manual dc 1-10-20ar&ac revb

8/19/2019 Manual Dc 1-10-20ar&Ac Revb

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Instruction Manual

Models DC-1, -10, and -20AC All in One Digital DC Spark Testers Models DC-1, -10, and -20AR Digital DC Spark Testers withoptional ARC Remote Display

DC-10AC with optional X3A Horn/Light Tower shown

Clinton Instrument Company

295 East Main StreetClinton, CT 06413 USA

Telephone: 860.669.7548 Fax: 860.669.3825www.clintoninstrument.com


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Rev B 2/14


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DC-AC & -ARDigital DC Spark Tester Series

Clinton’s DC-AC & DC-AR DigitalD.C. Spark Tester series will t almostanywhere on the wire line, working either as

a standalone spark tester or as part of a fully

process-controlled quality system.

The spark tester is available in 1KV,

10KV, and 20KV models and in four con-

gurations:

>>DC-AC all-in-one spark tester

>>DC-AR spark tester and remote 19” ARC

display located up to 200 feet away

>>DC-AR spark tester and remote BRC

Smart Controller located up to 200 feet

away

>>DC-AR spark tester, without display, that

receives and responds to digital commands

from a PLC or computer

Equipped with a 4” long bead chain

electrode, the spark tester meets UL444 teststandards for communications cables at vir-

tually any line speed. If the manufacturer’s

main concern is nding bare wire, the BRC

Smart Controller can identify lengths of

bare wire 1/2” or longer, based on line

speed indication from an encoder, tachom-

eter signal or serial interface.

Digital test voltage and fault count

displays are easy to read, and a safety

interlock switch removes high voltage when

the electrode cover is lifted. Wiring and

setup are done externally-- there is no need

to open up the unit.

Membrane switches on the display

panel all the spark tester to be congured

for respooling or extrusion modes and to

set the length of time that process control

relay contacts are energized after a fault

occurs. The form C relay contacts are

accessible on a rear panel connector for

easy wiring to external alarms, lights or

machines that are to be controlled by the

spark tester. Optional communication

modules are available to integrate the spark

tester into old or new control systems.

1KV versions (DC-1AC or DC-1AR)

with high density brush electrodes accu-

rately test at voltages from approximately

50 volts to 1000 volts DC and are non-

destructive. Please contact the factory

regarding your application.

DC-1AR/BR-1A Brush Electrode

DC-10AR/BD-14 with BRC Smart Controller

>>Reliable DC spark testing at any speed

>>1KV, 10KV and 20KV models>>Versatile configurations

>>Test voltages from 50v

>>Optional bare wire differentiation

>>Wide range of electrode styles

>>CE approved

DC-10AR/BD-14with ARC Remote Display

(Computer shown in photos not included nor offered by CIC.)

DC-20AC/BD-14with optional X3AHorn/Light Tower


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Voltage Test Range: DC-1AC or-AR ......................50v to 1KV (minimum voltage varies on electrode design.) DC-10AC or-AR ........ ........ ....500v to 10KV (minimum voltage varies on electrode design.)

DC-20AC or -AR ........ ........ ...500v to 20KV (minimum voltage varies on electrode design.)Output Current: DC-1AC or -AR .....................2 milliamperes maximum. DC-10AC or -AR ...................1.5 milliamperes maximum. DC-20AC or -AR ...................0.75 milliamperes maximum.Fault Indication ..................... red 3-digit 14.2mm high LED display; amber indicating light.Fault Response ........................Less than 1 millisecond.Fault Resolution .......................1.5 milliseconds.Detection Sensitivity DC-1AC or -AR .....................200 µa. at 1000v. DC-10&20AC or -AR .............Less than 600 µa. at 5KV.Operating Modes......................Continuous HV/Remove HV on Fault. Momentary Process Control/Latch

until Reset.Process Control .........................Relay, form “C” contacts rated 1 amp max @ 240VAC, 2 amps max

@120VAC, for both NO and NC circuits.Power Requirements .................100 to 240VAC 1 amp, 49-61 Hz. Power supply is self-adjusting.Communications ......................RS-485 Serial Interface; Analog (optional); Ethernet (optional);

Profibus (optional).Safety .....................................CE Approved.

Designed to IEC-1010.

DC-AC& -ARSPECIFICATIONS

DC-AC& -ARELECTRODES

BD-12 .............Bead Chain Assembly 1” Product Diameter, 2” along wire line.BD-13 .............Bead Chain Assembly 1” Product Diameter, 3” along wire line.BD-14 .............Bead Chain Assembly 1” Product Diameter, 4” along wire line.

BD-15 .............Bead Chain Assembly 1” Product Diameter, 5” along wire line.BD-22S ...........Bead Chain Assembly 2” Product Diameter, 2” along wire line.

Bead Chain Assemblies (DC-10&20AC/AR only) :

Roller Assemblies:

R-46 ...............Roller Assembly .25” (6mm) max. Product Thickness,6” (150mm) Product Width.

Brush Assemblies:

BR-1A .............Brush Assembly Phosphor Bronze 1” Product Diameter.BR-3A .............Brush Assembly Phosphor Bronze 3” Product Diameter.FB-12 .............Fiberlite Brush Assembly.

295 East Main St. • Clinton, CT 06413 USA • Tel: 860.669.7548 • Fax: 860.669.3825 • www.clintoninstrument.com

Please consult factory for help in choosing equipment for specific applications.

Specifications subject to change without notice. 10/11 EN

Measurements for AC model.

A

A

BC

DE

F

B C D E

Wireline Center

HorizontalVertical

F

BD-22S

BD-15

BR-3A, BR-3ALZ

BRTC-6

15.4" [292 mm]

Call Factory for Details


BD-12,13, 14, BR-1A,BR-1ALZ, FB-12

13.9" [353 mm]

9.5"[241 mm]

10.5"[266 mm]

11.4"[290 mm]

11.4"[290 mm]

11.5"[293 mm]

11.6"[294 mm]

11.5"[293 mm]

7.5"[190 mm]

3.8"[95 mm]

10.0"[254 mm]

19.1"[292 mm]

12.5"[318 mm]

13.5"[344 mm]

12.5"[318 mm]

16.3"[414 mm]

17.8"[452 mm]

8.5"[216 mm]

9.4"[240 mm]

9.4"[240 mm]

9.6"[244 mm]

4.3"[109 mm]

4.8"[120 mm]

11.0"[279 mm]

11.5"[290 mm]

Measurements for models AR with optional ARC. ARC display dimensions.

A

A

B

D

C

E

BC

D

E

BD-12,13, 14, BR-1A,BR-1ALZ, FB-12

A B C D

ABCDE

19.0" 5.8" 3.5"17.0" 1.8"

Wireline Center

HorizontalVertical

E

BD-15

BR-3A, BR-3ALZ

BRTC-6

13.9"[353 mm]

7.5" [190 mm]

9.4" [240 mm]



8.5"

[216 mm]BD-22S

9.4" [240 mm]

16.3"[414 mm]

15.4" [292 mm]

17.8"[452 mm]

19.1"[292 mm]

9.6"[244 mm]

12.5"[318 mm]

13.5"[344 mm]

12.5"[318 mm]

11.6"[294 mm]

11.5"[293 mm]

3.8"[95 mm]

4.3"[109 mm]

4.8"[120 mm]

11.0"[279 mm]

11.5"[290 mm]

10.0"[254 mm]

A B C D E F

19.0” [482.6] 17.0” [431.8] 1.8” [44.4] 3.5” [88.9] 5.8” [145.9] 7.6” [192.6]

A

B

C DE

F

BRC display dimensions.


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Table of Contents

Declaration of Conformance ................................................................................................ i

Safety ........................................................................................................................................ 1

Electrical Shock Hazard From Production

Line Spark Testers .................................................................................................................... 3

Installation ............................................................................................................................... 4

Wiring: AC/AR Terminal Block Connections ................................................................... 9

Spark Tester Controls ..........................................................................................................12

Front Panel Programming ...................................................................................................14

Testing Your Product ........................................................................................................... 16

Calibration .............................................................................................................................18

Maintenance ..........................................................................................................................20

Troubleshooting .................................................................................................................... 21

Replacement Parts ................................................................................................................23

Grounding of Conductors During the Spark Test.......................................................... 24

Warranty ................................................................................................................................. 26

Electric Shock Considerations for Electric Vehicle Charging Systems .....................Appendix


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Declaration of ConformanceManufacturer: Clinton Instrument Company

295 East Main Street

Clinton, CT 06413 USA

Herewith declares that Models DC-XXA/AC/AR DC Spark Testers are in conformance with the provisionsof the following EEC directives:

2004/108/EC Electro-Magnetic Compatibility Directive (EMC)

2006/95/EC Electrical Safety Low Voltage Directive (LVD)

Conform to the emissions requirements of EN 61326:1997 including A1:1998 and A2:2001:

IEC 61000-3-2:2000 Harmonics

IEC 61000-3-3:1997 Flicker

CISPR 16:1998 Class B, Conducted Emissions, 150 kHz to 30 MHz

CISPR 16:1998 Class A, Radiated Emissions, 30 MHz to 1 GHz

Conform to the immunity requirements of EN 61326:1997 including A1:1998 and A2:2001:

IEC 1000-4-2:1995 Electrostatic Discharge

IEC 1000-4-3:1995 Radiated Immunity

IEC 1000-4-4:1995 EFT/Burst, Power and I/O Leads

IEC 1000-4-5:1995 Surge Immunity, Power Leads

IEC 1000-4-6:1996 Conducted Immunity, Power Leads and I/O Leads

IEC 1000-4-11:1994 Voltage Dips and Interrupts

Conform with safety requirements of EN 61010.

Clinton, CT USA November, 2005

Marianne C. Szreders, President Theodore P. Lane, Chief Engineer


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DC-1/10/20 AC & AR Instruction Manual - Page 1

Models DC-1/10/20 AC & AR DC Spark Testers

Safety

Safety Symbols

The symbols depicted below are safety symbols placed on the spark tesequipment. It is important to understand the meaning of each.Instruction manual symbols: Caution - refer to the manual to protect against damage to the equipmenor to avoid personal injury.

Caution - risk of electric shock symbol.

Earth (ground) symbol.

Environmental Conditions

The Model DC-A High Frequency Sine Wave Spark Tester is designed tobe safe under the following conditions:

• Indoor use.

• Altitude to 2000 m.

• Temperatures from 5ºC to 40ºC.

• Humidity to 80% R.H. at 31ºC, decreasing linearly to 50% R.H. a40ºC.

The Clinton Instrument Company certies that this equipment met its

published specications at the time of shipment. Clinton further certies that its calibration measurements are traceable to the United StatesNational Institute of Standards and Technology to the extent allowedby the Institute’s calibration facility. For customer service or technicalassistance with this equipment, please contact: The Clinton Instrument Company 295 East Main Street, Clinton, CT 06413 USA Telephone: 860-669-7548 • Fax: 860-669-3825 Website: www.clintoninstrument.comEmail: [email protected]

Avoid the Risk of Fire!

Every time your wire line stops, be sure that the HV in the electrode goesoff. If the HV remains ON while your wire line is stationary, the wireinsulation within the electrode will heat and there is a danger of combustion. Refer to the table in “Installation” labeled “Terminal Block Con-nections,” under HV Enable on how to safely install your spark tester.


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Page 2 - DC-1/10/20 AC & AR Instruction Manual

Models DC-1/10/20 AC & AR Digital DC Spark Testers

Caution: Pacemaker Warning

Clinton Instrument Company strongly advises any individual using apacemaker or other such medical device to avoid operating or being inthe vicinity of spark testers. Current studies indicate that such medicaldevices can malfunction in the presence of electrical and magnetic elds.

When a fault occurs in the electrode of a Clinton spark tester, both highand low frequency electromagnetic elds are generated. The strengthsof these emissions are unknown, since they depend on test voltage andother variables. The danger is greater when a customer does not groundthe inner conductors of a test product. While Clinton cautions its cus-tomers to ground the test product for safety reasons, many times this warning is ignored. In this situation, both the spark tester and the entirelength of the wire line will radiate these emissions. There is also a seri-ous risk of electrical shock if an individual comes into contact with anungrounded test product.email: [email protected].


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Electrical Shock Hazard From ProductionLine Spark Testers

by Henry H. Clinton

The commonly accepted maximum values of 60 Hz. current passingthrough the human adult body which permit a subject to let go of elec-trodes are nine milliamperes for males and six milliamperes for females At 3000 Hz. this value increases to about 22 milliamperes for men or 15milliamperes for women. DC currents do not present the same let–goproblems, but a subject can readily let go at a level of 60 milliamperes. A continuous 60 Hz. current above 18 milliamperes stops breathing forthe duration of the shock only. Ventricular brillation may occur abovea level of 67 milliamperes. The reaction current level of 60 Hz. is about .5 milliamperes. Above thilevel a muscular reaction can occur which can cause a secondary acci-dent. The DC and 3 kHz. levels are probably considerably higher.

Capacitor discharge energy of 50 Joules (watt–seconds) is regarded ashazardous.Clinton DC spark testers are current limited to 5 milliamperes or less Three kiloHertz spark testers are limited to 4 milliamperes or less, and60 Hz. types to 7 milliamperes. Impulse spark testers can deliver a maximum charge of about .2 Joules 248 times per second. All these sparktesters have current outputs above the reaction level, but none above thelet–go threshold level. Because of the possibility of secondary accidentcaused by muscular reactions, operators should be protected against accidental shock. Electrodes are supplied with interlock switches, and theseshould not be disabled. The conductor under test should be groundedIf an operator must inspect the product by touching its surface while it isbeing spark tested, he should be electrically insulated from his environ-ment, and any possible cause of a secondary accident caused by reactionshould be eliminated.For references, see: Dalziel, Ogden, Abbot, “Effect of Frequency onLet-Go Currents,” Transactions of A.I.E.E., Volume 62, December1943, and Dalziel, “Electric Shock Hazard,” I.E.E.E., Spectrum, February 1972.


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Installation

CAUTION: The installation procedures listed below are to be performed by qualied service personnel only. Failure to follow these proce-dures may result in danger to personnel and equipment damage.

Unpacking

Remove the Spark Tester from the carton. Retain the packing materialin the event that the unit is returned for calibration or service at somefuture time.

The following items are packed with the spark tester:

1. A power cord.

2. A green terminal block connector for process control connections. After it is wired, it will plug into the terminal block on theback of the spark tester.

3. An instruction manual.

4. An RS-485 connector (included with DC-AC, DC-AR, ARC).

5. RS-485 connecting cables (if ordered separately for DC-ACDC-AR with ARC).

6. Rack Mount Kit (for ARC).

Site PreparationSelect a suitable location for the spark tester:

The DC Spark Tester is designed for use in a xed location, permanentlyconnected to its power source. The unit may be mounted on a table oron a Clinton oor stand and should be placed at wire line height and within easy reach of the operator. Review the diagram located on page30 for mounting dimensions.

To mount the AC/AR unit on a horizontal surface:

With a screwdriver, remove the (4) plastic feet from the tapped inserts in

the bottom of the spark tester chassis. Insert (4) M-6 screws through themounting surface into the (4) tapped inserts. Be sure the screws do notextend into the chassis more than ½ inch (12mm).

To install the AC/AR unit on a Clinton floor stand:

Assemble the oor stand as directed by the instructions accompanying the stand or see page -- of this manual. Secure the tripod base ofthe oor stand to the shop oor using ½” (12mm) bolts and washers


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Remove the (4) plastic feet from the tapped inserts on the bottom of thespark tester chassis, as shown above. Mount the spark tester to the standby feeding the (4) M-6 screws supplied with the oor stand through thebottom of the oor stand plate and into the (4) tapped inserts in thebottom of the spark tester.

Provide for ventilation of the Test Module/electrode:

As with any apparatus producing a spark or electrical corona, the DC-ASpark Tester produces ozone in the electrode region. While ozonereverts harmlessly to oxygen within a few minutes, an external air extraction system is recommended and should operate whenever the sparktester is in use. The exhaust of the external air extraction system shouldbe discharged either outdoors or into some area well away from workers

Test Module Wiring Requirements

Install an external disconnecting device (“Panic or“Kill” Switch):

Install an external switch or circuit breaker in close proximity to thespark tester and within easy reach of the operator. The switch or circuibreaker must meet the relevant requirements of IEC 947-1 and IEC947-3 and should be marked as the disconnecting device for the equip-ment. The rating of the circuit breaker or fuse should be no greater than5 amperes.

CAUTION: Be sure the external disconnecting device is OFF and lockedout before continuing.

Ground the Spark Tester:

Locate the safety ground terminal on the back panel of the spark testerRemove the outer nut and the crimp terminal. Crimp a 16 ga. (1, 29mm2, 1, 31 cross section) stranded insulated wire (preferably green witha yellow stripe) to the crimp terminal. Fasten this to the safety groundterminal and secure with the keps nut. Connect the other end to a safetyground system in accordance with EN 60204-1:1993, Section 5.2, Table1.X3A Horn/Light Tower

Customers who have purchased an X3A Horn/Light Tower should pro-

ceed to the X3A Horn/Light Tower section below for X3A installationand operating instructions. When you have completed the X3A installation, disregard the “Terminal Block Wiring (no X3A)” instructions fol-lowing and skip to the section entitled, “Connecting the HF-15AR to ARC.”

If you do not have an X3A, skip to the section entitled, “Terminal Block Wiring (no X3A)” and begin wiring the HF-15A spark tester.


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X3A Horn/Light Tower

Unpacking

Remove the following items from the carton:

1. X3A Horn/Light Tower with mounting plate. Note: If the X3A

was ordered for the BD-22 electrode, the carton should containthe BD-22 mounting plate (part #91243).

2. Power Cord (part #03780)

3. A 4 conductor cable, with a 9-pin terminal block connector onone end and a 10-pin connector on the other.

Installation

1. Decide which side of the spark tester you wish to mount theX3A. Note that you may have to remove the small plate from

the X3A chassis and secure it to the opposite side so that thegreen X3A terminal block is accessible from the spark testerback panel. Mount the X3A using the mounting plate and the(4) bolts that attach the end guard to the spark tester, as shownin the picture to the left.

2. Make sure the spark tester is off before wiring to the X3A.

3. Locate the 10-pin green terminal block on the back of the X3Aand the 9-pin terminal block on the back of the spark tester. The X3A is supplied with a 4 conductor cable. The 10-pin con-nector will plug into the X3A terminal block and the 9-pin con-

nector will connect to the spark tester terminal block. Priorto inserting them, pins 1-5 of the 10-pin connector should be wired to accessory equipment with 22 guage or larger, strippedback 1/4” (6mm) and fed into the green terminal block con-nector at the proper pin numbers, as described on the followingpage. Pins 1-3 of the 9-pin connector should be wired as shownon the following page.

4. When wiring the two units, notice that pins 8-5 on the sparktester are now being used to communicate with the X3A. Thefunctions of pins 8-5 on the spark tester have now been trans-ferred to pins 5-1 on the X3A terminal block. When the wiringis complete, plug in the power cords to both X3A and the sparktester.


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X3A Horn/Light Tower Terminal Block Connections Spark Tester Terminal Block Connections

Conductor Designation Terminal Block Connections PinNo.

PinNo.

Terminal Block Connections Designation Conductor

4-conduc-tor cablesupplied

with X3A(22 gauge orhigher)

F A U L T R E L A Y

COM To Spark Tester: Wire pins 10-7 to sparktester pins 8-5 on the sparktester terminal block con-nector

10 9 Not Used

F A U L T R E L A Y

NC

NO 9 8 To X3A: Wire pins 8-5 to X3Apins 10-7 on X3A termi-nal block connector

COM 4-conduc-tor cablesupplied

with X3A(22 gauge orhigher)

H V

O N R

E L A Y

COM 8 7 NO

NO 7 6

H V O N R E L A Y

COM

Not Used 6 5 NO

(3) 22 ga.strandedconductorsrated 250V,less than10 metersin length,contained ina commoninsulatingsheath

F A U L T R E L A Y

NC Process Control:To activate external lights,alarms or relays* when a faultoccurs, wire them between dryrelay contact pins 5,4 & 3.

If the Lch function is ON(set on the front panel), thedry relay contacts will remainclosed until the RESET buttonis pressed or when pins 1&3are closed by remote switch

or relay. If the Lch functionis OFF, the dry relay contacts will return to normal stateafter the interval known as thePCd (Process Control Dura-tion, set on the front panel)has elapsed.

5 4 Not Used

COM 4 3 External Reset:To reset the spark tester fault relay

with an external switch, wire amomentary switch** between pins1&3. When these contacts close,the fault relay will return to anormal state. e interval that thecontacts are closed must exceed50 ms.

HV Enable:For HV on the

electrode, install a normallyclosed switch or relay contact**between pins 1&2. is switch orrelay should open automatically

when the wireline stop switch isactivated or be opened manuallyby the system operator when theline stops.

If the HV remainsON in the electrode when yourline is stationary, the wire insula-tion in the electrode will heat andthere is a danger of combustion.

RESET (3) 22 ga.strandedconductorsrated 250V,less than 10meters inlength, con-tained in acommon

insulatingsheath

NO 3 2 HVENABLE

22 ga.strandedconductorsrated 250V,less than10 metersin length,contained ina commoninsulating

sheath

H V O N R

E L A Y

COM HV ON Indication:Dry relay contact pins 1&2

will close when the test volt-age exceeds 500v. For anindication that HV is ON inthe electrode, wire a lamp orauxiliary device* here.

2 1 GND

NO 1

*When connecting auxiliary equipment to dry relay contacts pins 1, 2,3, 4, or 5, observe maximum ratings of 120VAC at 2 amps or 240VACat 1 amp.

**Switches and relays connected to pins 1,2, & 3 should be suitablefor 24V low current applications.

X3A Spark Tester Connections


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X3A Operation

X3A Horn/Light Tower will respond to faults depending on how your sparktester is congured. Please see the chart below. for the X3A response:

Spark TesterConfiguration X3A Response to Fault in Electrode

Lch on

rUF on

PCd nA

Red HV On Lamp will go off. Audible alarm will sound, and Yellow Fault Light will flashuntil the spark tester reset button is pressed.

Lch off

rUF on

PCd 2.00 sec

Red HV On Lamp will go off. Audible alarm will sound, and Yellow Fault Light will flashfor length of PCd (Process Control Duration) -2.00 seconds in this case.

Lch on

rUF off PCd nA

Red HV On Lamp will stay on. Audible alarm will sound, and Yellow Fault Light will flashuntil the spark tester reset button is pushed.

Lch off

rUF off

PCd 2.00 sec

Red HV On Lamp will stay on. Audible alarm will sound, and Yellow Fault Light will flashonly for length of PCd.

Terminal Block Wiring (no X3A installed)

Refer to the table below for information on pin functions. Locate the greenterminal block on the back of the spark tester and its companion green terminal block connector that came with the unit.

Conductors connecting auxiliary equipment, relays and switches should beshielded 22 gauge or larger and should be stripped back ¼” (6mm) and fedinto the green terminal block connector at the proper pin number. Shieldsfrom conductors connecting auxiliary equipment should be grounded to thesafety ground terminal.


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Terminal Block Connections Pin No. Designa-tion

Conductor

Fault Indication:

To activate external lights, alarms, or relays* when afault occurs, wire them between fault relay contact pins7,8, & 9.

In Latch Mode (Lch=ON) (set on the display), thefault relay contacts NO & COM will remain closeduntil the RESET button is pressed or when Pins 1 & 3are closed by remote switch or relay.

In Non-Latch Mode (Lch=OFF), the fault relaycontacts will return to normal state after the intervalknown as the PCd (Process Control Duration, set onthe display) has elapsed.

9 NC (3) 22ga. stranded conduc-tors rated 250V, less than 10meters in length, containedin a common insulatingsheath.

8 COM7 NO

HV ON Indication:

HV ON relay contact pins 5 & 6 will close when thetest voltage exceeds 50V. For an indication that HV isON in the electrode, wire a lamp or auxiliary device*here.

6 COM (3) 22ga. stranded conduc-

tors rated 250V, less than 10meters in length, containedin a common insulatingsheath.

5 NO

4 Not Used

External Reset:To reset the spark tester fault relay with an external switch, wire amomentary switch** between pins 1&3. When these contacts close,the fault relay will return to a normal state. e interval that the con-tacts are closed must exceed 50 ms.

HV Enable:For HV on the electrode, install a normally closed switch

or relay contact** between pins 1&2. is switch or relay should openautomatically when the wireline stop switch is activated or be openedmanually by the system operator when the line stops.

If the HV remainsON in the electrode when your line is stationary, the wire insulation inthe electrode will heat and there is a danger of combustion.

3 RESET (3) 22ga. stranded conduc-tors2 HV

ENABLE

1 GND

When connecting auxiliary equipment to dry relay contact pins 5, 6, 7, 8 or 9, observe maximum ratings of 120VAC at 2 amps, 240VAC at 1 amp.**Switches and relays connected to pins 1,2, & 3 should be suitable for 24V low current applications.

Wiring: AC/AR Terminal Block Connections


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ARC Remote Display Installation (If Purchased)

ARC Remote Display Assembly:

Customers that have purchased the ARC may wish to install it in a rackor panel as far as 200 feet away from the DC-AR spark tester. The user

must rst install the rack mount kit (shown to left), supplied with theremote display using the 6 8-32 x 1/2” screws and lockwashers provided To install in a 4.3” H x 18.7” W (11cm high x 48cm) rack space, be surethere is a minimum clearence of 1 inch (25mm) on the top and bottomof the ARC for ventilation. Slide the ARC carefully into place and fastenRS-485 cables for connection to the DC-AR and to a computer or PLCmust be purchased separately. Refer to page 25 for information on con-necting the RS-485 interface.

Ground the Remote Display:

Locate the safety ground terminal on the back panel of the ARC Remote

Display. Remove the outer nut and the crimp terminal. Crimp a 16 ga. (129 mm2, 1, 31 cross section) stranded insulated wire (preferably green with a yellow stripe) to the crimp terminal. Fasten this to the safetyground terminal and secure with the keps nut. Connect the other endto a safety ground system in accordance with EN 60204-1:1993, Section5.2, Table 1.

Connect the AR Test Module to the ARC Remote Display

RS-485 connecting cable(s) that you have purchased or wired yourselfare connected as shown below:

RS-485 Connections for the DC-AR with ARC:

On the back of the ARC Remote Display there are two RS-485 portsConnect the female port labeled “To HV Test Module,” located on theleft hand side, to the male port on the DC-AR test module labeled “RS-485 port,” with an RS-485 cable. Then connect the male port of the ARC labeled “RS-485 port” located on the right hand side, to a PLC orcomputer with an RS-485 cable.

Mains Power

Insert the power cord(s) provided with the DC-AC Spark Tester and the ARC Remote Dipslay (if purchased). Mains power for these units is selfadjusting from 100-240 VAC lamp, 49-61 Hz.

l

l

(Test Module)DC-AR

DC-AR with ARC Connections

Key: Male Port Female Port


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Prepare Your Product for Test

Insure that the product to be tested is dry as it enters the spark testelectrode. The combination of water and spark testing is not a desirableone. A continuous lm or sheath of water on the product can providean effective electrical path to the nearest grounded point. Efcient air wipes that can adequately dry the product before it enters the electrodeare available from Clinton.

Ground the product conductor(s). This is a safety precaution as well asa requirement of most spark test specications. Please see the paper“Grounding of Conductors During the Spark Test,” included in thismanual.

Position the product in the center of the electrode, through the safetyend guards. Be sure it will remain centered as it is being drawn throughthe electrode assembly. Lateral wire vibration which may be impercep-tible can cause phantom faults to register on the spark tester. Properlypositioned guides installed at entry to and exit from the electrode caneliminate this condition.

Double Check Your Connections

Double check all connections. Plug the power cord(s) from your sparktester into your power source.Check to make sure that all RS-485 cables are plugged into the proper

port.If you plan to communicate with a PLC or computethrough the spark tester’s RS-485 interface, refer to the sec-tion entitled, “Connecting the RS-485 Interface to a PLCor Computer.”If you plan to communicate with a PLC through an analog signal, referto the section entitled, “Analog Module Installation.”


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Spark Tester ControlsON/OFF Power Switch.

This switch is located on the rear panel of the spark tester and on the

rear of the ARC Remote Display (if purchased). Voltmeter.

The voltmeter indicates the voltage at the electrode. When the outpu voltage is adjusted to 1.0 KV, the voltmeter will read 1.0. A reading of10.2 indicates that the voltage at the electrode is 10.2KV.

VOLTAGE ADJUST buttons.

The spark test voltages range as follows:Model DC-1A- 50v-1.00KVModel DC-10A - 500v - 10.00 KV

Model DC-20A - 500v - 20.00 KV All spark testers can be adjusted in 100 volt increments by pressing theup and down VOLTAGE ADJUST arrow buttons under the voltmeterPress and hold a button to increase the speed at which you change the voltage setting. The test voltage can be turned OFF or ON from a remote location undethe following conditions: (1) the power switch is ON; (2) there is a remoteswitch connected between Pins 1 & 2 of the terminal block that is locatedon the back of the unit.

FAULT light.

The FAULT light will illuminate in response to a single pinhole faulin the electrode. It also indicates that the FAULT relay contacts are infault condition, activating any accessories that are connected. If the Lch(Latch on Fault) function is ON, the FAULT light can be turned OFFin 2 ways: (1) by pressing the RESET button below it; or (2) closing aNO remote switch or relay contacts wired between Pins 1 & 3 of thegreen rear panel terminal block. Simultaneously, the fault counter relaycontacts will reset to normal position. If the Lch function is OFF, theFAULT light will go OFF automatically and the fault relay will return tothe normal state after an interval known as the Process Control Duration(PCd, which is programmed on the front panel) has elapsed.

RESET button.If the Lch (Latch on Fault) function is ON, the RESET button wilreturn the fault relay contacts to their normal state and turn OFF theFAULT light. The RESET button will have no effect on the number offaults registered on the Fault Counter.

Fault Counter.

The 3-digit Fault Counter registers a count each time a pinhole fault is


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detected in the electrode. It can be reset to zero with the COUNTERRESET button.

COUNTER RESET button.

Press to reset the number of faults shown on the Fault

Counter to zero.

Bead Chain Electrode.

When the spark tester power is ON and the clear protective cover isdown, the test voltage set on the spark tester front panel is applied tothe product under test as it runs through the electrode. 1”, 2”, 3” and 4”bead chain electrodes are available. Other electrodes are available. Pleasecontact factory for details.

Clear protective cover.

The clear cover protects the operator from coming into contact with the

energized electrode.

Safety interlock switch.

This switch turns OFF the high voltage in the electrode when the clearprotective cover is lifted. Do not attempt to defeat the safety interlockswitch.

Safety end guards.

Metal end guards on each end of the high voltage test module preventhe operator from reaching into the energized electrode. The test prod-uct should be centered in the electrode to avoid damage to the product.

HV ON Light {on DC-AR Test Module, if purchased}

A large red HV ON light on the top of the AR Test Module illuminate when high voltage in the electrode exceeds 500 volts.


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Front Panel Programming

1. All-in-one spark tester: Turn OFF the ON/OFF power switchlocated on the back panel. Press and hold in the RESET button

while turning ON the ON/OFF power switch on the back panel

Two-piece spark tester: Leave the test module power switch ONand turn OFF the power switch on the ARC front panel. Pressand hold in the RESET button on the ARC front panel whileturning ON the ON/OFF power switch on the ARC back panel

2. The Voltmeter and Fault Counter will read: CON SYS (Congure System), indicating that you can now congure the spark tessystem. Release the RESET button.

3. The 7 functions (Lch, rUF, PCd, ELE, FS, dFn, or EFn)described in the table on the following page, will be displayed

on the Fault Counter. The selected option for that function wilbe displayed on the Voltmeter. Please note that only the rstve functions need to be set and that the nal 2 functions (dFn& EFn), simply display rmware version numbers of the sparktester.

4. Press an up or down VOLTAGE ADJUST button to choose adifferent option for that function.

5. To program the next function, press the COUNTER RESETbutton, and it will display on the Fault Counter. The selectedoption for this function will display on the voltmeter. Press a VOLTAGE ADJUST up or down arrow button to select a differ

ent option for that function.

6. Repeat this sequence for all 7 available functions.

7. When you have made your choices for each of the 7 functionspress the RESET button and they will be accepted and savedby the system. The system will immediately begin to functionaccording to the new system conguration with the voltage athe last preset value.


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Function FunctionDescription

Option Option Description

EFA Electrode Fault Action

LcH When a fault occurs in the electrode, the procestrol relay (pins 7,8, &9) latches in fault mode umanual or remote reset.

nLc When a fault occurs in the electrode, the procestrol relay (pins 7, 8, &9) closes momentarily, reing to normal position after the PCD (process c

duration) interval has elapsed.rUF When a fault occurs, the process control relay (p

8, & 9) latches in fault mode and the voltage inelectrode will be removed until manual or remo

PCd Process ControlDuration

numericvalue

e Process Control Duration operates only whLch function (Latch on Fault) is OFF. It is an inthat begins when a fault is detected in the electrand it determines the length of time the fault recontacts remain closed, energizing any auxiliaryequipment connected to those contacts. e PCmay be set for lengths from 100ms to 2 1/2 sec.alarms and lights require a signal of at least one in length before responding; the fault relay contclosure time should be set to the duration needeactivate accessories connected to the relay. If a sarc should occur in the electrode before the ProControl Duration has elapsed, the contacts rem

closed until that interval has ended.nA e Process Control Duration does not apply if

Lch function (Relay Latch on Fault) is ON.

ELE ElectrodeLength alongthe Wire Line

number(1,2,3,4,5)

Choose a value of 1,2,3,4, or 5. is represents 1”,2”,3”,4”, or 5” long electrode length along th wireline (the horizontal dimension of the electrthat will cover your test product).

FS Regulates thefault thresholdcurrent. Prod-ucts with highercapacitive load-ing characteris-tics may inducefalse counting when the faultthreshold cur-rent is at itsminimum level(0=most sensi-tivity).

0-4 (0=most sensitive (default), 4=least sensitive

dbn Display build number.

EFn Test Module firmware version number.

PPS Password ProtectSettings

YES Password is required to enter configuration menis option also allows the user to lock the keyb

NO Password is not required to enter the configuratmenu. is option does not allow the user to lokeyboard.

PAS 3 digit number

(000-999)

Set the password with this function using the updown arrows to adjust the blinking digit and thRESET button to cycle through the digits. e

password is what’s used to access the configuratmenu and lock the keyboard.

Loc number

(0, 1, 2)

When PPS is “yes” and keyboard is locked, it win the mode selected below.

0=locks out voltage adjust buttons only

1= locks out voltage ajust buttons and RESET

2= locks out entire keyboard


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Testing Your ProductCAUTION: During installation, the DC-A Spark Tester was pro-grammed to report and respond to faults in specic ways. Internal set-tings must not be changed except by qualied personnel.

CAUTION: Do not touch the wire while it is being tested.

CAUTION: When the DC-A is operated with bare wire in the electrodefor an extended length of time, i.e., several minutes or longer, damage tothe equipment may result. This condition should be avoided, either by

switching the spark tester OFF manually or by a zero speed switch operated by the machinery, each time the wire line is not moving.

CAUTION: If the HV remains ON in the electrode while your wirelineis stationary, the product insulation within the electrode will heat andthere is a danger of combustion. Refer to the table “Terminal BlockConnections” in the “Installation” section of this manual on how tosafely install your spark tester.

1. Thread your product through the bead chain electrode. Be sure

the wire is centered in the electrode.

2. Verify that the product conductor(s) are grounded. If this is nothe case, do not proceed. Contact service personnel to reviewthe spark tester installation.

3. Turn ON the external disconnecting device to bring power tothe spark tester.

4. Turn the spark tester power switch ON. Push the front paneRESET button and the COUNTER RESET button, if necessary, so that both the Voltmeter and Fault Counter 0.

5. Start the wireline. Press the VOLTAGE ADJUST up arrowbutton until the voltmeter indicates the desired test voltage value.

The spark tester will operate in accordance with the settings selectedduring “Installation” and “Front Panel Programming.” See the table on

the following page for possible spark tester functions.


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Spark Tester Modes/Functions Display Programming Terminal Block Connections

Extruder Mode:

When a fault occurs, the fault relay closes momen-tarily for the Process Control Duration, activatingauxiliary devices on 7, 8, & 9 for that interval. erelay automatically returns to normal state and theFAULT light goes OFF. Voltage on the electrodestays ON.

Lch=OFF

rUF=OFF

PCd= a value between.05 and 2.5 seconds

Switch or jumper between pins 1 & 2for HV in electrode. Auxiliary deviceson 7, 8, & 9.

Respooler Mode, High Voltage OFF:

When a fault occurs, the fault relay latches, theFAULT light goes ON, auxiliary devices on 7, 8,& 9 are activated, and voltage on the electrode isremoved until RESET.

Lch=ON

rUF=ON

PCd=N/A


Respooler Mode, High Voltage ON:

When a fault occurs, the fault relay latches, theFAULT light goes ON and auxiliary devices on 7,8, & 9 are activated until RESET. Voltage on the

electrode stays ON.

Lch=ON

rUF=OFF

PCd=N/A


External RESET:

A remote switch will reset any relay that is latched,reset any auxiliary devices connected to the relaycontacts, turn OFF the front panel FAULT light,and reset the FAULT COUNT LED.

Remote switch between pins 1 & 3.

Remote ON/OFF HV: Remove jumper on pins 1& 2 and wirea remote ON/OFF switch in its place.

HV ON Indication:

HV ON relay contact pins 5 & 6 will close whenthe test voltage in the electrode exceeds 50V.

Lamp or auxiliary device between pins5 & 6.

Fault Sensitivity:Regulates the threshold current. Products withhigher capacitive loading characteristics mayinduce false counting when the fault threshold isat its minimum level (0=most sensitivity).

FS= number 0-4


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Calibration The DC Spark Testers may be reasonably expected to retain its accuracyfor a period of one year from the date of calibration under conditionof normal use.

CAUTION: The calibration procedures listed below are to be performedby qualied service personnel experienced in high voltage safety proce-dures only. Failure to follow these procedures may result in danger topersonnel and equipment damage.

An accurately calibrated Electrostatic Voltmeter (EVM) is required forthis procedure. The EVM has a mirrored area to assist in eliminatingerrors in reading. The correct way to read the meter is to move the viewing position (your eye) until the reection of the needle in the mirror isdirectly behind the needle itself, and observe the needle position on thescale. This eliminates any parallax error that might result from viewing

the meter at a slight angle.

Calibration

1. Before connecting to the EVM, turn ON the spark tester andadjust the voltage to 0 using the VOLTAGE ADJUST downarrow button. Turn OFF the spark tester.

2. With the power OFF, zero the EVM. Clip the HV lead from theEVM to the electrode of the DC-A. Use high voltage insulated

wire.

3. Connect the ground terminal of the EVM to ground. Set theEVM range switch to one of the following ranges.

If testing to 1KV, set the EVM to 1KV.If testing 1 - 4KV, set the EVM to the 5KV range.

If testing 4 - 8KV, set the EVM to the 10KV range. If testing 8 - 16KV, set the EVM to the 20KV range. If testing 15 - 20KV, set the EVM to the 30KV range.

4. Turn the spark tester ON. Using the voltage adjust buttonsslowly increase the voltage until the EVM reads the exact tes voltage at which the spark tester is most often used (for exam-

ple, 3KV, 5KV, 7.5KV, etc.); record the DC-A Voltmeter readingat each of these points.

5. Compare the Voltmeter readings to the EVM true voltagesIf the DC-A voltage readings are within factory specications(within 2% of the EVM reading), turn OFF the spark tester anddisconnect the EVM from the spark tester and GND.

6. If the readings are not within tolerance, do not disconnect the EVMProceed to the next section.


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Recalibration

1. Using the VOLTAGE ADJUST arrow buttons, adjust the voltage to one of the following:

Model DC-1A-adjust to 1KV

Model DC-10A - adjust to 10KV Model DC-20A - adjust to 20KV Once the voltage has been set, turn OFF the spark tester.

2. Press and hold the VOLTAGE ADJUST and COUNTERRESET buttons down and turn ON the spark tester.

3. The Voltmeter & Counter will display the following:

This readout indicates that the spark tester is at a Set Point (SP)of either 1KV, 10KV, or 20KV.

4. Press the COUNTER RESET button. The DC-A Voltmeter &Counter will display the following:

This readout indicates the spark tester’s Voltage Output (UO).

5. Adjust the voltage using the VOLTAGE ADJUST buttonsuntil the EVM reads the equivalent of what is displayed inthe voltmeter. (ex. 10KV for the DC-10A, or 20KV for theDC-20A)

6. Press the COUNTER RESET button. The DC-A Voltmeter &Counter will display the following:

This readout indicates the spark tester’s Actual Voltage (AU).

7. Press a VOLTAGE ADJUST arrow button just once to adjusthe voltage readout toward 10.0KV. Every time you press a VOLTAGE ADJUST button, you will see the FAULT lighash, and after a few seconds, the voltage readout will reect thechange. Repeat this step until the AU (actual voltage) displayedon the DC-A Voltmeter matches the EVM reading.

8. Turn OFF the spark tester.

9. Return to steps 1 through 6 above to take calibration readings.

Calibration Alternatives

There are alternatives to the EVM calibration. Clinton Instrument rec-ommends the use of a digital voltmeter with an accuracy of better than2% and capable of reading 1000 volts DC. Please refer to manufacturer’sinstructions on how to connect and use these devices.


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Maintenance

Fuses

The fuses in the equipment are not expected to fail in normal operation Their failure may be an indication of equipment malfunction requiringqualied repair personnel.

There is one fuse associated with the spark tester’s operating voltagelocated in the ON/OFF power switch on the back panel of the unit To change the fuse review the following instructions.

Use a 1 Amp 250VAC 5x20mm low breaking time delay fuse. This fuseis located in the ON/OFF power switch and is accessible with a athead screwdriver as seen in the picture to the left.

Two additional fuses (for relay protection) that could be defective arefound on the main printed circuit board, behind the back panel.

Periodic Inspection

It is important to inspect the electrode and electrode mounting plateperiodically for residue and wear.

Insulation and water deposits can reduce the effectiveness of the sparktest. The red electrode mounting plate may be wiped with a clean, drycloth. Bead chain assemblies contaminated with insulation residue shouldbe removed from the high voltage test module and cleaned with a wirebrush. Broken safety covers and mounting plates and electrode assemblies with worn brushes or missing beads should be replaced immedi-ately.

The red electrode mounting plate, clear cover, and bead chain assemblie

are subject to damage and contamination that is not always visible. Theyshould be replaced if current leakage occurs.

Refer to the “Troubleshooting” section for assistance with electricaproblems.


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TroubleshootingCAUTION: Troubleshooting is to be performed by qualied service personnel only. Failure to follow the procedures in this manual may result indanger to personnel and equipment damage.

Phantom faults are being indicated.

1. Lateral wire line vibration or water may be present. See “Installation” for information on drying, centering and restraining theproduct in the electrode.

2. The high voltage mounting plate may be contaminated with diror conductive material. Clean the mounting plate or replace.

3. Inspect proper grounding of inner conductor.

4. Contact factory to determine correct sensitivity levels.

The Voltmeter LED Display blinks 00.0.

1. The clear safety cover is open.

2. There is no switch or relay contact between Pins 1 & 2 (GNDand HV ENABLE). Refer to the table in “Installation” labelled

“Terminal Block Connections,” under HV ENABLE.

Equipment at relay terminals COM and NO or NC is not

activated when a fault occurs.

1. The PCd (process control duration) value may be too short fothe auxiliary equipment to recognize.

2. Check fuse on main pc board.

The spark tester controls are ON but the equipment doesnot function.

1. The high voltage test module interlock switch is not closed.

2. The terminal block connector is not plugged in.

3. F101 fuse is blown.

4. There is no switch or relay contact between Pins 1 & 2 (GNDand HV ENABLE). Refer to the table in “Installation” labelled“Terminal Block Connections,” under HV ENABLE.


30/40



Both RS-485 cables are connected to my DC-AR withARC, however, the remote display reads an “Err” “001”error.

1. Make sure that the RS-485 cable attached to the electrode and

the RS-485 cable attatched to the computer or PLC are pluggedinto the proper ports on the back of the remote display.


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Replacement Parts Note: Printed circuit boards are carefully constructed and calibrated at the factory. Components

are not supplied for eld repair of boards. Please return faulty circuit boards to the factory or to

your Clinton sales representative for quick and inexpensive repair and calibration.

Part Number Part Description

02606 2 amp low breaking time delay fuse, 5x20mm

02603 1 amp time lag fuse, 5x20mm

91088 Printed circuit board, display

A/AC Control Unit Display unit complete for all-in-one spark tester

91061 Power entry module (ON/OFF Switch)

91178 Printed circuit board, main for units without the HV power supply

91192 Relay PC Board

25002 Assy Bead Chain BD-12 w/trough & kydex cover

35002 Assy Bead Chain BD-12 no trough or kydex


35002 & 30050 Assy Bead Chain BD-13 no trough or kydex


91462 Cover Clear Safety

91046 Hinge

91048 Electrode Mounting Plate for BD-12, BD-13 & BR-1A

03004 Switch, Interlock

91069 Terminal Block Connector Kit (Green)

03780 Power Cord, 120V Unit

Optional Accessories

FS-4 Floor Stand for DC-1A, 39-42” Adjustable wireline height

838/3 High Speed Air Wipe, .020-.315” product dia.

688/3 Adjustable Orifice Air Wipe, .076-.472” product dia.

674/3 Adjustable Orifice Air Wipe, .118-.866” product dia.


32/40



Grounding of conductors duringthe spark testby Henry Clinton

Reprinted from March 1986 Issue of Wire Journal

MEASURING & TESTING

Nearly all industry-wide specifications for insulated wireand cable pertaining to in-line spark testing require the grounding

or earthing of the conductors under test. It is the purpose of this

discussion to examine the reasons for this and to define the

conditions which allow for a safe and effective spark test when

conductors are not grounded. Although this testing mode cannot

be used to satisfy most industry specifications, it can be useful

when quality must be strictly monitored and conductor grounding

is inconvenient or impossible.

D-C spark testing

If a direct potential is used for spark testing, it is absolutely

necessary to ground the con ductor or conductors under test. In Fig.

1, Cg represents the ca pacitance of the prod uct to ground, which

could be in the range of 100 to 2,000 picofarads, de pending on the

size and length of the conductor.

If the conductor is not grounded, the potential on the conduc-

tor with respect to ground will rise when the first insulation fault

passes through the electrode. This is because Cg charges to wards

the D-C test potential ap plied to the electrode through the arc.

If the conductor is not grounded but is initially at ground po -

tential, when the first insulation defect passes through the elec-

trode, an arc forms between the electrode and the conductor. The

current flow ing through this arc charges ca pacitance Cg, elevating

the potential of the conductor by a value which is a func tion of arc

time dura tion and the value of the current. After the defect or fault

has com pleted its passage through the electrode, Cg retains this ele-

vated potential, since Cg has no discharge path to ground. The ef -

fective test potential on the product insulation is now reduced by

this retained conductor potential. If a second insulation flaw

traverses the electrode, additional charging of Cg takes place, fur-

ther reducing the effective test potential. Eventually the effective

test potential falls below that re quired to cause an arc to oc cur on

the passage of an insulation flaw, and all subsequent flaws will be

undetected. Usually, current and traverse time are large enough to

sully charge Cg on the passage of the first flaw, so it will be the only

one detected.

Furthermore, the en tire length of product is now charged to

the test po tential. If the operator accidentally comes into con tact

with the conductor or with a flawed insulation area anywhere along

the wire line, Cg can discharge through his body to ground. If by

coincidence a faulted insulation area is within the elec trode, the

maximum current out put of the spark tester can also pass through

his body. While this current , in the case of Clinton spark testers, is

well below a dangerous level, the involuntary muscular reaction

resulting from this event can itself cause a secondary accident.

It is thus apparent that from the dual stand points of utility and

safety the conductors of a product being spark tested with a D-C

potential should be grounded.

A-C spark testing, general

If an A-C potential is used for the spark test, and the conduc-

tors are not grounded, the diagram in Fig. 2 applies.

Note that the electrode to product capacitance Ce is shown,

and that Ce and Cg com prise a voltage divider which determines the

A-C potential from conductors to ground, and also the effective

test potential applied across the product insulation.

If Cg is very large com pared to Ce, Eeff is nearly equal toEapp. For exam ple, if Ce = 5pf and Cg - 1000pf, 99.5% of the

applied test potential is impressed across the prod uct insulation. If

Cg is 100pf, however, the effective test voltage drops to 95% of the

applied value.

Power mains frequency testing

When an insulation defect passes through the electrode, the

arc which forms to the ungrounded conductor in effect con nects

the con ductor to the electrode. If the spark tester operates at the

1 0 .0 0

I

o

POWER DC KILOVOLTSRESET

10 KVDCSPARKTESTER MODEL STB-10G

FAULT

FAULT COUNT

IVO

0 0 0

C g

D-C SPARK TESTER

FIG. 1

C

C

e

g

A-C SPARK TESTER

FIG. 2

0000

P1

E R

15.00

I

o

POWER RMS KILOVOLTS PERCENTLOAD TEST RESET

FAULT

HIGH FREQUENCY SINEWAVETESTER MODELHF-20GB

C g C g

C g

C C

g

e

C e

C e

E cond

E cond

E cond

E app E eff

E app

E eff

E eff

E eff

clinton instrument company


33/40




34/40



Warranty The information contained in this document is subject to change with-out notice. The Clinton Instrument Company makes no warranty of anykind with regard to this material, including, but not limited to, the implied

warranties or merchantability and tness for a particular purpose. The Clinton Instrument Company shall not be liable for errors contained herein or for incidental damages in connection with the furnish-ing, performance, or use of this material.

We warrant to the original purchaser that the equipment described hereinis free from defects in materials and workmanship for a period of oneyear from the date of invoice, our obligation under this warranty beinglimited to repair or replacement of the defective parts. This warrantydoes not apply to fuses, lamps, or any normally expendable parts. Anypart appearing to have defects in material or workmanship, upon our

examination only and as determined by us, and providing the equipmenthas not been subject to abuse, misuse, or alteration, will be repaired orreplaced at no charge for materials and labor, either upon receipt of thedefective part or equipment, transportation charges prepaid, at our plantor at the equipment location, as selected by us. No parts or equipmentshall be returned without our prior permission. Any parts replaced underthis warranty shall be warranted until the expiration date of the origina warranty.

The warranties herein are in lieu of all other warranties, expressed orimplied, and of all other obligations or liabilities on our part concerningthis equipment.


35/40


Electric Shock Considerations for ElectricVehicle Charging Systems

By Walter Skuggevig, Research Department, Melville, reprinted courtesy

of Underwriters Laboratories Inc. This technical paper was presented inDecember 1993 at the National Conference on Electric Vehicle Infra-structure, sponsored by the Electric Power Research Institute, ArizonaPublic Service, Salt River Project, and the Electric Vehicle Associationof the Americas.

Electric Shock - What Is It?

Before electric shock can be addressed with a view towardprevention, the term and the concept should be explained. There area number of physiological effects that can occur from electric currenthrough the human body. From the standpoint of electrical safety, criticaphysiological effects are startle reaction - related to perception, muscletetanization, ventricular brillation and burns. each effect occurs at a different or increased level of electric current.

Perception and Startle Reaction

A few microamperes available from a conductive surface canbe felt as a tingling sensation if the conductive surface is lightly rubbedor tapped with the nger. These small currents are harmless, but if perceived by a consumer, the “electric” sensations might appear sinister

The tingling sensation can raise suspicions, although perhaps not warranted, about the safety of a product. A 60-Hz sinusoidal current over 0.5 mA RMS can cause aninvoluntary startle reaction, particularly in women. The current itself isharmless, but the uncontrolled movement of a startled person can causesecondary accidents including spills and falls. The American NationalStandards Institute (ANSI) document C101-1992 species 0.5 mA as thegeneral limit for 60-Hz leakage current from appliances. At frequencies lower and higher than power distribution frequencies, higher current is necessary to produce the same level ofsensation. For direct current, a limit of 2 mA is often used. Continuously owing direct current may not produce a particularly strong sen-

sation, but a sudden change in the current caused either by makingor breaking the circuit can produce a strong, momentary sensa-tion. The higher the DC current, the stronger the sensation whenthe current is started or interrupted. At frequencies of approximately

1 kHz and higher, it can be estimated that the threshold of startle reaction is approximately equal to 1 mA per kHz of frequency. Forexample, if a specic level of reaction from current at 1 kHz occurs at 1mA, then a similar level of reaction would occur from 10 mA at 10 kHz The same level of reaction would occur from 100 mA at 100 kHz, and


36/40


so on. Leakage current measuring instruments, such as those speciedin ANSI C101-1992, take into account the effect of high frequencieson the body. These instruments produce readings that are “frequency- weighted,” and indicate the level of possible physiological effect. Thereadings correspond to the current magnitude in mA only at low frequencies such as 60 Hz.

Muscle Tentanization

Electric current over 5 mA at 60 Hz can cause muscle tetanization. Tetanization is dened as the state of continuous contraction of amuscle undergoing a series of rapidly repeated stimuli. A person withtetanized muscles may be unable to let go of a conductive part, may beimmobilized (frozen), or may be unable to breathe while the currentows. Tetanization lasts as long as the current ows. When the currentstops, the effect stops, and the muscle returns to normal function. However, the effect can be fatal if breathing stops long enough. If immersed

in water, an immobilized person could drown. In a manner comparableto perception, tetanization occurs at a higher current threshold for DCand for higher frequencies.

Ventricular Fibrillation

Ventricular brillation is a disorder involving disorganized arrhythmic motion of the heart that affects blood circulation. Unlike muscle tetanization, ventricular brillation can be triggered by a short-duration burstof current of sufcient magnitude. Ventricular brillation is not spontane-

ously reversible in humans and, if not treated quickly with special debrillating equipment, will continue until the person dies (within a few minutes)from loss of circulation of the blood. The magnitude of limb-to-limb current sufcient to cause ventricular brillation is greater than that which would cause muscle teta-nization. Therefore, limits for continuous current (e.g., lasting over veseconds or so) are usually based on muscle tetanization considerations. A general limit that has been used by UL for a number of product categories including ground-fault circuit-interrupters is describedas I = 20 T -0.7 for bursts of 60-Hz current down to 20.9 millisecondsI is in RMS mA calculated over the duration of the current; T is thecurrent duration in seconds. For durations between four and 20.9 milli

seconds, the current is limited to 300 mA. Below four milliseconds, thecurrent is limited by I = 6.3 T-0.7 . These equations represent curvesdrawn under threshold brillating data points from laboratory experi-mental work conducted with animal subjects. For durations shorter than a tenth of a second, the limits for ACand DC current are the same. For current lasting only a few millisecondsa narrow piece of a 60-Hz sinusoid is not substantially different froma rectangular DC pulse. For durations over a tenth of a second, direccurrent has higher limits. Animal test data indicates that for long dura-


37/40


tion exposures to combinations of AC and DC, the parameter of current that is most related to the threshold of ventricular brillation is thepeak-to-peak value of the current, if the DC component is low enoughso that there is reversal of the current each cycle. In fact, as long as thecurrent reverses, the presence of a DC component is not signicant withregard to the ventricular brillation threshold. If the DC componen

is high enough to preclude reversal of the current of each cycle of the AC component, then the occurrence of ventricular brillation is morerelated to the peak value of the composite waveform. In no case shouldthe peak of the composite continuous waveform of AC and DC exceedthe peak-to-peak value of the AC component at its maximum permitted value. For example, at one second duration or longer, if the ventricularbrillation limit for an AC sinusoidal current is 20 mA RMS, the corresponding limit for a direct current would be 40, which is 56.6 mA. Ifthe duration is between 0.1 and 1.0 second, the equation I = 56.6 T-0.25describes a suitable limit for DC current.

Burns Prevention of electrical burns is a very complex subject. Thereare many variables that are difcult to control or estimate. A limit of 70mA RMS, independent of frequency, has been used in a number of standards to address burns. At this current level, it is not likely that a severeburn injury would occur that would involve an appreciable volume ofskin tissue. This limit becomes important at frequencies over severalkHz, because limits addressing other hazards would not automaticallyprevent burns. There are a number of commonly used techniques to reduce therisk of electric shock. Each has attributes that render it more effective

for certain applications. In some cases, a combination of techniques maybe the best method to reduce the risk of electric shock to an acceptablelevel. The protective mechanism should be compatible with the natureof the product, its ratings, habits and behavior of the people using theproduct, and the environment in which the product is used.

Grounding

The principle of equipment grounding can be described asfollows: all accessible conductive parts are connected together and to

earth by a network of low-impedance conductors to create an equipotential environment. Two important considerations are the reliability ofthe connections and the impedance of the conductors at the frequencies involved. Ground monitors that interrupt current and/or sound analarm can enhance reliability. Low impedance in the grounding conductor circuitry is important in order to maintain low voltage to ground onaccessible conductive parts during a fault before an interrupting deviceshuts off the circuit.


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Double Insulation

Double insulation enhances the reliability of the electrical insulation of a product to reduce the likelihood of insulation breakdown thacould cause an electric shock. Each part of a double-insulation systemshould be independent and must be fully capable of acting as the soleinsulation. If one insulation fails, the other must have all of the requiredattributes to prevent electric shock. It is important that the two parts ofthe double-insulation system are as truly independent as feasible. Bothinsulations should not be vulnerable to the same act (e.g., a drop on ahard surface or immersion in water) or deteriorating agent (e.g., hightemperature or over-surface contamination).

Ground-Fault Circuit Interrupter

A ground-fault circuit-interrupter (GFCI) monitors the difference in the current owing between the power conductors serving

a load. If the difference exceeds a predetermined level, it is assumedthat the difference in current could be owing through a person’s bodyand the GFCI rapidly trips. The speed of interruption is, by design, fastenough to avert ventricular brillation. A typical Class A GFCI trips inapproximately one cycle of 60 Hz, and is intended for use on circuitsthat have no more than 150 volts to ground. Circuits with more than 150 volts to ground could cause higher body currents during a ground-faultthat would require a considerably shorter trip time to avert ventricularbrillation. Class A GFCIs used in the United States for electric shockprotection have a differential current trip rating of 5 mA. As such, thesedevices protect consumers from ventricular brillation, as well as muscletetanization, which prevents them from breaking contact.

Many GFCIs are rated for a 15- or 20-ampere, 60-Hz loadMany GFCIs have not been designed or tested for use on circuits involving larger loads, higher frequencies, non-sinusoidal waveshapes and DCcomponents. New designs of GFCIs may be needed for use on some ofthe electric vehicle charging circuits. A GFCI discerns load current from possible electric shock current by where the current ows. Current owing both to and from theload through the differential transformer is considered by the device tobe acceptable. Current greater that the trip rating that ow outside thedifferential transformer is not acceptable. If a load is congured so thaa current carrier is connected to an accessible part, shock current mightbe able to ow and not be discerned by a GFCI as being different fromordinary load current. For example, if one side of the circuit is connected to the vehicle chassis, then shock current between an accessibleenergized part and the vehicle chassis would appear to the GFCI as loadcurrent. A GFCI would not be able to protect against this type of fault. If the system contains more than one source of voltage that canbe hazardous, a single GFCI may not be able to protect against electricshock. Both sources need to be considered by the protection scheme.


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Shielding

Shielding can be used to limit voltages that can appear on accessible conductive parts during fault conditions when products generatehigh voltages internally. A properly connected shield will prevent voltageon the accessible conductive parts from exceeding line voltage duringfault conditions. This can help a GFCI function within its design capabilities and protect people effectively from electric shock from productsthat would otherwise demand a faster trip speed of the GFCI for shockprotection. Fire hazards resulting from short-circuits involving the shieldand internal high-voltage supplies can be controlled by overcurrentdevices, temperature-sensitive devices and similar products.

Polarization

Polarization is a form of shielding. If the physical layout of aproduct is such that parts connected to one side of the line of a groundedsystem are more likely to be touched or fault to accessible parts, then theline connections should be such that the grounded side of the line isconnected to those more exposed parts. This can involve the use ofplugs and connectors that permit mating with only one polarity.

Interlocks and “Smart” Circuits

Interlocks and “smart” circuits can be used to keep potentiallyhazardous parts de-energized unless specic safety conditions are satis-ed. Some of these “safety” conditions include specic covers that musbe closed, specic connectors that must be fully mated with the properreceptacles, or a power source that “handshakes” with the intended loadand nothing else but the intended load. “Smart” circuits may involve waveshaping and recognition net works that permit current of recognizable traits to ow, but that also deenergize the circuit if the current is not shaped by the load in preciselythe expected way. The addition of a human body in the circuit would add

a load of characteristics that are different from expected, and the source would be rapidly de-energized. The protective mechanisms that should be required may bedifferent for each product design. In general, the system of protectionagainst electric shock should consist of one or more of those mechanisms that will effectively reduce the risk of electric shock to an acceptable level. The choices should be appropriate, feasible and consistent with today’s technology. The National Electrical Code contains requirements for the


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installation of electrical products, but product safety standards cover thedetails and complexities of the design and construction of the variouproducts, including which protective mechanisms or combinations ofprotective mechanisms are considered satisfactory to meet the need forprotection against electric shock. Manufacturers of electric vehicles, charging ports and associ

ated equipment need to consider this information as they design theelectric cars of the future. If the new vehicle designs include the appropriate protection equipment to prevent potentially dangerous physi-ological effects, then electric vehicles will provide a modern, safe andenvironmentally friendly mode of transportation.

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