Sourcetronic MD-5060 Series User manual

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MD-5060x
5 kV digital insulation tester
User’s Guide
GU-1290
© 2008 SOURCETRONIC. All rights reserved.
Printed in Germany.

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Safety warnings
Before to use this instrument the User’s guide and Safety warnings must be read
and understood.
Safety procedures and rules for working near high voltage energized systems
must be observed during the use of this equipment. The generated voltages may
be dangerous.
Do not connect or disconnect the test leads during the measurement.
Do not touch the test leads before the high voltage indicator turn-off.
Be careful not to make short-circuit between the high voltage terminals and the
“R” or “Guard” terminals while a measurement is running, because it could be
dangerous for the operator.
Be sure that there are not any voltage difference between the points to which the
megohmmeter will be connected to, neither between them and ground.
The panel, terminals and connectors of the equipment must stay dry and clean.
This equipment should be used only by a trained and competent
person, strictly applying suitable safety rules.
Used symbols
Caution, risk of electric shock.
Equipment complies with current EU Directives.

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Index
1. Description.........................................................................................................6
2. Control panel .....................................................................................................8
2.1. Keyboard ....................................................................................................9
2.2. Indicators..................................................................................................11
2.2.1. High voltage indicator.........................................................................11
2.2.2. Display...............................................................................................11
3. Tests definition................................................................................................. 12
3.1. Test voltage..............................................................................................13
3.2. OP. MODE................................................................................................13
3.3. LIM. “Pass-fail test” ...................................................................................14
3.4. Voltmeter..................................................................................................15
3.5. Memory (HOLD)........................................................................................15
3.6. Filter..........................................................................................................15
3.7. Dielectric Absorption Index (DAI) ..............................................................15
3.8. Polarization index (PI)...............................................................................16
3.9. Step Voltage Test (SVT) ...........................................................................16
3.10. Built-in printer..........................................................................................17
3.11. Battery status check................................................................................17
3.12. Auto power-off.........................................................................................18
4. Battery charger................................................................................................18
5. Step by step instructions..................................................................................19
6. MegaLogg2 Software.......................................................................................23
7. Data collection in the computer........................................................................23
8. Printer..............................................................................................................26
9. Technical specifications...................................................................................27
10. Application note 32 ........................................................................................30
11. Warranty........................................................................................................33

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1. Description
The SOURCETRONIC model MD-5060x digital smart insulation tester is
versatile, robust and easy-to-use equipment. It uses an efficient well
experienced technology, which provides reliable, safe and accurate
measurements of insulation resistances up to 5,000,000 MΩ@ 5 kV, with
4 pre-selected test voltages: 500 V - 1 kV - 2.5 kV - 5 kV, with the
possibility of increasing or decreasing these values in steps of 100 V or
500 V.
A state-of-the-art microprocessor controls the equipment operation and
enables the incorporation of advanced features which make measure-
ments easier:
Auto-range selection
Built-in printer enabling tests recording.
NVRAM memory, enabling storing up to 4000 readings to be later
downloaded to an IT equipment.
Built-in chronometer, indicating elapsed time, in minutes and seconds,
since the test started.
Real-time clock, indicating hour, minutes and calendar.
Voltage measurement, really applied during the test.
Polarization index calculation and automatic indication (PI).
Dielectric absorption index calculation and automatic indication (DAI).
RS232 output with optical insulation for the acquisition of readings
carried out with software and hardware.
Timer enabling programming of test duration up to 30 sec., 1 min
(absorption index), 3 min, 10 min (polarization index) and 30 min
SVT - Step Voltage Test.
Programmable limit. It makes it possible to carry out “Pass-fail test”.
Switchable filter to minimize external noise interference.

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Other features important in this equipment are the negative voltages that
refer to the zero potential terminal (R), for detecting moisture within the
installations, due to the electroendosmosis effect.
Due to its reduced dimensions and weight, power supply autonomy and
mechanical resistance, this equipment is suitable for fieldwork under
extreme weather conditions. It is easy to carry, very simple to be operated
and resistant to violent treatment, which unavoidably includes frequent
bumps, extremely high or low temperatures, intense vibrations during
transportation over rough roads, long exposure to direct sunlight,
splashes of water, sand and other wind-carried particles, etc. Everything
without affecting its accuracy, comparable to the best laboratory insulation
testers.

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2. Control panel
Voltage output terminal (-V)
Zero reference terminal (+R)
Guard terminal (G)
Display
Keyboard
RS232 communication port
Power supply input
Paper feed control

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2.1. Keyboard
Button
Function
Led
On/Off switch.
-
When activated, it allows to program test
voltage in steps of 100 V. It enables the fast
voltage selection keys .
100 V steps test
voltage.
When activated, it allows to program test
voltage in steps of 500 V. It enables the fast
voltage selection keys .
500 V steps test
voltage.
Fast selection of 500 V test voltage.
500 V test voltage.
Fast selection of 1 kV test voltage.
1 kV test voltage.
Fast selection of 2.5 kV test voltage.
2.5 kV test voltage.
Fast selection of 5 kV test voltage.
5 kV test voltage.
When activated, it allows to program the
Operation Mode (Normal, SVT or TIMER).
Indicates Operation
Mode is enabled.

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When activated, it allows to program the limit of
the “Pass-Fail test”.
Indicates LIM function
is on.
Increase the value that is being programmed.
-
Decrease the value that is being programmed.
-
It activates the filter that minimizes external
noise interference.
Indicates filter function
is on.
Displays the actual voltage applied.
-
It shows the battery charge status on the
display.
Indicates that the
battery charger is in
operation.
Hold - freeze the last reading on the display.
MEM function is on.
It displays the calculated value as the result of a
Dielectric Absorption Index.
-
It displays the calculated value as the result of a
Step Voltage Test (SVT) or Polarization Index
(PI).
-
Turns On/Off the printing of the measured
values on the printer.
The printer is on.
Starts the test.
Indicates that the test
is being carried out.
End of test.
-

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2.2. Indicators
2.2.1. High voltage indicator
A light indicator displays the occurrence of high voltage on the
output terminal during the measurement and keeps lit until the
discharging process has been completed.
Do not touch the test leads before the high voltage indicator turn-off.
2.2.2. Display
Alphanumeric LCD where the measurement result, the corresponding
measuring unit, the elapsed time since the measurement started, the
analogue indication by means of a bargraph and messages to the
operator are displayed (in English).
Analogue bargraph
The equipment analogically indicates the resistance value being
measured. The bargraph provides a visualization of the gradual variation
of the insulation resistance value during the test.
Built-in chronometer
It features the elapsed time (in minutes and seconds) since test voltage is
applied.
Real time clock

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It has a real time clock with date, hours and minutes indication, to make
identification of tests recorded in paper or in memory easier.
Test number
Tests are automatically numbered by the equipment to make their
identification easier. The test number is printed at the beginning of each
test and it is stored in memory.
Model and serial number
At the beginning of each test, the equipment model, as well its serial
number, are registered, making it possible to relate the obtained results
with their respective equipment Calibration Certificate.
3. Tests definition
The MD-5060x is an extremely versatile equipment, which allows to carry
out several kinds of insulation tests automatically, recording all the results
in its internal memory or printing them. It is necessary to define the tests
properly, selecting its parameters before starting the test:
Test voltage
Equipment operation mode
Minimum resistance limit, for the “Pass-fail test”
These three parameters shall be defined before starting the test. The test
voltage is the only parameter that can be modified during the test. The
keys makes it possible to enter the different equipment
programming modes. The (decrease) and (increase) keys select the
value. The functions of the keys are mutually exclusive. Selecting
one of these keys implies releasing any other selected key.

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3.1. Test voltage
The or key enable the test voltage programming mode. Whenever the
equipment is turned-on, the key will be selected by default.
:: Enables test voltage adjustments in 100 V steps.
:: Enables test voltage adjustments in 500 V steps.
Pre-set voltages
Fast selection keys for pre-set test voltages.
:: Selects 500 V voltage.
:: Selects 1 kV voltage.
:: Selects 2.5 kV voltage.
:: Selects 5 kV voltage.
To operate them it is necessary that one of the keys or is selected.
Increase / Decrease test voltage
:: Increases the present test voltage in 500 V or 100 V steps.
:: Decreases the test voltage in 500 V or 100 V steps.
To operate them it is necessary that one of the keys or is selected.
3.2. OP. MODE
The key makes it possible to select the equipment operation mode, the
test type or its duration. The possible operation modes are:
Normal Mode
Resistance measurement test with unique voltage, without time limit.

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SVT Mode
Carries out the step voltage test automatically, always starting with 500 V
and reaching the programmed voltage, in 500 V steps.
Timer Mode
Defines the test duration. The possible values are 30 sec, 1 min, 3 min,
10 min and 30 min. The defined time is shown on the display. This
programming must be carried out before starting the test. Press the key
during the test makes it possible to hardly visualize the selected value,
without any possibility of adjusting it.
When the selected mode is different from the Normal mode, the
key led flashes in order to warn the operator that the
equipment is programmed for a special test (SVT or with
Timer).
3.3. LIM. “Pass-fail test”
The key allows to program the lower insulation limit in 10 MΩ,
100 MΩ, 1 GΩor 10 GΩ. By using this key, the insulation tester
will indicate with a BEEP (intermittent sound) and with the key
led when the insulation resistance is lower than the
programmed limit acting, in this case, as a “Pass-fail test”
device. The key led will remain flashing until the test is

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finished or until the measured resistance limit is higher than the
programmed limit.
3.4. Voltmeter
By pressing the key, the equipment will measure the voltage effectively
applied to the element being tested.
3.5. Memory (HOLD)
The key allows to hold the last performed reading on the display, at the
moment this key was pressed, without interrupting the test. When this key
is pressed again, the equipment updates the resistance and time values.
The key led and the letter Hon the display indicates that the function
was activated.
3.6. Filter
When insulation measures are carried out in transformers or in large
dimension machines, in presence of strong electromagnetic fields, it is
possible that the equipment reading is unstable, especially for resistance
values higher than 300 MΩ. In these cases it is convenient to press the
key before starting the measurement. This function allows to reach the
insulation resistance value in an upward curve without significant
oscillations.
3.7. Dielectric Absorption Index (DAI)
The key makes it possible to visualize the Dielectric Absorption Index
value on the display. For this kind of test, the equipment should be
connected, applying voltage to the sample for 60 seconds. After this
period, the operator must press the key to read the absorption index
value on the display. If this key is pressed before the 1-minute period has
elapsed, the display will show DAI = - - -. The Dielectric Absorption Index
is the ratio between the insulation resistance value measured after 60
seconds and the value measured after 30 seconds. This value is useful to
determine whether it is necessary to perform preventive and predictive

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maintenance on the coils (transformers, engines and motors, generators,
etc.).
3.8. Polarization index (PI)
The key makes it possible to visualize the Polarization Index value on
the display. For this type of test, the equipment must be connected and
applying voltage to the sample for 10 minutes. After this period, the
operator must press the key to show the PI value on the instrument
display. If the key is pressed before the 10-min period has elapsed, the
display will show PI= - - -. The polarization index is the ratio between the
insulation resistance value measured after 10 min and the value
measured after 1 min. This index is useful to determine whether it is
necessary to perform preventive and predictive Maintenance in order to
detect any insulation resistance wear and tear due to the excess of dust,
dirt, grease, or else the action of chemical or physical agents, etc.
3.9. Step Voltage Test (SVT)
After selecting the SVT function with the key, the operator must select
the test maximum voltage with the key. In this function, the equipment
allows the selection of maximum voltages only from 500 V up to 5000 V in
500 V steps. If the operator selects a halfway voltage between two 500 V
steps by using the key, the equipment will carry out the test from the
500 V up to reaching an equal voltage value or a value that is straight
below the 500 multiple value. During the first minute the generated test
voltage is of 500 V. This voltage is incremented in 500 V steps until it
reaches the maximum programmed voltage. Each voltage step is applied
during one minute, and the resistance is measured before going up to the
following voltage. The test result is calculated with this formula:

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After the test is finished, the value can be recovered by pressing the
key.
3.10. Built-in printer
In order to enable the printing function press key. Measured values will
be printed each 15 seconds, and the Dielectric Absorption Index and
Polarization Index will be printed after 1 minute and 10 minutes
respectively. Printing may be started or stopped at any time during the
test. However, it is convenient to turn the printer on before starting the
test in order to print it complete, including the heading.
3.11. Battery status check
During the measurement, it is possible to check the battery status. The
key must be pressed. If the battery charge is enough, it will read “BAT
OK”. If the charge is not enough, the message will be “LOW BAT”, and
the battery should be recharged. The analogue bargraph will give an
approximate idea of the remaining charge percentage (at least 20% is
required for a normal operation).
When the battery charge reaches the normal operation minimum value,
the message LO BAT appears automatically in the area where the test
tension value is indicates, alternating it every 1 second.

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3.12. Auto power-off
The Auto-Power-off function turns off the equipment consumption
(independently of the timer function) in two situations:
During the measurement - After 35 minutes of operation, without
allowing that the battery status checking function is carried out during
that period.
Idle equipment - After 10 minutes of inactivity.
4. Battery charger
This equipment has an intelligent built-in circuit that controls the battery
charge and doesn’t allow the equipment to operate during the charging
process. In order to charge the battery, follow this procedure:
Verify that the On/Off switch is switched off.
Connect the power supply cable plug into input . After a while, the
battery charge indicator ( key led) will blink alternatively in green and
red during one second, while the charger verifies the initial condition of
the battery to select the optimised parameters of the charge.
The following chart summarizes the meaning of LED luminous indications:
Green and red
flashing alternatively
Test of the initial condition of the battery when plugging
the mains, during one second.
Permanent red
Battery under charge.
Flashing red
Charging current is less than normal.

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Permanent green
The charging process has been successfully finished.
Battery OK.
Flashing green
The charging process has finished, nevertheless the
battery hasn’t received the complete charge.
At the end of battery useful life, the battery must be recycled or
disposed of properly, in order to protect the environment.
The rechargeable battery does not show the “memory effect” and there are no
restrictions to start charging it as many times as is needed. However the battery
could be damaged if remains in deep discharge for a while.
To avoid this effect, charge the battery before left the equipment in storage and
don’t let pass more than 30 days without recharge, even if the instrument wasn’t
used (under storage, the battery loses part of its charge).
5. Step by step instructions
Check if there is no differences of potential voltage between the points
where the equipment shall will be connected to, nor between them and
the ground.
1. Connect the red security terminal (red cable) to the insulation tester
(-V) output terminal (see figure).
2. Connect BNC terminal to the ZERO REFERENCE (+R) terminal and
the terminals to the element to be measured as indicated in the figure
below.

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The test leads in the picture are merely illustrative.
3. The G (GUARD) terminal can be used or not, according to the
measurement that is going to be carried out.
IMPORTANT:
During measurements, the equipment must be electrically referred to
earth in order prevent the equipment from being on a high potential,
which may produce unstable readings. When insulation is measured
regarding grounding, the R terminal is connected to earth and the
condition by means of which the equipment potential setting is
fulfilled. If the measurement is performed between two parts, which
are not grounded (for example, between two phase conductors in a
tree-phase cable), the megohmmeter GUARD terminal must be
grounded. This implies that whenever a measurement is
performed, one of the GUARD or R terminals must be grounded,
but not both of them simultaneously. SOURCETRONIC

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Application Note 32 explains the usage of Guard terminal for
minimizing the parasite resistance effect, whose influence one
intends to minimize.
4. Turn the equipment by using the On/Off switch.
5. The following message will appear on the display:
6. The PRESS START message will appear immediately.
7. In order to make repetitive tests performance easier, when the
equipment is turned on, the test voltage will be the same voltage
selected for the last performed test, meanwhile the equipment will be
in the 500 V steps voltage test programming mode ( key led
flashing). To modify this voltage, use the and keys or the fast
selection keys. For a voltage test fine adjustment (in 100 V
steps) press the key. In this condition, the and keys make it
possible to decrease or increase the 100 V steps test voltage to
select 500, 600, 700, ... 5000 Vdc.
8. To leave the voltage test programming mode just press the activated
key again in order to deactivate it (the associated led will stop
flashing). Now, the voltage selected value will be recorded in the
equipment RAM memory for future tests.

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9. Press key. The high voltage led turns on immediately,
indicating that the equipment internal generator is applying
voltage to the element that is being tested. If, during the
test, it is necessary to change the test voltage, item 7
sequence shall be repeated.
10. For a few seconds, the self-scale smart system will search for the
most convenient range for the value being measured. Meanwhile, the
display will show the message:
11. Then, the display will show the test number, the selected voltage
value and it will start the elapsed time count. If the measured value is
within the device scope, the test number indication will provide place
for the resistance value indication and its corresponding unit, and it
will start the analogue bargraph indication.
12. If, for example, the measured value is 601 MΩwith a selected
voltage of 1000 V the display will initially remain on during a few
seconds, as it is shown below, informing that test 12 was started.
13. After a few seconds, in the same example, the display will indicate
that the measured resistance value is 601 MΩ, as it is shown: