Megger TDS40, TDS60 Operating Manual

Test and Diagnosis System

TDS40 / TDS60

(Stand-alone test operation)

Operating Manual

Issue: 01 (01/2014) - EN
Item-Nr.: 83549

1-3

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: +49 / 9544 / 68 – 0

F: +49 / 9544 / 22 73

E: [e-mail]

Hagenuk KMT

Kabelmesstechnik GmbH

Megger USA

Röderaue 41

D - 01471 Radeburg / Dresden

T: +49 / 35208 / 84 – 0

F: +49 / 35208 / 84 249

E: [e-mail]

4271 Bronze Way

Dallas, Texas 75237-1019 USA

T: 1-800-723-2861

F: 1-214-331-7399

E: [e-mail]

 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.

1-4

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.

1-5

INHALTSVERZEICHNIS

1. GENERAL INTRODUCTION ................................................. 1-9

1.1 General Instructions ............................................................................ 1-10

1.2 General Safety Instructions and Warnings ........................................ 1-11

2. TECHNICAL DESCRIPTION ............................................... 2-13

2.1 Description of the Functions .............................................................. 2-13

2.2 Model Options ...................................................................................... 2-13

2.3 Technical Specifications ..................................................................... 2-14

2.4 Scope of Delivery and Options ........................................................... 2-15

2.5 Description of the Test Procedure with VLF-Voltage ....................... 2-16

2.6 Testable Cable Capacitance in VLF Mode ......................................... 2-19

2.7 Cable Capacitance that Can be Diagnosed in DAC Mode ................ 2-20

2.8 Description of Components ................................................................ 2-21

2.8.1 Operating Module .................................................................................. 2-21

2.8.2 Display of the Operating Module ............................................................ 2-22

2.8.3 Connections ........................................................................................... 2-23

2.8.4 Protection Covers of the Module ............................................................ 2-24

2.8.5 Transportation Protection Bottom from the Operating Module ............... 2-25

3. SETTING UP OPERATION .................................................. 3-27

3.1 Safety Precautions ............................................................................... 3-27

3.2 Electrical Connection for Stand-alone Test Operation ..................... 3-29

3.2.1 General Rules for Making Connections ................................................. 3-29

3.2.2 Procedure .............................................................................................. 3-30

3.2.3 Connection of the External Safety Device (Optional) ............................. 3-31

4. Operating in Stand-alone Test Mode ................................ 4-33

4.1 VLF- / DC-Test ...................................................................................... 4-33

4.2 Sheath Fault Location ......................................................................... 4-35

4.3 Starting the Test / Location ................................................................. 4-36

5. Additional Functions .......................................................... 5-39

5.1 Adjustment of Language ..................................................................... 5-39

5.2 Viewing the System Information ......................................................... 5-39

1-6

5.3 Viewing / Setting the System Parameters .......................................... 5-40

5.4 Entering / Changing the Administrator Password............................. 5-41

5.5 Returning to the Start Menu ................................................................ 5-42

6. Optional Features ............................................................... 6-43

6.1 Detection of Breakdown and Short Circuit ........................................ 6-43

6.2 Measurement of Leakage Current....................................................... 6-43

6.3 Internal Protocol Printout .................................................................... 6-44

6.4 Cable Tests using a SystemCard ........................................................ 6-47

6.4.1 SystemCard and „WinkisVLF“ ................................................................ 6-47

6.4.2 Parametrising the SystemCard .............................................................. 6-48

6.4.3 Logging to SystemCard .......................................................................... 6-49

6.4.4 Operating the Test and Diagnosis System with a SystemCard .............. 6-50

6.5 Function User Setup / User Level ....................................................... 6-52

6.6 Re-Setting the System Settings / Deleting the Print Templates ....... 6-53

6.7 Adjustment of the System Time .......................................................... 6-54

7. Repair and Fault Diagnostics............................................. 7-55

7.1 Replacing Fuses ................................................................................... 7-55

7.2 Exchanging the Paper Roll or Ink Ribbon of the Printer ................... 7-56

7.3 Replacing the Battery of the System Clock ....................................... 7-57

7.4 Connecting Cables, HV Couplings ..................................................... 7-58

7.5 Operational and Error Messages ........................................................ 7-58

7.5.1 Classification of Messages ..................................................................... 7-58

7.5.2 Operational Messages about State of System ....................................... 7-59

7.5.3 Operational Messages about Switching Conditions ............................... 7-62

7.5.4 Error Messages and Warnings ............................................................... 7-64

1-7

Abbildungsverzeichnis

Fig. 1: Time frame of polarity reversal (type Plus) ............................................ 2-16

Fig. 2: Shape of 0.1 Hz cosine-rectangular VLF voltage (type Plus) ................. 2-17

Fig. 3 Operating module - Front View .............................................................. 2-21

Fig. 4: Display of the Operating module (View of the standard operating mode)2-22

Fig. 5: Connections (in the example of the TDS60) .......................................... 2-23

Fig. 6: Protection cover of the Operating module .............................................. 2-24

Fig. 7: Shorting device / Protection cover of the HV module ............................. 2-24

Fig. 8: Transportation protection bottom from the Operating module ................ 2-25

Fig. 9: Connection scheme ............................................................................... 3-30

Fig. 10: Connection of the external safety device ............................................... 3-31

Fig. 11: Start menu ............................................................................................. 4-33

Fig. 12: Selection of the operation mode ............................................................ 4-33

Fig. 13: Selection of the test voltage ................................................................... 4-34

Fig. 14: Selection of the test time ........................................................................ 4-34

Fig. 15: Selection of the pulse rate ..................................................................... 4-35

Fig. 16: Switching on high voltage ...................................................................... 4-36

Fig. 17: Display of the logged measurement values ........................................... 4-36

Fig. 18: Display of instantaneous data ................................................................ 4-37

Fig. 19: Display of the set voltage value ............................................................. 4-37

Fig. 20: Start menu after the test has been finished ........................................... 4-38

Fig. 21: User Setup: Language ........................................................................... 5-39

Fig. 22: Setup: System information ..................................................................... 5-39

Fig. 23: Setup: Parameters ................................................................................. 5-40

Fig. 24: Setup: Enter password ........................................................................... 5-41

Fig. 25: Setup: Entered password ok .................................................................. 5-41

Fig. 26: Setup: Enter new password ................................................................... 5-42

Fig. 27: Setup: New password stored ................................................................. 5-42

Fig. 28: Setup: Return to start menu ................................................................... 5-42

Fig. 29: Breakdown detection ............................................................................. 6-43

Fig. 30: Setup: Protocol printout off .................................................................... 6-44

Fig. 31: Setup: Protocol Printout Standard.......................................................... 6-44

Fig. 32: Setup: Protocol off ................................................................................. 6-49

Fig. 33: Setup: Protocol extended ....................................................................... 6-49

Fig. 34: Start menu with system card inserted .................................................... 6-50

Fig. 35: Start menu after new system settings have been stored ....................... 6-51

Fig. 36: Setup: User profile ................................................................................. 6-52

Fig. 37: Setup: Memory....................................................................................... 6-53

Fig. 38: Setup: Date / Time ................................................................................. 6-54

1-8

Fig. 39: Setup Date / Time: Adjusting the day of the week .................................. 6-54

Fig. 40: Setup Date / Time: Adjusting the minutes .............................................. 6-54

Fig. 41: Setup Date / Time: Saving by F1 ........................................................... 6-54

Fig. 42: Unscrewing the printer front cover ......................................................... 7-56

Fig. 43: Removing the front cover ....................................................................... 7-56

Fig. 44: Removing the ribbon cartridge ............................................................... 7-56

Fig. 45: Inserting the ribbon cartridge ................................................................. 7-56

Fig. 46: Inserting the paper roll into the printer.................................................... 7-57

Fig. 47: Paper feed button .................................................................................. 7-57

1-9

1. GENERAL INTRODUCTION

The test and diagnosis system TDS40/60 shall be used for the stated field of application
in cable diagnosis and cable testing 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 TDS40/60.

Each person involved in the assembly, operation, maintenance, and repair of the
TDS40/60 is required to have read this handbook carefully.

Only trained and/or instructed staff are permitted to deal with the TDS40/60 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 TDS40/60 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 TDS40/60 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 test and diagnosis system TDS40/60 is an upright device and has to be only
transported and operated in upright position.

1-10

1.1 General Instructions

Safety precautions

This manual contains basic instructions for the commissioning and operation of the
device / system. For this reason, it is important to ensure that the manual is always
available to the authorised and trained operator. He needs to read the manual
thoroughly. The manufacturer is not liable for damage to material or humans due to non­observance of the instructions and safety advices provided by this manual.

Locally applying regulations have to be observed!

Labelling of safety instructions

The following symbols may be present on the packaging material, on the instrument and
in the manual:

Symbol Description

WARNING

Indicates a potential danger of an electric shock that may result in fatal

or serious injury.

CAUTION

Caution (refer to accompanying manual for instructions)!
Indicates a potential danger that may lead to slight or moderate injury.

The notes contain important information and useful tips for using the
system. Failure to observe them can render the measurement results

useless.

Working with products from Megger

It is important to observe the generally applicable electrical regulations of the country in
which the device will be installed and operated, as well as the current national accident
prevention regulations and internal company directives (work, operating and safety
regulations).

After working on the system, it must be voltage-free and secured against reconnection as
well as having been discharged, earthed and short-circuited.

Use genuine accessories to ensure system safety and reliable operation. The use of
other parts is not permitted and invalidates the warranty.

1-11

Operating Staff

This system and its peripheral equipment may only be operated by trained or instructed
personnel. Anyone else must be kept away.

The system may only be installed and operated by an authorised electrician. DIN VDE
0104 (EN 50191), DIN VDE 0105 (EN 50110) and the German accident prevention
regulations (UVV) define an electrician as someone whose knowledge, experience and
familiarity with the applicable regulations enables him to recognise potential hazards.

Declaration of Conformity (CE)

The product meets the following security requirements of the European Council
Directives:

• EMC Directive (2004/108/EG)

• Low Voltage Directive (2006/95/EG)

1.2 General Safety Instructions and Warnings

Intended application

The operating safety is only guaranteed if the delivered system is used as intended.
Incorrect use may result in danger to the operator, to the system and the connected
equipment.

The limits described under Technical Data may not be exceeded.

Behaviour at malfunction of normal operation

The equipment may only be used when working properly. When irregularities or
malfunctions appear that cannot be solved consulting this manual, the equipment must
immediately be put out of operation and marked as not functional. In this case inform the
person in charge who should inform the Megger-service to resolve the problem. The
instrument may only be operated when the malfunction is resolved.

Five safety rules

The five safetey rules must always be followed when working with HV (High Voltage):

1. De-energise

2. Protect against re-energising

3. Confirm absence of voltage

4. Earth and short-circuit

5. Cover up or bar-off neighbouring energised parts

1-12

Using cardiac pacemaker

Physical processes during operation of high voltage may endanger persons

wearing a cardiac pacemaker when near these high voltage facilities.

Firefighting in electrical installations

• According to regulations, carbon dioxide (CO2) is required to be

used

as extinguishing agent for fighting fire in electrical installations.

•

Carbon dioxide is electrically non conductive and does not leave
residues. It is safe to be used in energized facilities as long as the

minimum distances are maintained. A CO2 fire

extinguisher must be

always available within electrical installations.

•

If, contrary to the regulations, any other extinguishing agent is used
for fire fighting, this may lead to damage at the electrical installation.

Megger disclaims any liability for cons

equential damage.

Furthermore, when using a powder extinguisher near high-

voltage

installations, there is a danger that the operator of the fire

extinguisher will get an electrical shock from a voltage arc-

over (due

to the powder dust created).

• It is essen

tial to observe the safety instruction on the extinguishing

agent.

• Applicable is DIN VDE 0132.

WARNING

Dangers when working with high voltage

Working on high voltage systems and equipment – especially in non­stationary operation – requires particular care and safety-

conscious action
on the part of test personnel. VDE regulations 0104 on setting up and
operating electrical test systems, as well as EN 50191 and national

standards and regulations must be strictly adhered to.

• The test system generates a da

ngerous test voltage of up to 40

resp. 60 kV

PEAK

.

• The test system may not be operated without supervision.

• Never fail to use safety equipment or put it out of operation.

•

Operation requires minimum two people whereas the second person

must be able to activate the emergency switch in case of danger.

•

To prevent dangerous charge accumulation, earth all metal parts in

the vicinity of the high voltage equipment.

2-13

2. TECHNICAL DESCRIPTION

2.1 Description of the Functions

The test and diagnosis system TDS40/60 enables the standard-compliant testing of
medium voltage cables and other equipment with a 0.1 Hz cosine rectangular test
voltage of up to 40 kV

PEAK

or 60 kV

PEAK

.

With the help of such a cable test, operation-endangering faults as well as insulation
faults (e.g. water tree damages in PE/XLPE cables or local damages in PILC cables) can
be safely brought to failure. Due to the integrated breakdown detection, this test process
takes place without damage to the fault-free cable insulation.

In combination with the partial discharge measurement system PDS 60, the TDS40/60
forms a fully adequate diagnosis system (TDS NT) which is suitable for the partial
discharge diagnosis on medium voltage cables according to the standards. In this stage
of expansion the system is operated by remote control and can be operated in the VLF or
DAC (damped AC) mode.

This manual solely describes the operation of the test and diagnosis system

TDS40/60 in the stand-alone test operation. For info

rmation regarding the

connection of the partial discharge measurement system PDS

60 and the remote

operation of the system please read the manual of the PDS 60.

2.2 Model Options

The model options of the test and diagnosis system differ in the following attributes:

TDS40Basis

40 kV test voltage; only negative voltage source

TDS40Plus

40 kV test voltage; negative and positive voltage source (higher test

performance as a result)

TDS60Basis

60 kV test voltage; only negative voltage source

TDS60Plus

60 kV test voltage; negative and positive voltage source (higher test

performance as a result)

2-14

2.3 Technical Specifications

Parameter TDS40 TDS60

Output voltage DC 3 … 40 kV 3 … 60 kV

Output current source 7 mA 5 mA

Leakage current measurement
(optional)

Range of indication
Resolution of indication

0 - 7 mA
10 µA

0 - 5 mA
10 µA

VLF-test

Output voltage
Frequency
Voltage form

3 … 40 kV

PEAK

0.1 Hz
cosine rectangular

3 … 60 kV

PEAK

0.1 Hz
cosine rectangular

Sheath fault location

Voltage
Pulse rate

3 … 10 kV
4 s (1:3), 4 s (1:5), 6 s (1:5), 6 s (1:9)

DAC-operation

Output voltage
Frequency

3 … 40 kV

PEAK

58 … 410 Hz

3 … 60 kV

PEAK

58 … 475 Hz

Testable cable capacitance in the
VLF-operation

(also see section 2.6)

for full operating temperature range 2.2 µF (Basis)

4.4 µF (Plus)

0.8 µF (Basis)

1.6 µF (Plus)

At normal temperatures (≤20 °C) and
with restrictions regarding the
accuracy of the leakage current
measurement values

2.4 µF (Basis)

4.7 µF (Plus)

1.0 µF (Basis)

2.0 µF (Plus)

Cable capacitance to be tested in
the DAC-mode

(see section 2.7)

Discharge device integrated, 4,7 µF in 5 s integrated, 2,0 µF in 2 s

Power supply

230 V ±10 %, 50 ... 60 Hz or optionally
120 V ±10 %, 60 Hz

Power consumption max. 500 VA

Operating temperature range -25 °C ... +55 °C

Storage temperature range -40 °C ... +70 °C

Operating humidity 30 °C, 93% rel.

humidity

30 °C, 93% rel. humidity
up to 50 kV

30 °C, 70% rel. humidity
from 50 to 60 kV

2-15

Parameter TDS40 TDS60

Protection class (in accordance with

IEC 61140 (DIN VDE 0140-1))

I

Ingress protection rating (in
accordance with IEC 60529 (DIN
VDE 0470 1))

IP21

Dimensions (W x H x D) 56 x 113 x 41.5 cm 62.5 x 118 x 62 cm

Weights (depending on the model) 55 kg + 48.5 kg (Basis)

55 kg + 55.5 kg (Plus)

85 kg + 48.5 kg (Basis)
85 kg + 55.5 kg (Plus)

2.4 Scope of Delivery and Options

Equipment Power cord 2.5 m
Earth cable 5 m
HV connection cable 5 m
HV connection clamp (red) with MC plug
Operational earth connection adapter
Manual
Equipment case

Optional features Detection of breakdown
Leakage current measurement
Logging
Protocol printout

Optional equipment External safety device (128309600)

2-16

2.5 Description of the Test Procedure with VLF-Voltage

Because of the space charges formed in the dielectric of the cable, DC test methods
prove to be dangerous when applied to PE and VPE cables and should therefore never
be used on such types of cables.

Nowadays we can 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 power­frequency AC voltage as used so far.

A 0.1 Hz VLF test system must meet the following demands:

• The repetition rate has to be so low, that the power that is set free in any
existing PD-channel (PD = 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 hand, it
must be fast enough that any space charge at the tip of a PD-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 quick
polarity reversal taking place within a frequency close to the power frequency.

Fig. 1: Time frame of polarity reversal (type Plus)

Load-dependend frequency during polarity inversion:

TDS40Basis

40 ≤ f < 410 Hz

TDS40Plus

30 ≤ f < 410 Hz

TDS60Basis

55 ≤ f < 475 Hz

TDS60Plus

40 ≤ f < 475 Hz

VLF CR 0.1 Hz

polarity reversal

Oscillation with

30 … 475 Hz
(see below)

2-17

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.

Fig. 2: Shape of 0.1 Hz cosine-rectangular VLF voltage (type Plus)

After a period of 5 seconds, the voltage source will be disconnected from the system
resp. discharged via a resistance.

Subsequently, the polarity reversal is initiated. The test voltage changes its polarity from
minus to plus.

Depending on the size of capacitance of the connected test object, time of the polarity
reversal is between 1 and 17 ms.

Due to the losses which occur during the polarity inversion, the positive voltage is always
decreased by these losses.

After a 5 seconds dwelling period at positive polarity (device option Basis) or equalisation
of the polarity reversal losses due to recharging by the positive DC voltage source
(device option Plus), the return to negative polarity takes place.

The negative voltage source is reconnected to the test object.

2-18

The loss of voltage caused by twice changing the polarity (device option Basis) will now
be compensated for by recharging with the negative DC source. In contrast to this at the
device option Plus the losses of a polarity reversal are immediately compensated.

The back-up capacitor has the following tasks:

- It slows the ring-around event down to the ms range even for short cables,

- It compensates a part of the losses during the polarity reversal.

2-19

2.6 Testable Cable Capacitance in VLF Mode

2-20

2.7 Cable Capacitance that Can be Diagnosed in DAC Mode

TDS40 

TDS60 

2-21

2.8 Description of Components

2.8.1 Operating Module

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 "HVOff" (red)
10 Key "HVOn" (green)
11 Key-operated switch "Interlock"

12 Key "Mains On" (white)

3

4

5
6

7

2

1

12

11 10 9 8

2-22

2.8.2 Display of the Operating Module

Fig. 4: Display of the Operating module (View of the standard operating mode)

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

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

VLF mode

10kV

5min

0.

0kV

0.00mA

Prepared . HVOn?