Megger MJ160 Bedienungsanleitung

Major MEGGER® Insulation Testers

MJ159 (212159), MJ160 (212160), MJ359 (212359), MJ459 (212459), MJ559 (212559)

User Guide MEGGER®

Contents

Safety Warnings 3

General Description 4

Operation

Testing precautions 5

Preliminary checks 5

Battery condition check (MJ459 and MJ559)5

Battery replacement (MJ459)5

Battery Charging (MJ559)5

Performance checks 6

Voltage measurement 6

Resistance Measurement 6

Insulation testing 7

Using the Guard terminal 7

Fuse Checking and Replacement 8

Speciﬁcation 9

Accessories 12

Application Notes

Preventive maintenance 13

Insulation Testing Concepts 14

Repair and Warranty 15

Safety Warnings

•Safety Warnings and Testing Precautions must be read and understood before the

instrument is used. They must be observed during use.

• The circuit under test must be switched off, de-energised and isolated before any test

connections are made.

• Test leads, probes and crocodile clips must be in good order, clean and with no broken

or cracked insulation.

• Circuit connections must not be touched during a test.

• Circuits must be discharged before disconnecting the test leads.

• Replacement fuses must be of the correct type and rating.

• When making a voltage measurement, the ‘Test’ button must not be pressed.

• The instrument should not be used if any part of it is damaged.

• U.K. Safety Authorities recommend the use of fused test leads when measuring voltage

on high energy systems.

• Refer to ‘Testing Precautions‘ for further explanations and precautions.

NOTE

THE INSTRUMENTS MUST ONLY BE USED BY SUITABLY TRAINED AND COMPETENT PERSONS.

General Description

Major Megger MJ159, MJ160, MJ359, MJ459, and

MJ559 testers are compact instruments designed to give

rapid, accurate and direct measurement of continuity and

insulation resistance of domestic and industrial wiring, cables,

transformers, motors, generators electrical machinery and

appliances.

Being self-powered, the instruments are suitable for use

during installation and commissioning work as well as for

service and maintenance applications.

Insulation measuring range is 0,1 Ωto 2000 MΩ(MJ160

0,1 Ωto 1000 MΩ). Automatic discharge for capacitive circuits

under test is provided.

A guard terminal can be used to minimise the effects of

surface leakage when carrying out insulation resistance tests.

In addition each instrument has a 5000ΩResistance range

making them ideal for testing electrical installations.

Nominal test voltages are 100 V, 250 V, 500 V and 1000 volts

selectable. (MJ160: 50 V, 100 V, 250 V and 500 volts).

All instruments have a mains (line) voltage measuring range

of 0 to 600 V. Although calibrated for a.c voltage, this feature

will give decaying voltage indication following the testing of

equipment possessing capacitance.

The instruments use a moving coil meter with taut band

suspension; white scales on a black scale plate and an

orange ‘dayglow’ needle indicates the resistance value being

measured.

MJ159 and MJ160 are powered by a low voltage, hand

cranked, brushless a.c generator which is connected, after

rectiﬁcation, to a d.c. to d.c. converter. The generator is

designed to be easy to turn even under full load.

Dual powered units are mains (line) powered with either an

internal hand cranked generator, or battery cells that are re-

chargeable by the instrument’s internal charger.

The MJ359 is dual mains (line) or hand cranked generator

powered.

The MJ559 is dual mains (line) or rechargeable battery

powered.

Power for the MJ459 is derived from six 1,5 V (IEC LR6)

cells. The cells are connected to a d.c. to d.c. converter to

provide the test voltages.

MJ459 and MJ559 are ﬁtted with a button switch to enable

the battery charge to be checked.

The case is robust, yet light-weight, made from a strong

polycarbonate plastic. Mounted on top of the case is a 5

position, rotary, range selection switch and a ‘Test push

button.

Three shrouded 4 mm terminal sockets marked ‘-’, ’G’ and ’+’

are provided on the side of the case for test lead connection.

Test lead resistance is included in the instrument calibration.

For this reason, only the test leads supplied or replacement

ones should be used.

After the test leads have been connected to the instrument

terminals, the carrying handle folds down neatly over them.

Should the carrying handle accidentally become detached

from the case it may easily be ‘sprung’ back into position.

Operation

TESTING PRECAUTIONS

1. The instruments must only be used by suitably trained

and competent persons.

2. The instruments can give an electric shock. Highly

capacitive circuits (e.g. long lengths of cable) charged to

several kV can create a potentially lethal charge. Circuit

connections must not be touched when testing.

3. Care must be taken to prevent capacitive circuits

becoming disconnected during a test, leaving the circuit

in a charged state.

4. The voltmeter and automatic discharge feature of the

instruments should be regarded as additional safety

features and not a substitute for normal safe working

practice.

5 Fuse replacements must be of the correct type and

rating. See ‘Speciﬁcation‘.

6. If any part of the instrument is damaged, it should not be

used, but returned to the manufacturer or an approved

organization for repair.

7. Should the plug on the power cord (MJ359 and

MJ559) not be the type for your receptacles (socket

outlets) do not use an adaptor. Use a suitable alternative

power cord, or if necessary change the plug by cutting

the cord and ﬁtting a suitable plug.

The colour code of the cord is :

U.S.A. U.K./ International

Ground) Green Yellow/Green

Neutral White Blue

Line Black Brown

If using a fused plug, a 13 Amp fuse to BS1362 should be

ﬁtted.

PRELIMINARY CHECKS

Battery Condition Check (MJ459 &MJ559)

Before initial use of MJ559, charge the battery. To carry out

a battery condition check, press the black battery condition

button (marked ) and conﬁrm that the needle settles within

the portion of the scale marked with the battery symbol. If the

needle settles at less than half scale, the cells must be

replaced (MJ459), or re-charged (MJ559) before

proceeding with any checks or testing.

Battery Replacement (MJ459 only)

The cells are housed in a battery compartment in the base of

the instrument. To change the cells, use a screwdriver to

remove the battery cover securing screw and lift off the

battery compartment cover. Install 6 IEC LR6 cells ensuring

that the polarity is as marked on the base of the battery

compartment. Replace and secure the battery compartment

cover.

Battery Charging (MJ559)

Using the power cord supplied, connect the tester to a

standard a.c. power supply (120 V 50/60 Hz). The red

CHARGE indicator will light to indicate that charging is in

progress. A full charge takes approximately 16 hours. The

MJ559 may be used for testing at the same time as the

battery is being charged.

The circuit under test must be completely de-energized

and isolated before test connections are made.

Operation

Performance Checks

The instrument will operate in any position, but the speciﬁed

accuracies assume that the instrument is face up, on a ﬁrm

level surface. This is particularly true for hand cranked units

to obtain a smooth constant crank speed.

1) Without the test leads being connected to the instrument,

but with the rotary selector switch set to the 1 kV range

(MJ160 to 500 V range) press and hold down the ‘Test’

button, whilst turning the generator handle,(MJ159, MJ160

and MJ359) at >180 rev/min.The meter pointer should

remain over the ‘∞’ (inﬁnity) position on the scale. This

establishes that there is no leakage through the instrument

itself.

2) Check that the test leads, probes and crocodile clips are

in good order, clean and with no broken or cracked insulation.

Connect two of the test leads to the ‘+’ and ‘-’ terminals on the

side of the instrument case and ensure that their clips are not

touching anything.

3) Press the ‘Test’ button again and keep it pressed whilst

turning the generator handle (Hand cranked models) at >180

rev/min and observe the meter needle. The needle should

rest over the ‘∞’ (inﬁnity) position on the scale. If it does not,

the test leads may be faulty and should be inspected more

closely for damage. Replace them if necessary with

calibrated leads available as optional accessories

4) Connect the test lead clips together, press the ‘Test’

button and turn the generator handle (hand cranked models)

again. The meter should read zero. If it indicates inﬁnity or a

high resistance value the leads may be open circuit and

should be inspected further. Replace them if necessary.

(Shorting the leads together and obtaining a zero reading also

shows that the instrument is working).

Note:—To avoid creating leakage paths when insulation

testing, it is advisable not to allow the leads to twist together

nor trail across metalwork etc. more than is really necessary.

Voltage measurement

When not testing (i.e. in standby mode) the instruments act as

a voltmeter (0 to 600 Volts a.c.) Therefore, as soon as the test

leads are connected to the item under test, any a.c. voltage

present will be immediately shown. Thus indication is given

that the item has not been completely de-energized.

The instrument also monitors circuit discharge when the

‘Test’ button is released following an insulation test on a

capacitive item, e.g. a long cable. In this case it is important

to realize that the actual voltage (d.c. in nature) is not given,

but the meter does indicate when the voltage has decayed to

zero and therefore when it is safe to remove the test leads.

Note, however, that the instrument does not indicate the

presence of negative d.c.voltage.

Resistance Measurement

With the leads connected to the instrument, and having

completed the Preliminary Checks:

1) Set the selector switch to the ‘Ω’position.

2) Connect the leads across the isolated circuit.

3) Press and hold the ‘Test’ button and turn the generator

handle (hand cranked models) at >180 rev/min.

4) The resistance will be indicated on the ‘Ω’scale.

Note:- If necessary repeat the continuity test with the leads

reversed. The effects of any stray e.m.fs. in the sample under

test may then be negated by taking the average of the two

readings.

Insulation Testing

After connecting the test leads to the instrument and carrying

out the Preliminary Checks:

1) Set the selector switch to the required test voltage.

Connect the test leads to the isolated circuit to be tested,

as follows:-

(a) For insulation tests to earth (ground):- Connect

the ‘+’test lead to earth (ground) or the frame of the

equipment,and the ‘-’ lead to that part of the circuit to be

tested.

b) For insulation tests between wires:- Connect a lead to

the core of each of the wires.

2) Press the ‘Test’ button and whilst keeping it pressed

turn the generator handle (hand cranked models) at

>180 rev/min.

3) The meter needle will indicate the value of insulation

resistance on the ‘MΩ’scale.

If a capacitive circuit is tested the needle will initially deﬂect

towards zero and then gradually rise to its ﬁnal steady value

as the capacitance is charged up to the output voltage of the

tester.

If several successive readings of ‘∞’are obtained, connect

the two farthest ends of the test leads together and carry out

a check on the leads. A zero reading should result which

double checks that the leads are not disconnected or broken

and therefore, the insulation resistance readings are correct.

Note:—With non-hand cranked models, the readings are

taken after pressing the ‘Test’ button, there is no other control

to operate.

Capacitive circuits automatically discharge through the tester

when the ‘Test’ button is released. The approximate

discharge voltage will be indicated on the voltage scale. Wait

a few moments for the voltage to decay to zero before

disconnecting the test leads.

Using the Guard terminal (G)

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, 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’.

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.

Leakage Path

to ‘-’ve terminal

to ‘G’ terminal

to ‘+’ve terminal

Operation

Fuse checking and Replacement

Resistance Circuit Fuse Check

1) Disconnect the test leads and set the rotary selector

switch to the ‘Ω’ position.

2) Press the ‘Test’ button and keep it pressed whilst turning

the generator handle (hand cranked models).

3) The reading obtained should be beyond full scale.

If the reading is approximately zero on the Resistance scale,

the 500 mA fuse has ruptured and should be replaced.

Insulation Circuit Fuse Check

1) Connect the test leads together and set the rotary

selector switch to a ‘MΩ’ position.

2) Press the ‘Test’ button and keep it pressed whilst turning

the generator handle (hand cranked models).

3) The reading obtained should be zero on the insulation

scale.

If the reading is ‘∞’the 7 Amp fuse has ruptured and should

be replaced.

Fuse replacement

The fuses are held in a screw type holders situated in the

base of the instrument. Replace with fuses of the correct

size and rating (see Speciﬁcation on page 10). To change a

fuse, use a screwdriver to release the centre part of the holder

containing the fuse

Speciﬁcation

INSULATION RANGE

Insulation Resistance: 0,1Ω- 2000 MΩ(0,1Ω-1000MΩfor MJ160)

Nominal Test Voltages d.c: 100 V, 250 V, 500 V, 1000 V.

( MJ160 only is 50 V, 100 V, 250 V, 500 V)

Accuracy:

250 V, 500 V, 1000 V +30%, -0% maximum

50 V, 100 V, +40%, -0% maximum

Midscale: 4 MΩ(2 MΩfor MJ160)

Short Circuit Current: 1,9 mA (0,65 mA for MJ160)

Test Voltage characteristics:

Accuracy: ±1,25% of fsd on a 2,8 in. (71,1mm) arc length: [0,035 in. (0,9mm)]

RESISTANCE RANGE 0,1Ω- 5000Ω

Open circuit Test voltage: 3 V ±0,2 V

Short Circuit Current: 2 mA ±10%

Accuracy: ±1,25% of fsd on a 2,8 in. (71,1mm) arc length: [0,035 in. (0,09mm)]

Speciﬁcation

Maximum Load Capacitance: 1µF with less than ±0,1” pointer movement

Discharge: Up to 1µF capacitance is discharged from 1000V to less than 42,4 V in less than 4

secs

Safety Voltage Check

Voltage measurement: 0,1 V - 600 V a.c; the meter is RMS calibrated and average responding

Safety voltage indicator: Indicates the presence of d.c. voltages. Scaling is not the same as the a.c. meter.

True d.c. voltage equals scale reading divided by 2,22

Accuracy: 2,5% of full scale

Power Supplies

MJ159 and MJ160:Low voltage brushless a.c. generator. Cranking speed between 130 rpm and 170 rpm

MJ359:Dual operation low voltage brushless a.c. generator or 120 V 50/60 Hz mains

(line) supply

MJ459:Six IEC LR6 cells (AA) Battery life: not less than 1300 insulation

or Resistance range tests

MJ559:Dual operation 120 V 50/60 Hz mains (line) supply and rechargeable battery

Six Ni Cad cells (e.g. AA, NEDA 15 NC)

Safety: The instruments meet the requirements for double insulation to IEC 1010-1(1995),

EN 61010 (1995) to installation Category II, 300 V phase to earth (ground), 600 V

installation Category I

Flash Test: 6 kV a.c. r.m.s.

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