MegaPulse
1.2x50-7PF

IMPULSE TESTER

Instruction ManualDear Customer:
Congratulations! Compliance West USA is proud to present you
with your MegaPulse 1.2x50-7PF Impulse Tester.
Your
instrument features a groundbreaking logic-controlled circuitdesign and ergonomic front panel and represents the latest inhigh voltage impulse testing.
To fully appreciate all the features of your new instrument, wesuggest that you take a few moments to review this manual.
Compliance West USA stands by your instrument with a full oneyear warranty. If the need arises, please don't hesitate to call on
us.
Thank you for your trust and confidence.

Rev 0, May, 2015

Table of Contents
An Introduction to Impulse Testing with the MegaPulse PF series tester...................................................2
Safety Precautions ........................................................................................................................2
Test Personnel ................................................................................................................2
Testing Area ...................................................................................................................2
Safety Techniques ..........................................................................................................3
Using the MegaPulse Impulse Tester ...........................................................................................3
Introduction ..................................................................................................................................5
Section 3 ........................................................................................................................6
Operation ....................................................................................................................................................6
Setting up your Tester ..................................................................................................................6
AC Line Voltage Requirements....................................................................................................6
Fuse Replacement.........................................................................................................................7
Front and Rear Panel Features......................................................................................................7
Figure 1. Controls, Indicators, Connectors – MegaPulse 1.2x50-7PF Front Panel .......8
Table 1. Controls, Indicators, Connectors – MegaPulse 1.2x50-7PF Front Panel ........10
Figure 2. Controls, Indicators, Connectors – MegaPulse 1.2x50-7PF Rear Panel .........11
Testing ..........................................................................................................................................14
Technical Assistance ..................................................................................................................................16
Maintenance and Calibration ......................................................................................................................17
Introduction ..................................................................................................................................17
Service Information ......................................................................................................................17
General Maintenance....................................................................................................................17
Cleaning .........................................................................................................................17
Calibration Information ................................................................................................................18

1

Section 1
An Introduction to Impulse Testing with the MegaPulse PF series tester
The impulse test is designed to simulate impulse surges which occur in everyday life due tonearby lightning strikes, switching transients, and other high-frequency faults on the power
distribution network. Impulse testing is the fundamental method for empirical verification of theadequacy of insulation. Other methods of ensuring adequate insulation (AC or DC Dielectric
Withstand testing, measurement of over-surface creep age, through-air clearance, or distancethrough-insulation) are all extrapolated from the results of impulse testing. The impulse test is
performed to ensure that the insulation in question will be able to function properly whensubjected to similar impulse surges in the field.

Safety Precautions
The impulse withstand test can generate voltages in excess of 7000V peak at potentially lethal
current levels. Currents of as little as 5mA at 120 volts can cause death; the MegaPulse candeliver currents of more than 100 Amps peak for very short time duration. The potential forserious injury or death exists and personnel should be aware when they conduct this test.

Test Personnel
Personnel require special training to conduct the impulse test. They should understand electricalfundamentals clearly, and be aware that high voltage is adept and creative at completing a path toground. Instructions should include a warning against any metal jewelry. Operators should notallow others in the testing area, especially when tests are being conducted. Organization is to be
stressed. The operator should keep the area free of unused leads and equipment.

Testing Area
The area used for conducting the impulse test should be as remote as possible from normal
production line activities. Only personnel actually conducting the test should be allowed in thearea, and it should be taped or roped off to preclude casual entry by other employees. In
addition, the area should be marked "WARNING - HIGH VOLTAGE TESTING" or theequivalent to warn others of the nature of the testing taking place.
The bench being used should be non-conductive, and any exposed metal parts should be tied
together and grounded. If a conductive surface must be used, it should be grounded. Because of
sparking during an impulse test failure, it is not safe to conduct impulse testing in combustible
atmospheres.
It is imperative that a good ground be provided to the MegaPulse tester. Before connecting theequipment, ensure that the building wiring provides a low-resistance ground. If the MegaPulse
tester is used on a high-resistance grounding circuit, dangerous high voltages may be present to
the operator. In addition, the power to the Testing Area should be provided with an easily
reached shutoff switch which can be actuated by personnel outside the Area if needed.

2

Safety Techniques
The high voltage circuit of the MegaPulse 1.2x50-7PF can be shut off at any time by turning OFF
the rear power switch. Always press TRIGGER to discharge the tester before turning OFF.
The MegaPulse tester is provided with a VOLTAGE ADJUST knob on the front panel. Thisshould always be adjusted to the minimum position at the start of testing. In addition, this knob
should be adjusted back to the minimum position at the completion of all testing.
The MegaPulse tester is provided with a CHARGE switch that is in the unarmed "Standby"
setting when the tester is first turned ON. When the yellow CHARGE button is lit, the tester
will not provide high voltage until the CHARGE Button and the TRIGGER Button have beenpressed in order. To prevent inadvertent operation, the operator should be instructed not to press
the CHARGE Button until the test is ready.
The MegaPulse tester has been designed for one-touch operation with the right hand. If possible,
it should be set up to the left and in front of the equipment under test. The equipment under test
should be connected to the MegaPulse tester and then left alone by the operator. After theoperator is clear of the Tester and the equipment under test, the operator should turn the rearpanel power switch to ON, press the CHARGE Button, adjust the voltage to the desired level (asdisplayed on the front panel meter), then press the TRIGGER Button, with his right hand. This
will allow the greatest separation between the operator and the test being conducted. Note that
the CHARGE process will stop after 2 minutes if the TRIGGER button is not pressed.
The MegaPulse tester is designed to bleed the high voltage away after the test has concluded. Inorder to ensure that any voltage present in the equipment being tested has been completely bled
away, the operator should not unplug the equipment under test from the MegaPulse until thefront panel meter reads a safe level (40 volts or less is generally considered a safe level).
Pressing the TRIGGER button before disconnecting main power (or turning the equipment off)
will ensure that the internal capacitors are discharged as much as possible.

Using the MegaPulse Impulse Tester
The impulse test involves high voltage and caution should be exercised when using the tester.
The RETURN lead is referenced to building ground when properly connected. However, both
the OUTPUT and RETURN leads must always be treated as Hazardous whenever the powerswitch of the MegaPulse is in the ON position.
The MegaPulse impulse tester generates the impulse waveform only; it does not determine
Passing or Failing results. It is the operator’s responsibility to monitor the output waveform anddetermine Passing or Failing results. In monitoring the impulse waveform, consider thefollowing points: The Impulse waveform is high voltage and high frequency (short duration).
Always ensure that the measuring instrument (usually an oscilloscope with a high-voltage probe)
is rated for the voltage involved, and that the frequency response of the instrument and probe arecapable of measuring the output waveform of the MegaPulse Impulse Tester. A measuring
instrument or probe with a low frequency response will result in erroneous readings that could be
mis-read.

3

Pressing the POLARITY switch on the front panel can change the polarity of the output
waveform. The polarity is Normal when the NOR indicator is lit. In this case, the high voltage
will appear on the OUTPUT as a positive pulse relative to the RETURN jack. When thepolarity switch is in the Reverse position (REV indicator is lit), the high voltage will appear on
the OUTPUT as a negative pulse relative to the RETURN jack. The polarity switch only
operates when the CHARGE LED is lit, i.e. the output is not charged.
Note that the voltage meter may indicate that some residual voltage is present on the mainstorage capacitor, even when the tester is first turned ON. This is due to inherent charging of theinternal capacitors. Pressing the TRIGGER switch will discharge the capacitors (be sure not totouch the output and return leads when pressing the trigger switch).
Note that the peak amplitude of the measured output waveform is proportional to the voltage thatis read on the front panel of the MegaPulse, but it will always be somewhat lower. This isbecause the meter on the MegaPulse is measuring the voltage on the main impulse storage
capacitor. This voltage will intentionally dissipate to some extent before reaching the output
leads. Therefore, it is important to measure the peak amplitude of the output waveform, andadjust the output of the MegaPulse accordingly.
Determination of Passing and Failing results can prove difficult. To obtain the most accurate
results, it is generally necessary to perform multiple impulse tests on a few different test samples(that have adequate insulation to pass the impulse test). Take note of the impulse waveshape,
amplitude, and duration. Also note how much variance there is in the waveshape from test to
test. Also (if possible), perform impulse testing on some test samples that are known to haveinadequate (or damaged) insulation. Take note of the impulse waveshape, amplitude, andduration, when an insulation breakdown occurs.

4Section 2
Introduction
This manual contains complete operating, maintenance and calibration information for theCompliance West USA MegaPulse 1.2x50-7PF Impulse Tester.
••••

In case of trouble, the test can be immediately terminated at any time by turning the rearpanel power switch to the OFF position.
Before the test can commence, the unit must be armed by pressing the CHARGE Button.
The test will not begin until the TRIGGER Button is pushed.
Operator instructions are printed on the rear panel for quick reference.
Voltage is discharged by a resistor bank within the MegaPulse tester upon test completion.
Discharge progress is shown on the front panel meter.

Your tester is warranted for a period of one year upon shipment of the instrument to the original
purchaser.

Specifications
Specifications for the MegaPulse 1.2x50-7PF are listed in the table below and the component
designations are shown in Figure 1.

Figure 1. General diagram.
Model
1.2x50-7PF

Waveform
1.2x50 µs

Max. Voltage
7000 VC1
1 µF

Duty Cycle = 45s at 7000V

5

R1
76 Ω

R2
13 Ω

C2
0.033 µFR325 ΩSection 3
Operation
This section describes how to set up and make measurements with your Tester. We recommendthat you read the entire section carefully so that you can use all of the features of your Tester.

Setting up your Tester
Your Tester is shipped in a special protective container that should prevent damage to the
instrument during shipping. Check the shipping order against the contents of the container andreport any damage or short shipment to Compliance West USA. The container should include
the following:
•
•
•
•
•
•
•
•
•

The MegaPulse 1.2x50-7PF Tester
Two high-voltage test leads, 1 red and 1 black
An 18 AWG Line Power Cord
1.2x50-7PF Tester Instruction Manual
Manual – USB TestMinder
USB TestMinder Software CD
USBD Box
USB Cable
DB-9 Cable, Male – Male

If reshipment of the instrument is necessary, please use the original shipping container. If theoriginal shipping container is not available, be sure that adequate protection is provided toprevent damage during shipment. We recommend that the instrument be surrounded by at least
three inches of shock-absorbing material on all sides of the container.
Remove the tester from its container and place it on a test bench.

AC Line Voltage Requirements
AC line voltage requirements for your Tester are noted on the rear panel of the instrument. Do
not connect the instrument to a different voltage source. The cord packaged with your
MegaPulse Tester is for use in the United States. If another power cord must be used, the cord
must be rated for the maximum current noted on the rear panel. It must also meet therequirements of IEC 227 or IEC 245, and mains cords that are certified or approved by any
recognized national test house are regarded as meeting this requirement.

6

Fuse Replacement
There is a user-replaceable fuse (F1) located on the rear panel of the instrument. It is locatedbehind a door in the Power Inlet-Power Switch-Fuse Holder device. The fuse rating is noted on
the rear panel. Do not attempt to replace it with a fuse of any other rating.
Use the following procedure to replace the fuse F1:
1.
Turn the power switch to the OFF position.
2.
Unplug the instrument from the source of supply.
3.
Remove the power inlet cord from the instrument.
4.
Using a small screwdriver, pry open the fuse holder door.
5.
Replace the fuse with a new one of the correct rating.
6.
Replace the fuse holder door and power inlet cord.

Front and Rear Panel Features
Before using your Tester, take a few minutes to become familiar with the use of its controls,
indicators and connectors. The front panel features of the MegaPulse are shown in Figure 2 anddescribed in Table 1. The rear panel features of the MegaPulse are shown in Figure 3 anddescribed in Table 2.

7

Image for reference only

Figure 2. Controls, Indicators, Connectors – MegaPulse 1.2x50-7PF Front Panel

8

ITEM

NAME

1

VOLTAGE Adjust Knob

2

POLARITY switch

3

NOR REV indicator

4

CHARGE switch

5

CHARGE indicator

6

TRIGGER switch

7

TRIGGER indicator

8

VOLTAGE meter

FUNCTION
Adjust the digital voltage set point in the tester.
Press the voltage knob to display the voltage set point. This setting will blink for a few seconds on the front meter.
Turn Clockwise to increase the setting Voltage Setting Point before pressing CHARGE button.
Toggles the output pulse polarity from Normal to Reverse, Normal for positive and Reverse for Negative, The pulse willappear on the Output jack relative to the return jack
The polarity switch only operates when the CHARGE indicator is lit and the voltage on the display meter is less than 180V.
The polarity is Normal when the NOR indicator is lit and, Reverse when the REV indicator is lid.
Indicates the state of the Output Polarity switch.
NOR indicates Normal (Positive) position.
REV indicates Reverse (Negative) position.
Starts the charge process of the tester capacitor.
The CHARGE indicator will turn off after the CHARGE switch is pressed, and the TRIGGER indicator will turn on.
The charge process will stop after 2 minutes if the TRIGGER button is not pressed.
This Yellow indicator is lit to show that pressing the CHARGE switch is the next logical step in a test sequence.
CHARGE indicator is lit when the tester is turn ON an after pressing TRIGGER button.
CHARGE indicator will go out after pressing CHARGE button.
CHARGE and TRIGGER Indicators will be blinking if the Interlock Switch is open. (Only testers with Interlock Switch
Option)Triggers the output impulse waveform.
The impulse waveform will appear across the output leads.
This Red indicator is lit to show that the tester can be trigger.
TRIGGER indicator is lit for 2 minutes after the CHARGE button is pressed.
TRIGGER indicator will go out after pressing TRIGGER button.
TRIGGER and CHARGE Indicators will be blinking if the Interlock Switch is open (Only testers with Interlock Switch
Option)TRIGGER indicator will blink at when the Voltage. This effect will remain on until the TRIGGER switch is pressed.
(Only testers with PC Interface option)
Displays the output voltage set point.
The voltage reading will increase from zero to the voltage set point when the CHARGE button is pressed. Note that theVoltage meter may indicate that some residual voltage is present on the main storage capacitor, even when the tester is firstturned ON. This is due to inherent charging of the internal capacitors. Pressing the TRIGGER switch will discharge thecapacitors. Note that the peak amplitude of the measured output waveform is proportional to the voltage that is read of thefront panel of the MegaPulse, but it will always be somewhat lower. This is because the meter on the MegaPulse ismeasuring the voltage on the main impulse storage capacitor. This voltage will intentionally dissipate to some extent before
reaching the output leads.
The meter will start to flash at 7100V to indicate that voltage is in the maximum limits.
If unit includes PC Interface and the Keyboard is locked, the display will show OFF when a button is pressed.

9

ITEM

NAME

9

OUTPUT jack

10

RETURN jack

FUNCTION
The impulse waveform appears on the OUTPUT jack, referenced to the RETURN jack. When the POLARITY switch is in
the Normal position (NOR indicator is lit) the output will be a positive pulse. When the POLARITY switch is in the
Reverse position (REV indicator is lit) the output will be a negative pulse.
This is the return for the impulse waveform. This jack is referenced to the chassis of the MegaPulse, and is referenced toearth ground as long as the MegaPulse is properly grounded. Even though this jack is referenced to ground, it should betreated as hazardous whenever the MegaPulse is turned ON.

Table 1. Controls, Indicators, Connectors – MegaPulse 1.2x50-7PF Front Panel

10

1

2

3

4
5

Figure 3. Controls, Indicators, Connectors – MegaPulse 1.2x50-7PF Rear Panel

11

ITEM NO.

NAME

FUNCTION
Design to cool down the tester.

1

Fan

2

Appliance Inlet / Fuse holder /Power Switch3

RS-232 Interface (Optional)

Use supplied cordset to connect the MegaPulse 1.2x50-7PF tester to an appropriate source of supply. Fuse
holder provides access for Fuse replacement, and the Power Switch is used to turn the tester ON and OFF.
Allow the communication between the tester and computer interface; a RS-232 to USB is available.

4

Interlock Switch (Optional)

Emergency Stop
Close: Enables the tester buttons for operation.
Open: Stops any process in the tester and disables the buttons. The TRIGGER and CHARGE Indicators
will be blinking

5

Fuse replacement warning /Rating of power supply

Specifies replacement fuse and required supply voltage.

Table 2. Control, Indicators, Connectors – MegaPulse 1.2x50-7PF Rear Panel

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Initial Checkout Procedure
The following procedure will verify that the MegaPulse 1.2x50-7PF tester is working correctly.
We recommend that this procedure be conducted periodically to ensure proper operation of thetester. The following items are needed to conduct this procedure: A measuring instrument tomonitor the output waveform. Always ensure that the measuring instrument (usually an
oscilloscope with a high-voltage probe) is rated for the voltage involved, and that the frequency
response of the instrument and probe are capable of measuring the output waveform of the
MegaPulse 1.2x50-7PF tester. A measuring instrument or probe with a low frequency response
will result in erroneous readings that could be mis-read.
CAUTIONHigh voltage generated by the MegaPulse tester is exposed during this test. A risk ofshock exists. Exercise care when using the MegaPulse tester.
1.

Connect the tester to a proper source of supply using the included 18 AWG power supply
cord. Make sure that the front panel VOLTAGE adjust knob is turned fully
counterclockwise.
2. Plug the Output and Return test leads into the jacks on the front panel.
3. Connect the ends of the test leads to an appropriate measuring instrument (typically an
oscilloscope with a high-voltage probe). Note that the RETURN lead is referenced to thechassis ground of the tester. See Figure 4 as an example.
4.
Turn the Tester on. Toggle the POLARITY switch if necessary so that the NOR indicator
is lit.
5. Note that the Voltage meter may indicate that some residual voltage is present on the mainstorage capacitor, even when the tester is first turned ON. This is due to inherent charging
of the internal capacitors. Pressing the TRIGGER switch will discharge the capacitors (besure not to touch the output and return leads when pressing the trigger switch).
6.
Push the yellow CHARGE button. Verify the red TRIGGER indicator is now lit.
7. Adjust the VOLTAGE knob so that the front panel LED display is reading a voltage that issuitable for the measuring instrument that is being used. Push the red TRIGGER button,
and view the resulting impulse waveform on the measuring instrument.
8. Note that the peak amplitude of the measured output waveform is proportional to thevoltage that is read of the front panel of the MegaPulse, but it will always be somewhat
lower. This is because the meter on the MegaPulse is measuring the voltage on the main
impulse storage capacitor. This voltage will intentionally dissipate to some extent before
reaching the output leads.
9. Repeat steps 5 through 8, except this time toggle the POLARITY switch so that the REV
indicator is lit. Note that the impulse waveform will now be a negative pulse, so it willprobably be necessary to make adjustments to the measuring instrument to get a proper
reading.
10. Adjust the VOLTAGE knob fully counterclockwise, to the minimum position. Turn therear-panel power switch OFF.

13

Figure 4. Waveform Measurement Setup

Testing
This section describes how the MegaPulse 1.2x50-7PF tester is used to conduct a test. The test
can be stopped immediately at any time by turning OFF the rear-panel power switch.
1.

2.
3.
4.
5.

6.
7.

8.

Connect the tester to a proper source of supply using the included 18 AWG power supply
cord. Make sure that the front panel VOLTAGE adjust knob is turned fully
counterclockwise.
Plug the Output and Return test leads into the jacks on the front panel.
Connect the ends of the test leads to the equipment under test.
Turn the Tester on. Toggle the POLARITY switch as needed so that the NOR or REV
indicator is lit.
Note that the Voltage meter may indicate that some residual voltage is present on the mainstorage capacitor, even when the tester is first turned ON. This is due to inherent charging
of the internal capacitors. Pressing the TRIGGER switch will discharge the capacitors (besure not to touch the output and return leads when pressing the trigger switch).
Push the yellow CHARGE button. Verify the red TRIGGER indicator is now lit.
Adjust the VOLTAGE knob so that the front panel LED display is reading a voltage that issuitable for the measuring instrument that is being used. Push the red TRIGGER button,
when the desired voltage is displayed on the front panel meter.
Note that the peak amplitude of the measured output waveform is proportional to thevoltage that is read of the front panel of the MegaPulse, but it will always be somewhat
lower. This is because the meter on the MegaPulse is measuring the voltage on the main
impulse storage capacitor. This voltage will intentionally dissipate to some extent before
reaching the output leads.

14

15

Section 4
Technical AssistanceTechnical Assistance from Compliance West USA is available:
Phone: (800) 748-6224
Hours: 8:30 AM - 4:30 PM Pacific Time.
Also available on our web site at: www.compwest.com

Contact:
Compliance West USA
2120 Jimmy Durante Blvd, Suite 118
Del Mar, CA., 92014
United States of America.
Phone: (858) 481-6454
FAX: (858) 481-8527

16

Section 5
Maintenance and Calibration
WARNING
MAINTENANCE AND CALIBRATION INSTRUCTIONS ARE FOR QUALIFIEDPERSONNEL ONLY. TO AVOID ELECTRIC SHOCK, DO NOT PERFORM ANYSERVICING OTHER THAN THE CONTAINED IN THE OPERATING
INSTRUCTIONS.

Introduction
This section of the manual contains maintenance information for the MegaPulse 1.2x50-7PF
impulse tester. A 1-year calibration cycle is recommended to maintain the specifications of thefactory. The test equipment required for the performance test is a digital oscilloscope, highvoltage oscilloscope probe, digital meter and a high voltage probe.

Service Information
The MegaPulse tester is warranted to the original purchaser for a period of 1 year. This warranty
does not cover problems due to misuse or neglect. Malfunctions which occur within the limits of
the warranty will be corrected at no charge. Mail the instrument post paid to the manufacturer.
Dated proof of purchase is required for all in-warranty repairs. The manufacturer is alsoavailable for calibration and / or repair of instruments that are beyond their warranty period.
Contact the manufacturer for a cost quotation. Ship the instrument and your remittanceaccording to the instructions given by the manufacturer.

General Maintenance
To avoid contaminating the PWB with oil from your fingers, handle it by the edges or wear
gloves. If the PWB becomes contaminated, refer to the cleaning procedures given later in thissection.
WARNING
Dangerous voltages exist when energized. Exercise extreme care when working on anenergized circuit.

Cleaning
Clean the front panel and case with a mild solution of detergent and a damp sponge. Clean dust
from the PWB with clean, dry, low pressure (<20 psi)
CAUTION
Do not use aromatic hydrocarbons or chlorinated solvents for cleaning. These solutions
will react with the plastic materials used in the instrument.

17

Calibration Information
The Calibration Procedure should be performed annually and any time the instrument has been
repaired. The calibration procedure should be performed at an ambient temperature of 23°C
±5°C (73.4°F ±9°F). The procedure consists on internal components tolerance verification andcalibrating the meter reading to agree with the capacitor bank. The Calibration procedure must be
performed by qualified personnel, for more information contact Compliance West USA.

Voltage Stop Disable / Keyboard Enable by Keyboard.
If the MegaPulse 1.2x50-7PF tester includes TestMinder option and has the Voltage Stop by the
PC command activated, it is possible to disable it using the next keyboard sequence:
Note: Disabling Voltage Stop enables the keyboard.
Turn OFF the MegaPulse P tester.
Hold in the TRIGGER and NOR-REV buttons.
Turn ON the MegaPulse P tester.
Wait until the display shows rESE.
Release the TRIGGER and NOR-REV buttons.

18