its polarity from minus to plus.
Depending on the capacitance of the connected test object, the ring-around time during
polarity inversion is between 2 and 10 msec.
Owing to the losses which occur in both the polarity inversion coil L1 and V1 during
polarity inversion, the positive voltage is decreased by these losses.
After a 5 seconds dwelling period at positive polarity (Device option Basis) or
equalisation of the polarity inversion losses due to recharging by the positive DC
voltage source (Device option Plus), the return to negative polarity. takes place by
means of V1.
The negative voltage source is no longer discharged and again connected to the test
object.
The drop in voltage caused by twice ringing around (Device option Basis) will now be
compensated for by recharging from the negative DC source.
In contrast to this at the device option Plus the polarity inversion losses of a single ring-
around event are consistently compensated.
The back-up capacitor has three tasks:
- It slows the ring-around event down to the msec range even for short cables,
- it compensates for part of the losses during the ring-around event,
- it reduces the polarity reversal stress caused by travelling waves.

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Fig 1 represents the generated characteristics of the test voltage in the case of the
device option Basis.
Fig 1: Representation of the test voltage characteristics (Device option Plus)
0 1 2 3ms 0 1 2 3ms
time
Fig 2: voltage waveform during polarity inversion
Nachladung
22 kV
25 kV
25 kV
0
5
10
15
20 s
KV
20
0
-
20
28 kV = 3 x U0
22 kV

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12
2.3 Description of components of the VLF Test System 28 kV
2.3.1 Operating module
2 3
11 10 9 8
Fig 3: Operating module, Front View
1 Key "Emergency Off"
2 Analogue indication instrument test voltage (kV)
3 Display
4 Menu key F1
5 Menu key F2
6 Knob / push-button
7 Intake slot for the System Card
8 Protocol printer
9 Key "HV Off" (red)
10 Key "HV On" (green)
11 Key-operated switch "Interlock"
12 Key "Mains On" (white)
1
1
4
5
6
7
1

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2.3.2 Display of the Operating module
Fig 4: Display of the Operating module
1 Representation of parameters with value and content resp.
2 Representation of residual time and/or measuring values
3 Representation of operator guidance / status display
The representation of the residual time / measuring values (Fig 4; number 2) takes
place according to following pattern:
•Residual time 31:45 or after calling by the menu key F1 (Fig 3; item 4) e. g.
•HV-Set value !10.0 kV! (Return after residual time by the menu key F1) e. g.
•Measuring voltage -10.4 kV or independent to e. g.
VLF final voltage [-11.0 kV] (change back by the menu key F2) e. g. or
Storage voltage (-11.8 kV) (after breakdown in the cable) e. g.
•Measuring current –0.14 mA or independent to e. g.
VLF final current [-0.16 mA] (change back by the menu key F2) e. g. or
Storage current (-0.21 mA) (after breakdown in the cable) e. g.
Following signals are indicated in the line of operator guidance / status display
(Fig 4, item 3):
•Operator guidance „Select mode OK?“ e. g.
•Status display „Running. HVOff?“ e. g.
•Switching condition „HV interlock“ e. g.
•Cause for shutdown „Breakdown in cable“ e. g.
•Warning „34: No printer data“ e. g.
•Failure message „19: Coil overload“ e. g.
1
2
3

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2.3.3 VLF Test System as a whole
PE
PE
PE
VLF Test System
Fig 5: Connections at the right hand side of the VLF Test System
1 Mains input with F1, F2
2 Terminal clip for earth connection of the Operating module
Operating module
1
2


HV module