5 kV and 10 kV Insulation tester lead sets

Application Note

5 kV & 10 kV Insulation tester lead sets

Application note

Megger provide a range of lead sets and clips of different sizes and electrical characteristics for use with Megger 5 kV and 10 kV insulation resistance testers, enabling the user to choose the most applicable lead set for the work in hand. The design of the lead sets is intended to facilitate connection to a variety of de-energised systems for the purpose of making insulation resistance measurements. In all cases it is the responsibility of the user to employ safe working practices and verify that the system is safe before connection. Even electrically isolated systems may exhibit significant capacitance which will become highly charged during the application of the insulation test. This charge can be lethal and connections, including the leads and clips, should never be touched during the test. The system must be safely discharged before touching connections.

Megger test leads designed for the real world Providing Safety, Reliability and Practicality
At Megger we recognise that test leads are a key component of any precision instrument and that safety, long life, and the ability to provide reliable connections to the wide variety of test pieces found in real applications are of utmost importance. Careful design ensures repeatable connections, which are practical and safe to use. Only the best materials and most appropriate materials are used, to provide the essential blend of performance and safety. As an example the careful specification of the cable ensures it remains flexible in all conditions and has extremely good insulation properties which will not effect the measurements made. Megger uses only the best quality double insulated silicon cable; the inner insulation is specifically manufactured in a different colour to the outer sheath so to instantly highlight any damaged areas; a factor important not just for reliable measurements but safety too.

Megger test leads NEW designs using the latest technology

All of the lead sets in this application note are suitable for use with all current Megger 5 kV and 10 kV insulation resistance testers.

Using an insulation tester with poor or electrically leaky test leads can provide misleading measurements and may result in perfectly good insulation being diagnosed faulty, wasting both time and money on unnecessary repairs. This is especially so when using long test leads.

5 kV and 10 kV Insulation tester lead sets

Application Note

NEW Megger MIT 5kV and 10kV HV test leads

The range of HV test leads supplied for use with the MIT and S1 range of 5kV and 10kV insulation testers were developed from years of experience and practical testing, utilising the latest technology. These leads have been designed to be fully compliant with the latest release of the essential safety standard IEC61010-031 : 2008 which requires a fully insulated clip design essential in reducing arc flash accidents. IEC 61010-031 :2008 Important safety enhancements The international standard IEC 61010-031 details the Safety requirements for hand-held probe assemblies for electrical measurement and test. This was amended in 2008 and subsequently the new requirements became law early 2011. A number of amendments were made to the standard, but the most significant was to add a new section; Prevention of HAZARD from arc flash and short-circuits. Two hazards are considered; firstly the dangers of a probe tip or crocodile clip temporarily bridging two high energy conductors, and secondly the dangers of a contact being broken while current is flowing. These hazards are particularly applicable to many of the environments in which Megger MIT 5kV and 10kV instruments are used. Should a probe or clip momentarily short out two high energy conductors during connection an extremely high current will flow heating the metal and melting insulation. This itself may cause serious burns to the operator or bystander near the clip or probe Additionionally should the contact be broken while current is flowing arcing may occur leading to an extremely serious situation known as arc-flash. The standard describes the danger of arcing as follows: The arcing will ionize the air in the vicinity of the arc, permitting continued current flow in the vicinity of the probe tip or crocodile clip. If there is sufficient available energy, then the ionization of the air will continue to spread and the flow of current through the air continues to increase. The result is an arc flash, which is similar to an explosion, and can cause injury or death to an operator or a bystander. IEC 61010-031 :2008 requires probe tips and crocodile clips to be constructed to mitigate the risk of arc flash and short circuits, and this requirement applies to all crocodile clips or clamps that are rated to Installation Category III or IV (CATIII or CATIV) . The outer surfaces of crocodile clips must not therefore be conductive and no metal parts should be ACCESSiBLE (as defined by the standard) with the clip closed. During design phase detailed inspection measurement and test procedures are used to assess electrical creepage and clearance paths and compliance with the standard. Accessibility of conductive metalwork is assessed using an IEC standard test finger see below. The above processes along with extensive practical testing ensure that Megger test leads maintain class leading levels of safety, performance and practicality for the user.

Megger test clip being tested with a IEC standard test finger for creepage and clearance

5 kV and 10 kV Insulation tester lead sets

Application Note

The Megger Safety Philosophy

2. Protection from charged capacitance of long cables Locking HV insulated plugs / Non-removable test clips All Megger 5kV and 10kV insulation testing test leads are fitted with locking HV plugs at the instrument end. This reduces the likely hood of a plug loosing connection or pulling out; a situation which would could result in the load inadvertently remaining lethally charged at the end of a test and the instrument to incorrectly report that no voltage was present. The lock facility is simple to use and prevents plug end disconnection and therefore helps ensure the integrity of load discharge after a test

The electrical test environment in which Megger products are used often poses significant hazards and safety risks to users requiring high levels of training and competence. In these environments application of safe working practices is essential to ensure the safety of both operators and others. At Megger, we take product safety extremely seriously and pride ourselves on our reputation for high quality practical equipment designed to minimise the risk to the user. Whether a complex test instrument or a set of test leads the same rigorous process is employed. Insulation testing in HV, high energy, environments poses a number of unique hazards against which Megger has implemented innovative solutions to provided added protection. These hazards and protective features are summarised below and listed in order of importance:-

1. Maintaining practicality insulated clip

with

fully

In addition to the overall insulation requirements of a clip Megger considered the challenge of providing this protection without compromising the usability of the design. An insulated clip is great, but if the added insulation impedes the operation and ability to make reliable connection to the wide variety of bus bars, wires and terminals that are needed the design is useless and the operator may be tempted to remove the additional insulation to make connection. Meggers unique solution has been achieved by the addition of moving jaw covers that flex back when the clip is applied to a test piece. A simple but effective design. Simply align the arrows on the plug finger guard with the padlock symbols on the instrument to lock, and twist 90 to align with the open padlocks to un-lock. In addition, for the same reason, the test clips are not removable from the test lead.

5 kV and 10 kV Insulation tester lead sets

Application Note 3. Protection from high voltage in CATIV 600V environments As connection is made to more upstream supply systems, (Overvoltage Category IV relates to incoming supplies of inductrial premises), increased protection is required from overvoltages. These are transients that naturally occur on the supply, which are typically caused by switching actions or distant lightning strikes and present the connected equipment, test leads, clips etc with impulses of many thousands of volts. Such equipment must provide protection to the operator during the process of connection. A clip rated for use on a 600V supply in overvoltage category CATIV must be able to withstand such impulses up to 8kV. Megger Test clips are moulded from a high dielectric strength insulating polymer with carefully defined dimensions to ensure electrical creepage and clearance distances are maintained even under adverse conditions. For instance the unique fins on the front of Meggers large test clips are there not for styling, but to maintain the all important electrical creepage distances necessary for such environments whilst retaining a reasonably small and usable design. on equipment such as transformers with associated risks of working at height. In such situations even a small electric shock can cause the user to jump with potentially serious circumstances if this causes a fall. Fully insulated Megger clips help minimise the risk.

4. Protection from instrument output (5kV or 10kV) Many people fear the electrical output from their insulation tester which may be 5 or 10kV. However, in reality the current available from the instrument is generally limited to a few milliamprers and in itself presents a relatively low hazard. Whilst highly unpleasant a low current shock from an insulation tester will make you jump but under most conditions is only a serious hazard to those with a heart condition or fitted with a pace maker. The hazard here is not so much the output of the instrument but more the working environment. If the connected load is capacitive, a long cable perhaps, this can provide very significant energy when charged to high voltage by the instrument, and could prove lethal if touched. Additionally when testing insulation in many HV environments, it is not uncommon to have to climb ladders to reach connections

5 kV and 10 kV Insulation tester lead sets

Application Note Test clip markings explained with respect to protection to instrument output The square inside a square symbol is the IEC symbol for double insulation. In this example the test clip is therefore rated to 3 kV double insulation. In terms of protecting the user from the low energy output of an insulation tester this provides single insulation protection to 6 kV, enough to protect the user from the output of an insulation tester set to a test voltage of up to 6 kV Likewise a test lead marked double insulated with 5kV is suitable to protect the user from a insulation tester set to a 10kV output.

The anatomy of a good quality HV rated CATIV rated test clip

Curved jaws and wire gripping flat jaw tips Curved jaws to allow reliable connection round test pieces and flat jaw tips to provide excellent connection and gripping of individual wires

5 kV and 10 kV Insulation tester lead sets

Application Note Designed to maintain creepage and clearance

Fins

Fins increase surface creepage distance

Large finger guards to keep fingers back from live parts

Pivot guard maintains clearance from high voltage

Side Pivot guards maintain creepage paths

Cable strain relief at both clip and plug designed to withstand 5000 flexes with 10N pull force applied

5 kV and 10 kV Insulation tester lead sets

Application Note

TEST LEADS AVAILABLE FOR MEGGER 5kV AND 10kV INSULATION TESTERS

MEDIUM TEST CLIP LEAD

Clip details: Dimensions: 139 (L) X 73 (closed) mm Lead lengths available: 3 m, 10 m and 15 m Jaw opening: 34 mm diameter max Number in set: 3 Double insulation rating: 3 kV d.c. Basic insulation rating: 6 kV d.c. Safety specification: IEC61010-31:2008 The clips are therefore touch proof when closed CAT rating: 600 V a.c. CAT IV

Cable details: Lead lengths available: 3 m, 10 m and 15 m Insulation rating: 12 kV d.c. (Marked on cable) Cable type: Flexible dual insulated silicon (inner insulation layer coloured white to highlight damage) Application notes: These clips are designed for clamping on larger diameter test pieces but where space is at a premium. The insulation is designed only to protect the user from the output of Megger 5 kV and 10 kV (set below 6 kV) insulation resistance testers. Part numbers: 3m (10ft) 5m (16ft) 8m (26ft) 10m (33ft) 15m (50ft) 1002-531 1002-641 1002-642 1002-643 1002-644 The clips cannot in any circumstance be relied on to protect the user from live systems above 600V a.c. in a CATIV environment, or 1000V a.c. in a CATIII environment.

These test leads may also be supplied in none standard lengths to suit a particular application. Please contact Megger for a quotation. Minimum order quantities may apply.

5 kV and 10 kV Insulation tester lead sets

Application Note

LARGE TEST CLIP LEAD

Clip details: Dimensions: 220 (L) X 134 (closed) mm Jaw opening: 34 mm diameter max Number in set: 3 Double insulation rating: 5 kV d.c. Basic insulation rating: 10 kV d.c. Safety specification: IEC61010-31:2008 The clips are therefore touch proof when closed. CAT rating: 600 V a.c. CAT IV

Cable details: Lead lengths available: 3 m, 10 m and 15 m Insulation rating: 12 kV d.c. (Marked on cable) Cable type: Flexible dual insulated silicon (inner insulation layer coloured white to highlight damage)

Part numbers: 3m (10ft) 5m (16ft) 8m (26ft) 10m (33ft) 15m (50ft)

1002-534 1002-645 1002-646 1002-647 1002-648

Application notes: These clips are designed for clamping on larger diameter test pieces. The insulation is designed only to protect the user from the output of Megger 5 kV and 10 kV insulation resistance testers and systems below 600V to the category rating above. The clips cannot in any circumstance be relied on to protect the user from live systems above 600V a.c. in a CATIV environment, or 1000V a.c. in a CATIII environment.

These test leads may also be supplied in none standard lengths to suit a particular application. Please contact Megger for a quotation. Minimum order quantities may apply.

5 kV and 10 kV Insulation tester lead sets

Application Note

COMPACT TEST CLIP LEAD

Clip details: Dimensions: 58 (L) X 25 (closed) mm Lead lengths available: 3 m, 10 m and 15 m Jaw opening: 18 mm diameter max Number in set: 3 Double insulation rating: None Basic insulation rating: None CAT rating: Not applicable

Cable details: Lead lengths available: 3 m, 10 m and 15 m Insulation rating: 12 kV d.c. (Marked on cable) Cable type: Flexible dual insulated silicon (inner insulation layer coloured white to highlight damage) Part numbers: 3 m 8m 15 m 8101-181 8101-182 8101-183

Application notes: These clips are designed for clamping on test pieces where access is limited. There is no insulation on these clips. Extreme care must be taken to avoid electric shock when connecting/disconnecting due to the bare metallic clips.

5 kV and 10 kV Insulation tester lead sets

Application Note

CONTROL CIRCUIT TEST SET

Clip details: Dimensions: 58 (L) X 25 (closed) mm Jaw opening: 20 mm dia max (clip) Number in set: 2 Double insulation rating: 1 kV d.c. CAT Rating: 600V a.c. CATIII

Probe details: Number in set: 2 Double insulation rating: 1 kV d.c. CAT Rating: 600V a.c. CATIV

Cable details: Lead length: 3 m Insulation rating: 1 kV d.c. Cable type: Flexible double insulated silicon (inner insulation layer coloured white to highlight damage

Part number: 6220-822

Application notes: These clips are designed for testing low voltage circuits with test voltages up to 1 kV. The insulation is designed only to protect the user from the output of Megger 5 kV and 10 kV insulation resistance testers set to a maximum output voltage of 1 kV. Do not use this lead set at voltages above 1 kV.

5 kV and 10 kV Insulation tester lead sets

Application Note

CLIP SIZE COMPARISON

Large

Medium

Compact

Control circuit

Large

Medium

Compact

Control circuit

5 kV and 10 kV Insulation tester lead sets

Application Note

FUSED PROBE AND CLIP TEST LEAD SET

(For MIT515, MIT525 and MIT1025)

Clip details: Dimensions: 90 (L) X 41 (closed) mm Jaw opening: 20 mm dia max (clip) Number in set: 2 Double insulation rating: 1 kV d.c. CAT Rating: 600V a.c. CATIV

The clips cannot in any circumstance be relied on to protect the user from live systems above 600V a.c. in a CATIV environment, or 1000V a.c. in a CATIII environment. It is important to check fuse continuity before and after a test

Probe details: Number in set: 2 Double insulation rating: 1 kV d.c. CAT Rating: 600V a.c. CATIV

Cable details: Lead length: 1.25 m Insulation rating: 1 kV d.c. Cable type: Flexible double insulated silicon (inner insulation layer coloured white to highlight damage Fuse rating: FF500mA 50 kA see notes below Part number: 1002-913

Application notes: This fused probe and clip leadset is designed for testing low voltage circuits with test voltages up to 1 kV. The leadset is GS38 compliant, fitted with FF500mA 50 kA fuses, which allows voltage measurements to be made in safety when using the user selectable voltage measuring range on the MIT515, MIT525 and MIT1025 instruments. These clips are designed for testing low voltage circuits with test voltages up to 1 kV. The insulation is designed only to protect the user from the output of Megger 5 kV and 10 kV insulation resistance testers up to a maximum instrument test voltage of 1 kV.

5 kV and 10 kV Insulation tester lead sets

Application Note

COMPACT TEST CLIP WITH 5kV or 10kV SCREENED CABLE

Clip details Dimensions: 58 (L) X 25 (closed) mm Jaw opening: 18 mm diameter max Number in set: 3 Double insulation rating: None Basic insulation rating: None CAT rating: Not applicable

Application notes:
The test clips are designed for clamping on test pieces where access is limited. There is no insulation on these clips. Extreme care must be taken to avoid electric shock when connecting/disconnecting due to the bare metallic clips. The screened test lead set consists of: A black/negative test lead that has been screened. The screen is connected to the guard terminal of the instrument and terminated with a bare clip. A red/positive test lead that is not screened. Normal practice means that the positive lead is connected to ground (usually to limit the effects of electro-endosmosis), meaning any induced noise current goes straight to earth and not into the instrument.

Cable details: Lead lengths available: 5 kV rated 3 m, 15 m 10 kV rated 3m, 10m, 15m Insulation rating: 5kv or 10 kV d.c. Cable type: Flexible screened PVC Part numbers: 5 kV 5 kV 10 kV 10 kV 10 kV 3m 15 m 3m 10m 15m 6220-835 6311-080 6220-834 6220-861 6220-833

Screened Test Leads in use

Guard used to ignore leakage currents in the usual manor

Screened test lead

Screen connected to Guard terminal

5 kV and 10 kV Insulation tester lead sets

Application Note

Screened test lead set in use:

Positive un-screened lead connected as usual Screen connected to guard terminal. Noise current induced on screen is diverted away from measurement circuit. Negative lead connection

Screened cable termination

Screened cable

Screened cable running down the side of a transformer to the insulation tester.

Negative lead connected in usual way

Guard lead connected to remove the effects of leakage (In this case winding to transformer case measuring between windings)

Screened test leads are an important accessory for those working in high noise environments, and/or locations where test lead leakage could be a problem.

5kV and 10kV test lead selection chart

Leads supplied as standard and optional 5 kV Insulation testers Safety CAT rating BM15 MJ15 MIT515 MIT525 S1-552/2 S1-554/2 MIT1025 S1-1052/2 S1-1054/2 CATIV 600V CATIV 600V CATIV 600V CATIV 600V CATIV 600V CATIV 600V CATIV 600V CATIV 600V CATIV 600V CATIV 600V NONE NONE NONE NONE NONE NONE NONE NONE 10 kV Insulation testers

Clip type

Cat. No. Description

Medium test clip

1002-531 3m (10ft), 6 kV MEDIUM insulated clip, set of 3

lead

1002-641 5m (16ft), 6 kV MEDIUM insulated clip, set of 3

1002-642 8m (26ft), 6 kV MEDIUM insulated clip, set of 3

1002-643 10m (33ft), 6 kV MEDIUM insulated clip, set of 3

1002-644 15m (50ft), 6 kV MEDIUM insulated clip, set of 3

Large test clip

1002-534 3m (10ft), 10 kV LARGE insulated clip, set of 3

lead

1002-645 5m (16ft), 10 kV LARGE insulated clip, set of 3

1002-646 8m (26ft), 10 kV LARGE insulated clip, set of 3

1002-647 10m (33ft), 10 kV LARGE insulated clip, set of 3

1002-648 15m (50ft), 10 kV LARGE insulated clip, set of 3

8101-181 3m (10ft), BARE COMPACT clip, set of 3

8101-182 8m (26ft), BARE COMPACT clip, set of 3

Compact clip

8101-183 15m (50ft), BARE COMPACT clip, set of 3

6220-835

6311-080

6220-834

6220-861

6220-833

3m (10ft), BARE COMPACT clip, 5 kV SCREENED black lead, 3 clips, 2 leads 15m (50ft), BARE COMPACT clip, 5 kV SCREENED black lead, 3 clips, 2 leads 3m (10ft), BARE COMPACT clip, 10 kV SCREENED black lead, 3 clips, 2 leads 10m (33ft), BARE COMPACT clip, 10 kV SCREENED black lead, 3 clips, 2 leads 15m (50ft), BARE COMPACT clip, 10 kV SCREENED black lead, 3 clips, 2 leads

Control circuit 1 kV Clip = CATIII Probe = CATIV 600V

6220-822

3m (10ft), 1kV insulated probe and clip set for CONTROL CIRCUIT TESTING, set of 2

Fused 1 kV CATIV 600V

1002-913

1.25m (4ft) 1kV insulated FUSED probe and clip set for <1 kV voltage measurements, set of 2.

5 kV and 10 kV Insulation tester lead sets

Application Note

* These test leads may also be supplied in non-standard lead lengths to suit a particular

= Optional

= Supplied as standard

application / requirement. Please contact Megger for a quotation, minimum order quatities may apply

5 kV and 10 kV Insulation tester lead sets

Application Note

ADDITIONAL SAFETY WARNINGS

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. Circuit connections must not be touched during an insulation test. After completing a test, capacitive circuits must be completely discharged before disconnecting the test leads. Capacitive charges can be lethal. Tested items should 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. Test leads, including crocodile clips, must be in good order, clean, dry and with no broken or cracked insulation. The lead set should not be used if any part of it is damaged. These accessories are not designed to provide full levels of safety isolation to the operator if touched. The required physical dimensions would render this impractical. Safe working practices must be used. All safety warnings in the instruments user guide must be fully read and observed during use.

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