USER MANUAL - Instrumart
M
5 kV & 10 kV Insulation
Resistance Testers
USER MANUAL
1
G
If this equipment is used in a manner not specified by the
SAFETY WARNINGS
manufacturer, the protection provided by the equipment
may be impaired.
Safety warnings must be observed during use:
The circuit under test must be switched off, de-energised,
isolated and checked to be safe before insulation test
connections are made. Make sure the circuit is not
reenergised whilst the instrument is connected.
Only Megger supplied test leads must be used.
Circuit terminals must not be touched during an insulation
test or before suitable grounding of the unit under test is in
place in line with safe working practices.
After completing a test, capacitive circuits must be
completely discharged before disconnecting the test leads.
Capacitive charges can be lethal.
Tested items must be firmly shorted out with a shorting
link, after discharge, until required for use. This is to guard
against any stored dielectric absorption charge
subsequently being released thereby raising the voltage to
potentially dangerous levels.
The voltage indicator and automatic discharge features
must be regarded as additional safety features and not a
substitute for normal safe working practice.
It is rare, but in certain circumstances, breakdown of the
circuit under test may cause the instrument to terminate
the test in an uncontrolled manner, possibly causing a loss
of display while the circuit remains energised. In this event,
the unit must be turned off and the circuit discharged
manually.
Test leads, including crocodile clips, must be in good
order, clean and with no broken or cracked insulation.
The instrument must not be used if any part of it is
damaged.
Insulation testing in wet weather conditions might be
hazardous. It is recommended that this instrument is not
used in these circumstances. If this is unavoidable, the
user must take all necessary precautions.
This instrument is not intrinsically safe and must not be
used in hazardous atmospheres.
BATTERY WARNINGS
Do not disassemble or modify the battery. The battery
contains safety and protection devices which, if damaged,
may cause the battery to generate heat, rupture or ignite.
Never heat the battery in a fire or otherwise.
Do not pierce or damage the battery in any way
Do not subject the battery to strong impacts/shocks.
Do not expose the battery to water, salt water or allow the
battery to get wet.
Never short circuit, reverse polarity or disassemble the
battery pack.
In the event of a battery cell leaking, do not allow the liquid
to come into contact with the skin or eyes. If contact has
been made, wash the affected area with copious amounts
of water and seek medical advice.
Keep cells and batteries out of reach of children
Seek medical advice if a cell or battery has been
swallowed.
Do not leave a battery on prolonged charge when not in
use.
Retain the original product literature for future reference.
NOTE
THE INSTRUMENT MUST ONLY BE OPERATED BY
SUITABLY TRAINED AND COMPETENT PERSONS
Users of this equipment and/or their employers are reminded
that National Health and Safety Legislation requires them to
carry out valid risk assessments of all electrical work so as to
identify potential sources of electrical danger and risk of
electrical injury such as inadvertent short circuits.
2
Symbols used on the instrument
G
F
Caution: refer to user manual
Caution: risk of electric shock
Equipment protected throughout by Double Insulation.
Line Power / mains
c
Equipment complies with current EU directives.
Equipment complies with current “C tick” requirements.
Do not dispose of in the normal waste stream.
g
Earth
Universal Serial Bus (USB)
CAT IV 600 V
Overvoltage category IV (equipment installed at or near
the origin of the electrical supply to a building)
600 V refers to the rms phase-to-earth voltage that this
instrument can withstand to the overvoltage category
IV rating.
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Care of the instrument .................................................... 21 Leads .............................................................................. 21 Battery Care.................................................................... 21 Replacing the battery...................................................... 21 Technical Specification .......................................................... 23 Electrical specification ........................................................ 23 Environmental Conditions .................................................. 24 GENERAL SPECIFICATION.............................................. 24 Repair and Warranty.............................................................. 24 Calibration, Service and Spare Parts ................................. 25 Returning product to Megger UK & USA service centres... 25 Approved Service Centres ................................................. 26
Accessories, Equipment and Spares ..................................... 28
Table of contents and index
General description.................................................................. 5 Features................................................................................... 5 Instrument Controls and Indicators .......................................... 6 Preparations for Use ................................................................ 7 Initial instructions.................................................................. 7 Power lead and battery charging ......................................... 7 Functional verification .......................................................... 7 Calibration ............................................................................ 7 Storage................................................................................. 7
Operating instructions ............................................................. 8
General operation ................................................................ 8 Breakdown vs. burn mode ................................................... 9 Voltmeter .............................................................................. 9 Initial setup ..................................................................... 10 Lock Voltage ................................................................... 10 Alarm setting................................................................... 10 Recording temperature ................................................... 10 Breakdown mode / burn mode ....................................... 11 Running an insulation test .............................................. 11 Memory functions and downloading ............................... 12 Real-time output during insulation tests ......................... 12 Battery indicator.............................................................. 13 On screen error reporting ............................................... 13 Measurement Modes ......................................................... 14 ‘Spot’ IR test ................................................................... 14 Timed IR test .................................................................. 14 DAR and PI Insulation Tests .......................................... 14 Dielectric Discharge test ................................................. 15 Step Voltage Test ........................................................... 16 Ramp voltage test........................................................... 17 Measurement Techniques.................................................. 18 Understanding Measurement Currents .......................... 18 Insulation measurements above 100 GΩ ....................... 18 Terminals ........................................................................ 19 GUARD terminal, screened leads .................................. 19 Preventative measurement .................................................... 21 Cleaning ......................................................................... 21
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General description
software, PowerDB, or to popular third party spreadsheet
packages.
The new range of Insulation Resistance Testers (IRT) are
smaller and lighter than previous models, yet offer advanced
features, improved battery life and rapid charge capability. The
range consists of three models; an entry level 5 kV and two
fully featured units, one 5 kV the other 10 kV. Resistance
measurement capability is up to 10 TΩ for the 5 kV models
and 20 TΩ for the 10 kV model.
The MIT515, MIT525 and MIT1025 can be powered from the
mains supply or by it’s rechargeable battery, which provides
for 4½ to 6 hours of continuous testing with a 100 MΩ load,
depending on model. A battery level indicator on the LCD
display indicates battery capacity. Connecting power to
line/mains supply will automatically charge the battery whether
the instrument is switched on or off, except during testing.
A key productivity feature is the ability to operate with a
discharged battery when line/mains power is connected. An
intelligent battery charger ensures the optimum charge rate as
a function of battery level, resulting in extended battery life and
minimum charge times.
Features
The tough case provides ultimate protection for a portable
instrument and a clip-on lead pouch ensures that supplied
leads remain with the instrument at all times. The case lid is
removable for improved lead access. IP rating is IP65 with
case closed ensuring no moisture ingress. High reliability is
built-in and all models are safety rated to CATIV 600 V.
Five preset voltage ranges are provided in insulation test
mode, plus a user settable lock voltage range which is useful
for repetitive measurements at specific test voltages. All test
voltages can be adjusted before and during the test using
up/down buttons. Preconfigured diagnostic tests like
Polarisation Index (PI), Dielectric Absorption Ratio (DAR),
Stepped Voltage (SV) and a ramp test are available along with
basic and timed insulation resistance tests.
Simplicity of operation is achieved with two rotary switches
whereby test voltage range and test mode are self evident.
The large backlight display enables multiple results to be
displayed, for example, the step voltage test shows five step
voltage resistance results simultaneously.
Advanced memory storage includes time/date stamping of
results, logging of data and recall of results to screen. A fully
isolated USB device interface is used for safe transfer of test
records to all versions of Megger’s data management
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10 TΩ max. resistance, 20 TΩ
for MIT1025
MIT515 with IR, IR(t), PI and
DAR
MIT525, MIT1025 diagnostic
and over voltage tests - PI,
DAR, DD, SV and ramp test.
Operate and charge on line
power/mains (except during
actual test)
Light weight Li ion battery
CATIV 600 V safety rating
Advanced memory with time/date stamp
DC and AC voltmeter (30 V to 660 V)
Large LCD display with backlight
Download of saved results and logs via 10 kV isolated
USB cable (MIT525, MIT1025 only)
PowerDB Lite software included with MIT525 and
MIT1025
Instrument Controls and Indicators
1. Positive (+) terminal
2. GUARD terminal
3. Negative (-) terminal
4. USB device interface
5. Four arrow buttons and OK button
6. TEST button with associated HV warning lamp
7. Backlight button
8. Central rotary switch
9. Save button on MIT525 and MIT1025
10. Test mode rotary switch
11. LED indicating line power / mains
12. Display
13. Power socket
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User lock
voltage
Delete records
Timer
Download via
USB
Save
Filter
Open records
Alarm
Battery
Breakdown
mode
Ramp test
Burn mode
Danger HV
Refer to manual
Fuse
Noise detected
Preparations for Use
Initial instructions
Remove instrument, power lead and pouch from the
packing box.
Clip the test lead pouch to the lid.
Open the lid and familiarise yourself with the layout and
position of the IEC 60320 power inlet on the left side of
the panel. An isolated USB socket is found on the right
side of the instrument.
The battery must be charged between 0 ºC and 40 ºC
ambient temperature. If the battery detects a
temperature outside this range the battery symbol will
flash.
Power lead connection table
Connection
UK/International
USA
Earth/Ground
Yellow/Green
Green
Neutral
Blue
White
Live (Line)
Brown
Black
Unpack leads and pack them into the lead pouch.
Functional verification
Read the product manual, especially the warnings.
A quick reference is provided in the instrument lid.
Keep the original packaging for re-use.
Simply turning on the instrument will initiate a start-up process
and the display will respond. If an error is detected ‘Err’ will be
displayed with an associated error number.
Calibration
Power lead and battery charging
The MIT515, MIT525 and MIT1025 are supplied with a
calibration certificate which is automatically generated as part
of Megger’s final test procedure.
If the power lead supplied is not suitable for your
line/mains connection, do not use an adaptor. Always
use a power lead fitted with the correct plug. The
ground connection is not used as the instrument is
double insulated.
If using a fused plug, ensure that it is fitted with a 3 A
fuse.
Supply voltage: 90 to 265 V rms ac at 50/60 Hz.
A green LED illuminates when line power/mains is
present.
The battery will charge as long as the mains supply is
connected, except when a test is in progress.
For optimum battery life, charge the battery after each
use. Full charge duration is up to 2½ hours but a first
charge time of 3 hours is advised.
UKAS accredited calibration certificates are available from
Megger but this service is chargeable.
Storage
Instruments should be stored in storerooms which meet the
storage temperature and humidity specifications listed in this
document. If charging is incorporated in the storeroom the
room must be well ventilated.
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Operating Instructions
voltage range or mode is changed or by pressing the right
arrow/breakdown button.
General operation
The MIT515, MIT525, MIT1025 Insulation resistance testers
(IRTs) are primarily controlled by two rotary switches and a
TEST button used to start and stop a test (see section entitled,
‘Instrument Control and Indicators’). The central rotary switch
includes an ‘OFF’ position; the instrument switches on by
rotating the switch either clockwise or anticlockwise from this
position. A range of test voltages for insulation resistance tests
up to 5 kV for MIT515/MIT525 and 10 kV for MIT1025 are
available, including a user selectable voltage range which can
be set between 100 V and 5000 V or 10000 V depending on
model. The ‘lockable’ test voltage range can be adjusted in the
settings function.
Instrument controls are simple to operate. The central rotary
switch incorporates the OFF position. The left hand rotary
switch selects insulation test type (test mode switch). The
TEST button starts and stops a test.
The settings function is indicated by a spanner symbol and
facilitates lock voltage, low resistance alarm, temperature,
time/date adjustment. A light blue coloured section of the
rotary switch denotes memory functions; open records,
download via USB and delete records. A dedicated save
button is provided on the MIT525 and MIT1025 models and all
models have a backlight button.
A second rotary switch controls the insulation test mode
providing for the following tests:
All models have basic insulation resistance IR, timed
insulation resistance IR(t), Dielectric Absorption Ratio
(DAR) and Polarisation Index (PI) tests.
MIT525 / MIT1025 have additional tests; Dielectric
Discharge (DD), Step Voltage (SV) and ramp test.
Four arrow buttons and OK facilitate adjustment and selection
of settings, voltages and modes. Breakdown/burn modes are
set using the left and right arrow buttons. Backlight and save
functions are dedicated buttons. All models have backlight and
the MIT525 and MIT1025 have the Save button.
A cluster of directional buttons and an OK button are used in
settings and memory functions. The up/down arrows also
enable the test voltage to be adjusted during a test. Prior to
the start of an IR or IR(t) test, holding down the left arrow
button with a voltage level selected on the central rotary switch
will activate burn mode. Burn mode is deactivated if the
8
Voltage during discharge of a reactive load will be displayed in
addition to warning symbols. Non-reactive loads will discharge
too rapidly to show the voltage drop.
Breakdown vs. burn mode
In breakdown mode insulation tests are automatically stopped
when a fault causes the applied voltage to drop rapidly. Burn
mode IR tests ignore breakdown and continue to test the
insulation and are therefore destructive tests. Burn mode is
used to purposely create a carbon track in insulation to
facilitate fault location. Burn mode only operates at test
voltages of 500 V and above.
In the unlikely event of a fault during a test or during the
discharge process, the user is advised to check for flashing
high voltage warning symbols and the red LED on the
instrument panel will flash. If the warning symbols and LED do
not flash, turn off the instrument before disconnection.
Voltmeter
A voltmeter is incorporated in the
instrument and measures AC and DC
voltage from 30 V to 660 V. Frequency
(Hz) is measured and displayed for AC
voltages.
The voltmeter can be used to confirm
that the insulation is discharged and for
general purpose use. Positive and negative terminals are used
for the voltmeter function; do not connect the GUARD terminal
in voltmeter mode.
Before starting a test, the voltmeter detects any voltage
between the positive and negative terminals and will display
the voltage. If the voltage is above 50 V at the start of an
insulation test, a voltage is displayed on the analogue and
digital readouts to alert the user. The voltage displayed is
developed by current flowing through the internal discharge
resistance of the instrument. If the source impedance is high
the current will remain constant regardless of the value of the
internal discharge resistance.
In high electrical noise environments a lockout activates when
induced currents exceed the capability of the instrument to
remain within specified accuracies. The voltmeter reports the
voltage across the internal discharge resistor.
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OK button. The setting does not change even if the instrument
is switched off.
Instrument Control
Initial setup
Alarm setting
It is important to setup the Real Time Clock (RTC) on models
MIT525 and MIT1025 to ensure that records saved in the
instrument are time/date stamped correctly. The MIT515 does
not require time/date setting. The RTC has a separate battery
to maintain settings even when the primary battery is removed.
A low resistance alarm sounds when the resistance level of an
insulator reaches the alarm, assuming alarm has been
activated. The default alarm setting is 500 kΩ and inactive (X
is displayed on the right of the display). Set central and mode
rotary switches to the settings and IR positions respectively.
Press the right arrow button once. The low resistance alarm
can be set at the default value by simply pressing the OK
button, or changed to a different alarm resistance level using
the up/down arrow buttons and save it by pressing OK.
To set the clock and date,
select the settings
function on the central
rotary switch and turn the
mode rotary switch to IR.
Navigate using the
left/right arrows to where
the time and date is displayed.
Recording temperature
Set the time using the up and down arrows. Change the hours
and minutes then press OK to save.
The MIT525 and MIT1025 are able to record insulation
temperature measured by an independent thermometer. If you
do not wish to record temperature do not change the default
setting or reset it if it was previously set.
Move the central rotary switch to point to settings and press
the right/left arrow buttons until ‘tº ---‘ is displayed. The default
setting is no temperature record. This can be changed by
pressing up or down arrows to select either ºF or ºC
temperature entry. Pressing OK will confirm the setting and
result in a prompt for temperature to be entered whenever the
save button is pressed after completing any test. Up and down
arrows facilitate temperature entry in 1 ºC increments /
decrements.
Select the day/month format required, i.e. d:m for day:month
or m:d for month:day and press the right arrow button, then set
the date and press OK to save. A tick on the left of the display
indicates that a setting is saved, a cross is displayed during
adjustment indicates that it is not set. Exit settings by changing
the central rotary switch to a different position.
Lock Voltage
The user selectable ‘lock’ voltage range is set by adjusting the
displayed voltage using the up and down arrow buttons. When
the desired voltage is displayed, it is saved, by pressing the
10
Breakdown mode / burn mode
It is possible to adjust the test voltage using the up and down
arrow buttons, either before or during a test. Once a test has
begun, it is advisable to only adjust the voltage in the first 10s
of the test to prevent interference with the capacitive and
absorptive currents in the insulator.
The insulation resistance ‘IR’ test operates
in either ‘Breakdown’ or ‘Burn’ mode.
Default mode is breakdown.
A test is started by pressing and holding down
the TEST button for approximately 3 seconds. A
timer will be displayed to indicate elapsed time
during the test. The test is stopped, by pressing
the TEST button. As soon as the test is stopped a discharge of
the insulator is automatically initiated. An ‘StP’ indication
informs the user that the test is terminating and after a few
seconds the voltage on the terminals will be displayed. Left
and right arrows can be used to scroll between terminal
voltage, last test voltage and the set range voltage. In the
event of a terminal voltage of ≥50 V a voltage and warning will
be displayed.
Left and right arrow buttons toggle between
burn and breakdown mode when a voltage
range is selected. Press and hold left
arrow/burn to activate burn mode.
In breakdown mode the test will automatically terminate on
detection of a breakdown to prevent damage to the insulation.
Burn mode disables the normal breakdown detection and
test voltage continues after breakdown of the insulation.
This enables the location of the failure to be seen and
detected acoustically but it is a destructive test.
Do not disconnect instrument leads or clamps until the
LED and display warnings are switched off indicating that
the unit under test is discharged! Significant current can
be stored in reactive loads which act as capacitors or
inductors, which can be lethal.
Due to the potential damage that could occur, the unit
produces two long beeps when starting a test with burn mode
activated.
Running an insulation test
Before testing any reactive load the insulation must be
fully discharged.
The display shows the final resistance result, capacitance, test
current and Time Constant (TC) in addition to test duration.
The required
resistance test is
selected on the
mode rotary switch
at the bottom left of
the instrument
keypad. The test
voltage is selected
using the preconfigured voltage ranges on the central rotary
switch or the VL user settable/lockable voltage range.
On MIT525 and MIT1025 models the result can be saved by
pressing the dedicated save () button after a resistance or
voltage test is complete. The save button will appear
momentarily to confirm the data is saved. If a full test curve is
required the user must select logging by pressing the save
button before starting the test. Data will be logged every 5
seconds for the duration of a resistance test. It is not possible
to log voltages in voltmeter mode.
If temperature entry has been activated a prompt will appear
for the user to enter a temperature reading after IR and IR(t)
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insulation tests. DAR, PI, SV, ramp and DD tests will not
prompt for temperature input.
summary result. To download all results press an arrow
button.
Display backlight is activated by pressing the (J ) button. The
backlight button can be pressed a second time to deactivate
the backlight. Automatic deactivation will occur after a preset
timeout period if not deactivated manually.
Detailed instructions on how to interface with PowerDB are
available on the product CD on a document entitled
‘Interfacing MIT525, MIT1025 to PowerDB’.
PowerDB offers instructions specific to MIT525 and MIT1025
regarding the download procedure. When results are
downloaded the IRT can be disconnected from the PC after
the application releases the port.
Memory functions and downloading
Models MIT525 and MIT1025 have advanced storage, recall
and download functions to facilitate documentation of
insulation tests.
Deleting results
There are two delete functions; delete
a single result and delete all results.
Select the bin icon on the central rotary
switch. The first record indicated
contains the result of the last test
performed. Up/down arrows navigate
through records and the OK button is
used to select delete where the ‘X’
changes to a tick and the on screen bin icon flashes. A
subsequent press of the OK button activates the deletion.
Recall results
Setting the central rotary switch to
‘open folder’ position enables the user
to recall saved results beginning with
the most recent result. Up and down
arrow buttons enable the user to scroll
through results based on a sequential
four digit index. Left and right arrow
buttons scroll through a single result showing all saved test
data including time/date. Where logging has been enabled,
only the final result is displayed on screen. The full result can
be viewed by downloading to PowerDB/PowerDB Lite.
The default delete is a single test result, press the right arrow
button to select delete all test results from memory.
In saved results, the test mode is identified by the icon or
abbreviation of each test on the display. In addition, the open
folder icon is displayed to indicate recall memory mode.
Real-time output during insulation tests
PowerDB or PowerDB Lite can be used to record real time
data output from the MIT525 and MIT1025 models. Voltage,
current and resistance data is sent at a rate 1 Hz from the IRT
and displayed in real time on a graph, e.g. a plot of current
(µA) versus voltage (kV) for the ramp test.
Download results
PowerDB Pro, Advanced and Lite are
Megger’s asset and data management
software packages with integrated
forms for MIT525 and MIT1025
instruments.
Before running a test where a real time output is required,
attach a PC running PowerDB Pro, PowerDB Advanced or
PowerDB Lite via a USB cable. Check the product CD
provided with the instrument for a folder named, “Megger
USB.” If this folder exists, use it when starting PowerDB for the
The default download on the
instrument is a single test log or
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first time to find the driver, if not allow the operating system to
search the internet for the driver. Check the serial port
allocation on Device Manager, and enter the serial port
number allocated when starting PowerDB. PowerDB offers
instructions specific to MIT525 and MIT1025 regarding the real
time capture procedure.
the allowable charge temperature range, 0 ºC to 40 ºC, or that
the battery has failed.
On screen error reporting
Should an error be detected during the operation of the
MIT515, MIT525 or MIT1025, an error code is reported
preceded by ‘Err’ with the read handbook warning.
Start the application and activate real time data capture in the
form of choice. As soon as the test is started real time data
output will begin. When the test is complete ensure that the
form is saved in PowerDB Pro/Advanced/Lite.
Error codes are given in the following table.
‘Err’ code Fault
Battery indicator
The battery symbol on the LCD display contains four pairs of
segments. The battery is monitored continuously when the
instrument is turned on. The charge remaining in the battery, is
indicated by segment pairs as follows:
Fully charged battery
50% charged battery
Tests cannot be started, and the battery
may fail at any time
2
3
Output voltage over limit
FIFO (memory) overflow
4
HV board mismatch with control board setup
5
6
Battery low error
Control board detected inter-board
communication failure
7
Test button stuck
8
Measurement board i2c failed
9
Measurement board detected inter-board
communication failure
10
Isolation power supply cut-out
If an error occurs do not attempt to repair the instrument.
Obtain a repair number from Megger Instruments Limited,
carefully pack in a suitable box and send the faulty instrument
to the nearest Megger Approved Service Centre, if possible
noting the error that was reported.
Symbol flashes when there is not enough
charge for a test and the instrument will
turn itself off.
When mains power is present the indicator shows the battery
is being charged by animating the segments of the bar graph.
A blinking full battery icon indicates that the battery is
prevented from charging due to the temperature being out of
13
Timed IR test
Measurement Modes
A timed test IR(t) will
automatically terminate
an insulation test after a
preset time. Default timer
is set to 1 minute and is
adjustable within the
settings function. This is
a useful feature which
saves the user watching the display for the full duration of the
test and the possibility of missing the 1 minute reading.
‘Spot’ IR test
The spot insulation resistance test (IR) is selected on the test
mode rotary switch. Select the IR setting and then the required
test voltage using the preconfigured voltage ranges on the
central rotary switch or the VL user settable/lockable voltage
range. All preconfigured voltage ranges, but not VL, are
adjustable using up and down arrow buttons before and during
the test, but the latter should be limited to the first 10 seconds
of IR and IR(t) tests. Press and hold TEST to start the test.
Turn the central rotary switch to the settings position. Select
IR(t) on the test mode rotary switch. The default time of 1:00
minute will flash prompting the user to select a new time using
the up/down arrow buttons. Press OK to set test duration and
turn central rotary switch to desired test voltage. Press and
hold TEST to start the test.
To set the user defined
lock voltage VL, turn
the central rotary switch
to settings and the mode
switch to IR. The preset
voltage 5000 V will flash
and can be changed
using the up/down buttons. When the required maximum
voltage is displayed, press the OK button to save the setting.
This setting will remain until it is reset.
DAR and PI Insulation Tests
DAR and PI tests are measurements of resistance over time
expressed as a ratio of resistance at time t2 divided by
resistance at time t1. The assumption is that insulation
temperature does not vary widely over the duration of the test
so the resulting DAR
and/or PI value are
temperature independent.
Testing should be done at
or below 40 ºC, 104 ºF for
this assumption to hold.
Whenever VL is selected the set voltage is shown on the
display. The voltage lock is useful when, for example, testing
insulation of XLPE cables that should not be tested above
5000 V. The lock function will ensure it does not exceed the
VL voltage within the stated output voltage accuracy.
On test completion, insulation capacitance (C) and the Time
Constant (TC) associated with it is calculated and displayed.
DAR and PI timers t1 and
t2 are set when DAR or PI is selected on the test mode rotary
switch with the central rotary switch in the settings position.
Timer t1 is set first followed by t2. Up and down arrow buttons
are used to change the t1 and t2 default values and OK
confirms each setting.
Time Constant (TC) = Rinsulation x Cinsulation
14
Dielectric Discharge test
DAR and PI insulation test voltages are selected on the central
rotary switch by simply aligning the switch opposite to the
required insulation test voltage. Press and hold TEST to start a
DAR/PI test.
The Dielectric Discharge
(DD) or re-absorption
current test operates
during the discharge of
the dielectric under test.
Originally developed by
EDF, France’s power
utility company, it is a
diagnostic insulation test that allows ageing, deterioration, and
voids in the insulation to be assessed. The result is dependent
on the discharge characteristic so the internal condition of the
insulation is tested, largely independent of any surface
contamination.
DAR is defined as the ratio of insulation resistance at 1 minute
divided by insulation resistance at 30 seconds, although a 1
minute, 15 second DAR is also popular:
DAR = IR60s / IR30s
Insulation Condition
Poor
Acceptable
Excellent
DAR result
<1
1 – 1.4
1.4 – 1.6
The insulator must first be charged for a sufficient time to be
stable, i.e. charging and polarization are complete and the only
remaining component of current is leakage current due to the
insulation. On discharge the capacitive component of the
discharge current decays from a high value with a relatively
short time constant of a few seconds. The released absorption
current decays from a lower value with a relatively long time
constant of up to several minutes.
IEEE standard 43-2000, Recommended Practice for Testing
Insulation Resistance for Rotating Machines, defines PI as the
ratio of insulation resistance at 10 minutes divided by
insulation resistance at 1 minute:
PI = IR10min / IR1min
If IR1min > 5000 MΩ the PI may or may not be an indication of
insulation condition and is therefore not recommended by
IEEE std. 43.
Insulation Condition
Poor
Questionable
Acceptable
Good
The DD timer defaults to 30 minutes of charging, which is
generally sufficient time for full absorption to take place in an
insulation material. The default test voltage is set to 500 V so
the primary rotary switch must be set at or above 500 V.
PI result
<1
1-2
2-4
>4
The default DD test duration (t1) is 30 minutes insulation test
followed by a fixed 1 minute discharge. The initial 30 minute
period can be adjusted but care should be taken to ensure that
full absorption will take place in the insulation test period. DD
should be selected on the test mode rotary switch and settings
on the central rotary switch. Timer t1 is set using the up and
down arrow buttons and OK confirms the setting.
PI results > 1.5 are regarded as acceptable by IEC6008501:1984 for thermal class rating A, and PI results > 2.0 for
thermal class ratings B, F and H.
The ‘DD’ test requires the instrument to measure the
discharge current 1 minute after the removal of the test
15
voltage, which is greater than the primary time constant of the
discharge. On completion of the test, the instrument uses this
measurement along with the test voltage and calculated
capacitance to produce a figure of merit indicating the quality
of the insulation.
testing. If a PI test was performed to verify the winding’s
suitability for over voltage testing, the winding must be
completely discharged before the overvoltage test is
performed.
The SV test is based on the principle that an ideal insulator will
produce identical readings at all voltages, while an insulator
which is being over stressed, will show lower insulation values
at higher voltages.
DD = I1min/(V x C)
where I1min is the discharge current in mA one minute after
removal of the test voltage V in Volts and C is the capacitance
in Farads.
During the test the applied voltage steps incrementally by one
fifth of the final test voltage each minute for 5 minutes, taking
successive measurements.
DD results can identify excess discharge currents that arise
when a layer of multi-layer insulation is damaged or
contaminated, a condition that will be missed by both the IR
and PI tests. Discharge current will be higher, for a given value
of voltage and capacitance, if an internal layer is damaged.
The time constant of this individual layer will mismatch the
other layers, giving rise to a higher value of current than for
insulation that is ‘good’ in this respect.
Resistance readings for the first four ‘steps’ are displayed
under consecutive time designators ‘1m’ to ‘4m’. The 5 minute
reading is displayed by the main display. If the default 5
minute test duration is changed by the user the four readings
will not show the respective ‘1m’ to ‘4m’ indicators.
The SV test duration
can be adjusted if
desired from the 5
minute default value
using the up/down
arrows and OK to save
the setting.
Homogenous insulation will have a DD value of 0, while good
multi-layer insulation will have a value up to 2. The following
table is a guide to DD test results:
Insulation Condition
Bad
Poor
Questionable
Good
Homogenous
DD result
>7
4-7
2-4
<2
0
The step timer will always be set to total test time divided by
five. Too short a step time may result in incorrect readings and
too long a step time may over stress a motor.
The reference standard for step voltage testing is IEEE 952002.
Step Voltage Test
The SV test is a controlled overvoltage test that can be applied
to stator and rotor windings on synchronous and
asynchronous AC motors and the armature and field windings
on DC motors. It is advisable to perform a PI test before an SV
test to determine if the insulation is suitable for overvoltage
16
Ramp voltage test
The ramp voltage test is an overvoltage test similar to the SV
test but with improved control and warning of potential
insulation failure. The slow continuous voltage ramp is less
likely to result in unpredictable damage to the insulation than
the rapid step increases employed in SV test.
If a PI test was performed to verify the winding’s suitability for
over voltage testing, the winding must be completely
discharged before the over voltage test is performed.
The typical voltage ramp
(dV/dt) is 1 kV/min
which is the default for
MIT525/MIT1025. This
value is user adjustable
from the settings
function with the mode
rotary switch set to ramp. Up and down buttons are used to
adjust dV/dt to the required rate and OK confirms the setting.
Press and hold TEST to start.
The test will ramp the voltage until it reaches the selected test
voltage unless a breakdown or sudden rise in current is
detected. The result displayed after the test is the final
insulation resistance, voltage and current. If the result is saved
a complete curve of current (µA) and voltage (kV) is recorded
and can be read into PowerDB, PowerDB Lite or converted to
a spreadsheet so that the current vs. voltage curves can be
compared to published curves in IEEE 95-2002.
17
Insulation measurements above 100 GΩ
Measurement Techniques
Understanding Measurement Currents
Insulation resistance is defined as the dc test voltage divided
by the total current flowing in an insulator. The total current
has four components; capacitive current, absorption current,
conductance current and leakage current.
Measurements up to 100 GΩ can be made without any special
precautions, assuming that the test leads are reasonably clean
and dry. The guard lead can be used to remove the effects of
surface leakage if necessary. When measuring resistances
above 100 GΩ, the test leads should not be allowed to touch
each other, or any other object since this will introduce
leakage paths. Sharp points at the test lead connections
should also be avoided since this will encourage corona
discharge.
In the case of dry insulation conductance current may be
negligible, and the leakage current may be low, in which case
the absorption current will dominate the total current
measured.
The output is isolated, and so will float relative to ground such
that the positive terminal is at plus half of the test voltage, and
the negative terminal is at minus half of the test voltage with
respect to ground.
18
Leakages therefore occur between the positive terminal and
ground, between the negative terminal and ground, and
directly between the positive and negative terminals. These
leakages have a significant effect and can occur through air.
When making measurements above 100 GΩ therefore, the
user should ground the Guard lead where possible, otherwise
parallel leakage paths may occur.
Alternatively, screened leads are available as an optional
accessory from Megger. When using a screened lead the
screen is plugged into the Guard terminal, diverting any
leakage currents. This considerably improves measurements
made with a floating output, where the leads might touch each
other or another object other than the test piece.
Terminals
There are three test terminals marked +, - and GUARD. These
terminals are designed to accept only genuine Megger test
leads. Shutters across the terminals prevent accidental ingress
of dirt and other objects. Test lead plugs interlock with the
shutters and are released by rotating the test lead plug by a
quarter turn.
If the guard lead is grounded, and since the negative terminal
is at the same voltage as the guard terminal, the leakage into
the negative terminal will be considerably reduced. This will
improve accuracy because the current flowing into the
negative terminal is measured by the instrument and used to
calculate resistance. This technique is only permissible if the
item under test is isolated from ground. In this context isolated
means insulated by a resistance of at least 5 MΩ for the
positive terminal, or at least 10 kΩ for the negative terminal.
The GUARD terminal, as explained below, is only used in
cases where surface leakage currents need to be eliminated.
Most measurements use just the + and – terminals. The
instrument’s internal voltage generator drives the + terminal
with respect to the – terminal, current being measured in the –
terminal.
GUARD terminal, screened leads
For basic insulation tests and where there is little possibility of
surface leakage affecting the measurement it is unnecessary
to use the guard terminal, i.e. if the insulator is clean and there
are unlikely to be any adverse current paths.
However in cable testing for example, there may be surface
leakage paths across the insulation between the bare cable
and the external sheathing due to the presence of moisture or
dirt. Where it is required to remove the effect of this leakage,
particularly at high testing voltages, a bare wire may be bound
tightly around the insulation and connected via the third test
lead to the guard terminal ‘G’.
Conversely, if the positive terminal is grounded, then the
negative terminal will be at a voltage equal to the test voltage
relative to ground, which will result in an increase in leakage
current, and worsening of measurement accuracy.
19
The guard terminal is at the same potential as the negative
terminal. Since the leakage resistance is effectively in parallel
with the resistance to be measured, the use of the guard
causes the current flowing through surface leakage to be
diverted from the measuring circuit. The instrument therefore
reads the leakage of the insulator, ignoring leakage across its
surface.
The display will show a warning and fuse terminal symbol if
the internal guard terminal fuse has blown. The instrument
must be switched off to clear the message before further
testing is permitted. The fuse should be replaced by an
authorised repairer. The instrument may be used in the mean
time if the guard terminal not used. Refer to notes regarding
measurements above 100 GΩ above.
This diagram illustrates GUARD terminal used to prevent
surface leakage on cable insulation from affecting a high
resistance measurement.
Screened leads are available for the complete range of
insulation testers. They are useful in HV switchyards where
induced currents are an issue. The screen connects to
GUARD and prevents induced currents in the lead.
20
Preventive Maintenance
The battery pack contains Lithium-ion cells and should be
replaced when it no longer holds a charge. A new battery is
available as a spare part from Megger. Genuine Megger
battery packs must be used. Failure to use genuine parts
may affect product safety performance and will invalidate
your warranty.
Cleaning
Disconnect the instrument and wipe it with a clean cloth
slightly damped with soapy water or Isopropyl alcohol (IPA).
Care should be taken near the terminals, IEC power and USB
sockets.
Danger Electric Shock Hazard: Removing the lower case to
change the battery exposes the AC supply wiring which will be
at a hazardous voltage if the equipment is connected to the
AC supply.
Care of the instrument
The instrument should always be handled with care and not
dropped. Always ensure that the instrument is secured when
being transported to prevent mechanical shock.
Replacement involves removal of four screws from the bottom
of the instrument after which the base can be lifted away from
the front panel and internal moulded assembly. Care should
be taken to keep the front panel and moulding assembly
together. The battery pack is housed within a grey moulded
cover secured by four screws.
Leads
Leads are silicone insulated and perform well in all weather
conditions. Always keep the leads in the clip-on lead pouch
supplied with the instrument.
Regular inspection of leads is recommended to ensure they
are not damaged in any way. Damaged leads could affect
insulation resistance readings and are a safety hazard.
On no account must the transparent inner case be opened.
Hazardous voltages up to 10 kV will be exposed. No user
serviceable parts are inside. Refer servicing to qualified
service personnel. If there is any damage to the inner
transparent casing or its lid, then confirm that the Central
Rotary Switch is in the OFF position, disconnect the old
battery and DO NOT connect the new one. Refit the bottom
cover and contact Megger Instruments for service.
Battery Care
The battery should be charged on a routine basis at an
absolute minimum of once a year. However more frequent
charging, i.e. once per quarter is preferable.
Never attempt to charge the battery below 0 ºC or above
+40 ºC. The battery is charged by connecting line power at the
instrument IEC power socket.
Instructions:
1. Remove the lid, switch the central rotary switch to OFF.
2. Disconnect the IEC AC power lead and all test leads
before inverting the lower case, resting the front panel
on a soft surface so as not to damage the keypad.
3. Remove the four case fixing screws and lift off case
bottom.
4. Carefully unclip the battery cable connector leading
from the main printed circuit board to the battery and
remove the cables from recesses designed to hold
them in place.
Store the instrument in a cool, dry location to improve battery
life. Storage temperatures below freezing should be avoided.
Replacing the battery
Read and fully understand the warnings on the Li-ion battery in
the Safety Warnings section of this document.
21
5. Remove the four screws and lift off the battery cover.
6. Remove the used battery and replace with a genuine
spare battery ordered from Megger, ensuring correct
orientation of cable exit.
7. Route the battery cables via the recesses and clip the
battery connector to the printed circuit board battery
receptacle ensuring correct orientation.
8. Replace the battery cover and secure with the four
screws.
9. Ensure the alignment of the instrument panel and high
voltage moulding, then replace the lower case and
secure with the retaining screws. Take especial care
not to leave foreign bodies inside the casing.
10. Check and verify instrument operation.
22
Technical Specification
Short circuit current: 3 mA nominal*
* Maximum power regulation technology ensure maximum
power transfer throughout all loads not just at short circuit
outperforming many 5 mA testers
Electrical specification
Voltage input range: 85-265 V rms, 50/60 Hz, 100 VA
Battery
Battery life
MIT515, MIT525:
MIT1025:
11.1 V, 5.2 A hour, safety rated to IEC
62133:2003
Typical capacity is 6 hours continuous
@ 5 kV with a 100 MΩ load
Typical capacity is 4.5 hours continuous
@10 kV with a 100 MΩ load
Guard:
Capacitor charge:
MIT515, MIT525:
MIT1025:
<3 s/µF at 3 mA to 5 kV
<5 s/µF at 3 mA to 10 kV (MIT1025)
Capacitance range
(above 500 V):
250 V, 500 V, 1000 V, 2500 V, 5000 V
500 V, 1000 V, 2500 V, 5000 V,10000 V
10 nF to 25 µF dependant on
measurement voltage
Capacitance accuracy
(23 °C):
±10% ±5 nF
User defined test voltage:
MIT515, MIT525:
100 V to 1 kV in 10 V steps,
1 kV to 5 kV in 25 V steps,
MIT1025:
5 kV to 10 kV in 25 V steps
Accuracy (23 °C):
MIT515, MIT525:
MIT1025:
100 kΩ to 1 GΩ
Capacitor discharge:
MIT515, MIT525:
<250 ms/µF discharge from 5000 V
MIT1025:
<500 ms/µF to discharge from 10000 V
to 50 V
Battery charge time: 2.5 hours from deep discharge,
2 hours normal discharge
30 min. charge:
1 hour continuous test at 100 MΩ, 5 kV
Test voltages
MIT515, MIT525:
MIT1025:
Insulation alarm:
Voltage output accuracy
(0 °C to 30 °C):
+4%, -0%, ±10 V nominal test voltage at
1 GΩ
Current measurement
range:
0.01 nA to 6 mA
±5% to 1 TΩ, ±20% to 10 TΩ
±5% to 2 TΩ, ±20% to 20 TΩ
Current measurement
accuracy (23 °C):
±2% ±0.5 nA at all voltages
2% error guarding 500 kΩ leakage with
100 MΩ load
Interference (noise) rejection:
MIT515, MIT525:
1 mA per 250 V up to a maximum of
3 mA
MIT1025:
1 mA per 600 V up a maximum of 3 mA
Display range analogue: 100 kΩ to 10 TΩ
Display range digital:
MIT515, MIT525:
10 kΩ to 10 TΩ
MIT1025:
10 kΩ to 20 TΩ
Voltmeter range:
23
30 V to 660 V ac or dc, 50/60 Hz
GENERAL SPECIFICATION
Voltmeter accuracy: ±3%, ±3 V
Timer range:
Up to 99 minutes, 15 second minimum
setting
Memory capacity:
5½ hours continuous logging every 5 s.
or 33 logged PI tests
or 350 logged IR tests
Test regimes:
MIT515
MIT525, MIT1025:
IR, IR(t), DAR, PI
IR, IR(t), DAR, PI, SV, DD, ramp test
Interface:
USB type B (device)
Real time output:
USB, 1 reading/second (resistance,
current and voltage)
EMC:
Meets the requirements of IEC61326-1
Weight:
3000 m, test lead CAT rating valid to
2000 m, safe working practices must be
applied and clips must not be handled
until discharge is complete
Operating temperature: -20 °C to 50 °C
Storage temperature: -25 °C to 65 °C
Humidity:
Meets the requirements of IEC 61010-1, CATIV
600 V to 3000 m
Instrument must be operated with all test leads
connected above 2000 m
Dimensions: L 315 mm x W 285 mm x H 181 mm
Environmental Conditions
Altitude:
Safety:
90% RH non-condensing at 40 °C
Ingress protection: IP65 (lid closed), IP40 (lid open)
24
4.5 kg
Repair and Warranty
approved repair and calibration companies to offer excellent
in-service care for your Megger products.
If the protection of an instrument has been impaired it should
not be used, but sent for repair by suitably trained and
qualified personnel. The protection is likely to be impaired if,
for example, the instrument shows visible damage, fails to
perform the intended measurements, has been subjected to
prolonged storage under unfavourable conditions, or has been
exposed to severe transport stresses.
Returning product to Megger UK & USA
service centres
1. When an instrument requires recalibration, or in the event
of a repair being necessary, a Returns Authorisation (RA)
number must first be obtained from one of the addresses
shown above. You will be asked to provide the following
information to enable the Megger Service Department to
prepare in advance for receipt of your instrument, and to
provide the best possible service to you.
Model, e.g. MIT1025.
Serial number, to be found on the underside of the
case or on the calibration certificate.
Reason for return, e.g. calibration required, or
repair.
Details of the fault if the instrument is to be
repaired.
2. Make a note of the RA number. A returns label can be
emailed or faxed to you if you wish.
3. Pack the instrument in the original packing box to prevent
damage in transit.
4. Ensure the returns label is attached, or that the RA number
is clearly marked on the outside of the package and on any
correspondence, before sending the instrument, freight
paid, to Megger. Copies of the original purchase invoice
and packing note should be sent simultaneously by airmail
to expedite clearance through customs. In the case of
instruments requiring repair outside the warranty period, an
immediate quotation can be provided when obtaining the
RA number.
5. You may track the progress of your return on line at
www.megger.com
New instruments are covered by a two year warranty from
the date of purchase by the user, the second year being
conditional on registration of the product on
www.megger.com. Any unauthorised prior repair or
adjustment will automatically invalidate the warranty.
These products contain no repairable parts, with the exception
of the user replaceable battery, and if defective should be
returned to your supplier in original packaging or packed so
that it is protected from damage during transit. Damage in
transit is not covered by this warranty and replacement/repair
is chargeable.
Calibration, Service and Spare Parts
For service requirements for Megger Instruments contact:
Megger Instruments Limited
Archcliffe Road
Dover
Kent CT17 9EN
England.
Tel: +44 (0) 1304 502 243
Fax: +44 (0) 1304 207 342
Megger
Valley Forge Corporate
Centre
2621 Van Buren Avenue
Norristown PA 19403
U.S.A.
Tel: +1 610 676 8579
Fax: +1 610 676 8625
Megger operate fully traceable calibration and repair facilities,
ensuring your instrument continues to provide the high
standard of performance and workmanship you expect. These
facilities are complemented by a worldwide network of
25
Approved Service Centres
A list of Approved Service Centres may be obtained from the
UK address above, or from Megger’s website at
www.megger.com
Accessories, Equipment and Spares
Accessories (all models)
Included Accessories (all models)
Spare Li-ion Battery
User guide CD-ROM
Power lead
3 m leadset x 3, medium insulated clips
Included Accessories (MIT525, MIT1025)
USB cable
PowerDB Lite software
3 m leadset x 3, large insulated clips (MIT1025 only)
Optional Accessories
HV test lead sets
3 m leadset x 3, medium insulated clips
10 m leadset x 3, medium insulated clips
15 m leadset x 3, medium insulated clips
3 m leadset x 3, large insulated clips
10 m leadset x 3, large insulated clips
15 m leadset x 3, large insulated clips
3 m leadset x 3, bare clips
8 m leadset x 3, bare clips
15 m leadset x 3, bare clips
Part
Number
1002-531
25970-041
1002-534
1002-531
1002-532
1002-533
1002-534
1002-535
1002-536
8101-181
8101-182
8101-183
Screened HV test lead sets
3 m, 5 kV screened un-insulated small clips
15 m, 5 kV screened un-insulated small clips
3 m, 10 kV screened un-insulated small clips
10 m, 10 kV screened un-insulated small clips
15 m, 10 kV screened un-insulated small clips
6220-835
6311-080
6220-834
6220-861
6220-833
Other
CB101, 5 kV Calibration Box
Calibration Certificate - CB101
UKAS calibration Certificate CB101
6311-077
1000-113
1000-047
26
Part
Number
1002-552
M
This instrument is manufactured in the United Kingdom.
The company reserves the right to change the specification or design without prior notice.
Megger is a registered trademark
Part No. MIT515_525_1025_UG_en_V01 0312
www.megger.com
27
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