Clinton DC-1 Instruction Manual Download Page 1

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DC-1, -10, -20B Instruction Manual

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Models DC-1, -10 and -20B DC Spark Testers

Instruction Manual

295 East Main Street

Clinton, CT 06413 USA

Telephone: 860.669.7548 Fax: 860.669.3825

www.clintoninstrument.com

DC-20B/BD-12S shown with optional X3B Horn/Light Tower

Clinton Instrument Company

Summary of Contents for DC-1

Page 1: ...s DC 1 10 and 20B DC Spark Testers Instruction Manual 295 East Main Street Clinton CT 06413 USA Telephone 860 669 7548 Fax 860 669 3825 www clintoninstrument com DCDC 20B BD 12S shown with optional X3B Horn Light Tower Clinton Instrument Company ...

Page 2: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 1 Rev Null b0002 10 11 17 ...

Page 3: ...e for ventilation of the Test Module 13 POWER WIRING 13 Install an external disconnecting device 13 Mains Power 13 Ground the Spark Tester 13 TERMINAL BLOCK WIRING 14 CONNECTING THE SERIAL RS 485 16 CONNECTING TO THE ANALOG INTERFACE OPTIONAL 16 INSTALLING THE COMPACTCOM MODULE OPTIONAL 16 CONNECTING THE X3B OPTIONAL 16 Unpacking the X3B 17 Connecting the X3B 17 X3B to Spark Tester Connections 18 ...

Page 4: ...Discharge Bar DIS 30 High Voltage Enable HVE 30 VOLTAGE MONITOR OUTPUT OPTIONS 30 High Voltage On Lamp HVL 30 High Voltage Watchdog WDL 31 Electrode Voltage Percent Based Watchdog EVP 31 Actual Voltage Percent Based Watchdog AVP 31 Percent Load Limit PLL 32 FAULT OUTPUT OPTIONS 32 Fault Pulse FPL 32 Any Fault Alarm AFA 32 Pinhole Alarm PHA 33 Metal Contact Alarm MCA 33 Multi Pinhole Alarm MPA 33 G...

Page 5: ... FIELDBUS COMMUNICATIONS INTERFACE 42 FIELDBUS COMMUNICATIONS PARAMETERS 42 FIELDBUS SPARK TESTER PARAMETER ADDRESSES 43 CIC XM UTILITY 44 CALIBRATION 46 ST CAL CALIBRATION 46 EVM CALIBRATION PROCEDURE 46 Connecting the EVM 46 Taking Calibration Readings 47 Adjusting the Calibration 47 MAINTENANCE 48 FUSES 48 PERIODIC INSPECTION 49 TROUBLESHOOTING 50 SETTING FACTORY DEFAULTS 51 REPLACEMENT PARTS 5...

Page 6: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 5 EU Declaration of Conformity Declaration of Conformity ...

Page 7: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 6 Specifications ...

Page 8: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 7 ...

Page 9: ...from 5ºC to 40ºC Humidity to 80 R H at 31ºC decreasing linearly to 50 R H at 40ºC The Clinton Instrument Company certifies that this equipment met its published specifications at the time of shipment The calibrations of the equipment are checked against Measurement Standards Reference maintained by the Clinton Instrument Company The accuracy of these standards is traceable to the national standard...

Page 10: ...ese emissions There is also a serious risk of electrical shock if an individual comes into contact with an ungrounded test product Email support clintoninstrument com Electrical Shock Hazard from Production Line Spark Testers By Henry H Clinton The commonly accepted maximum values of 60Hz current passing through the human adult body which permit a subject to let go of electrodes are nine milliampe...

Page 11: ...d The conductor under test should be grounded If an operator must inspect the product by touching its surface while it is being spark tested he should be electrically insulated from his environment and any possible cause of a secondary accident caused by reaction should be eliminated For references see Dalziel Ogden Abbot Effect of Frequency on Let Go Currents Transactions of A I E E Volume 62 Dec...

Page 12: ...is returned for calibration or service at some future time The following items are packed with the spark tester 1 DC B Spark tester 2 RC Display With mounting bracket when ordered 3 A power cord 4 A 9 Pin green terminal block connector for process control connec tions After it is wired it will plug into the terminal block on the back of the spark tester 5 A 4 Pin green terminal block connector for...

Page 13: ...uipment as close to the extruder cross head as practical this generally means locating it just after the water cooling trough In this case it is important to wipe the water off of the product thoroughly before it enters the spark tester electrode containment Failure to adequately dry the surface of the wire or cable can cause false counting and can cause premature failure of the equipment To mount...

Page 14: ...ter is in use The exhaust of the external air extraction system should be discharged either outdoors or into some area well away from workers Power Wiring Install an external disconnecting device Install an external switch or circuit breaker in close proximity to the spark tester and within easy reach of the operator The switch or circuit breaker must meet the relevant requirements of IEC 947 1 an...

Page 15: ... of the spark tester and its companion green terminal block connectors that came with the unit Conductors connecting auxiliary equipment relays and switches should be shielded 22 gauge or larger and should be stripped back 6mm and fed into the green terminal block connector at the proper pin number Shields from con ductors connecting auxiliary equipment should be grounded to the safety ground term...

Page 16: ...e Watchdog High Threshold values Bare Wire OUT3 To activate external lights alarms or relays when a Bare Wire type fault occurs wire them between dry relay contact pins 3 4 If the output function is set LCH or RVF the dry relay contacts will remain closed until the RESET button is pressed or when pins 1 3 are closed by remote switch or relay output function is set to NLC the dry relay contacts wil...

Page 17: ...trument Company The cable composition is normally dictated by the PLC but ordinarily 22 gauge conductors individually shielded or shielded pairs are required The maximum length of the cable is also determined by the equipment the DC B is being connected to However it is recommended that the cable length not exceed 10 meters See the section entitled Analog Interface for the details regarding this i...

Page 18: ... picture to the left 2 Make sure the spark tester is off before wiring to the X3B 3 Locate the 10 pin green terminal block on the back of the X3B and the 9 pin terminal block on the back of the spark tester The X3B is supplied with a 4 conductor cable The 10 pin connector will plug into the X3B terminal block and the 9 pin connector will connect to the spark tester terminal block Prior to insertin...

Page 19: ...oltage exceeds 500v For an indication that HV is ON in the electrode wire a lamp or auxiliary device here HV ON Relay When connecting auxiliary equipment to dry relay contacts pins 1 2 3 4 or 5 observe maximum ratings of 120VAC at 2 amps or 240VAC at 1 amp External Reset To reset the spark tester fault relay with an external switch wire a momentary switch between pins 1 3 When these contacts close...

Page 20: ...rcent Load and the Set Point Values UP DOWN ARROW VOLTAGE ADJUST buttons The spark test voltage may be adjusted from 0 to the maximum voltage 1 000 for the DC 1B 10 000 for the DC 10B and 20 000 for the DC 20B in 100 volt increments by pressing the up and down arrow buttons under the voltmeter Press and hold a button to increase the speed at which you change the voltage setting Fault Counter The 3...

Page 21: ... RESET button will have no effect on the number of faults registered on the fault counter High Voltage On Lamp The high voltage On Lamp will turn on when the high voltage output level is above 500V Bead Chain Electrode When the spark tester power is ON and the clear protective cover is down the test voltage set on the spark tester front panel is applied to the product under test as it runs through...

Page 22: ...mal Sensitivity setting is Clinton Instrument Company s bench standard and will pass the IEC 62230 600 uA standard for spark tester sensitivity RED The Reduced Sensitivity setting will meet the NEMA WC 56 standard for spark tester sensitivity and will meet the IEC 62230 reduced sensitivity 1 2 mA standard used when high product capacitance causes false or phantom counting For more information cont...

Page 23: ...r and the electrode is made Set Point Voltage This is the desired test voltage that is input through the front panel controls or remotely by PLC Voltage Watchdog Test Voltage parameters may be set by users to ensure that adequate test voltages are always being used to test product These values can be based off of upper lower limits WDL or percentage of set point voltage EVP New Features Display Th...

Page 24: ...ting the flow of current during spark testing has always been the standard in spark testing The DC B revolutionizes the concept of fault detection by the use of DSP Based Fault Typing We can now differentiate 4 types of fault conditions Pinhole direct metal contact multi pinhole and gross bare wire Definitions of fault conditions Pinhole A pinhole is defined as a short duration fault where no dire...

Page 25: ...Tester Configuration Front Panel Navigating the Configuration Menu This section will explain how to navigate and configure the unit from the configuration menu using an RC Display Entering configuration While the RC Display is in normal run mode hold the Down Button CR Button for approximately four seconds The system will enter configuration mode and voltage output will be disabled If the display ...

Page 26: ...to the hardware output labeled OUT1 XXX is the configured function For sub menu items see the Spark Tester Outputs section of this manual This configures the Output Function assigned to the hardware output labeled OUT2 XXX is the configured function For sub menu items see the Spark Tester Outputs section of this manual This configures the Output Function assigned to the hardware output labeled OUT...

Page 27: ... CR Button 3 Configuration Menu Access Voltage Adjust CR Button R Button This is where the PIN number is displayed and can be modified The factory default PIN code is 111 This configures the voltage parameters for the unit This configures the unit s maximum voltage with 1 decimal place If more precision is needed use FADJ The setting of AUT will allow the maximum the unit will produce AUT Automati...

Page 28: ...used When No the output will remain inactive This delay used when voltage is called for till the voltage is output This is in seconds This configures the settings associated with fault detection for the unit FSMO TS0 This configures the unit s fault sensitivity mode See Fault Sensitivity in the Definition of Terms section of the manual for more information The values range from TS0 normal sensitiv...

Page 29: ...ion to calculate a fault pulse The FR setting will affect how different types of faults are categorized See the New Features section of this manual for more information on Fault Typing Configures the External RS 485 Modbus Communications port Changes will not take effect until the system is restarted This configures the RS 485 Modbus Slave Address where XXX is the slave address Configures the unit...

Page 30: ... less than 5 seconds a progress bar will be displayed and factory defaults will be reset in the unit Spark Tester Inputs Input functions are assigned to input pins labeled IN0 and IN1 located on the terminal block so that the unit will perform the required task High Voltage Enable HVE To enable high voltage install a wire jumper normally closed switch or relay between pins 1 2 See the 9 Pin Termin...

Page 31: ...eptable limits Discharge Bar DIS This output is the discharge bar output When enabled it will be activated when the voltage is enabled and the voltage setting is above 0 and disabled when the voltage is set to 0 or the voltage is disabled High Voltage Enable HVE This output will change state when the unit meets all conditions to generate high voltage Voltage Monitor Output Options High Voltage On ...

Page 32: ... output will change state when the electrode voltage monitor is within plus or minus the configured EVWP percentage of the set voltage Example Set point is 10kV EVWP is 10 If the electrode voltage is between 9kV and 11kV the output will signal Electrode Voltage Watchdog Percent EVWP Set as a percentage For more information on the Voltage Watchdog see the New Features section of this manual Actual ...

Page 33: ... than 50mS timings may not be exact when using relay type outputs Any Fault Alarm AFA This output will operate in 3 different modes NLC LCH RVF The Any Fault alarm is triggered by any high voltage fault that occurs See the Definition of Terms section of the manual for more information Any Fault Alarm Mode AFMO Non Latch Mode The output will change state for the configured AFMS time Latch Mode The ...

Page 34: ...ut will change state Metal Contact Alarm MCA This output will operate in 2 different modes NLC LCH The Metal Contact alarm will respond only to a direct metal contact fault type See the Fault Typing section of the manual for more information Metal Contact Alarm Mode MCMO Non Latch Mode The output will change state for the configured MCMS time Latch Mode The output will change state until it is res...

Page 35: ...LC LCH The Gross Barewire alarm will respond only to a Gross Barewire fault type See the Fault Typing section of the manual for more information Gross Barewire Alarm Mode GBMO Non Latch Mode The output will change state for the configured GBMS time Latch Mode The output will change state until it is reset at the front panel or remotely Gross Barewire Alarm Time GBMS Set in seconds 01 5 0 If GBMO i...

Page 36: ... greater than the configured MPLT Multi Pinhole Count Limit MPLT Amount of counts allowed before the output responds Gross Barewire Limit GBL This output will change state when the Gross Barewire count is equal to or greater than the configured GBLT Gross Barewire Count Limit GBLT Amount of counts allowed before the output responds Fault Combination Limit FCL Must be configured via USB computer in...

Page 37: ...el or remotely Any Barewire Alarm Time ABMS Set in seconds 01 5 0 If ABMO is set to NLC this is the time for which the output will change state Any Pinhole Alarm APH This output will operate in 2 different modes NLC LCH The Any Pinhole alarm will respond only to a Pinhole or Multi pinhole fault type See the Fault Typing section of the manual for more information Any Pinhole Alarm Mode APMO Non Lat...

Page 38: ...gn may impact performance of metal contact detection MULTI PINHOLE A series of high voltage discharges no less than 2 5 x electrode length where the electrode does not make physical contact with the conductor of the product being tested Note Although an accurate line speed is not required for Multi Pinhole Fault Typing the minimum length typed as a Multi Pinhole Fault 2 5 x Electrode Length is rel...

Page 39: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 38 Spark Tester Configuration USB Contact factory for details at support clintoninstrument com ...

Page 40: ...l minutes or longer damage to the 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 Similarly if the HV remains ON in the electrode while your wire line is stationary the product insulation within the electrode will heat and there is a danger of combustion Refer to the table Terminal Block Wir...

Page 41: ...s RS 485 Connector The pin configuration for the RS 485 port is listed in the table below Pin Name 1 TX 2 TX 3 RX 4 RX 5 GND 6 NC 7 NC 8 NC 9 NC RS 485 Parameters The default parameters of for the RS 485 Serial port as listed below To change the port address or the baud rate see the Configuration Menu Options Note if the unit is being controlled directly from the RS 485 port on the back panel the ...

Page 42: ... input at this pin changes the spark tester s output voltage proportionally 7 Remote Fault pulse collector Max Voltage 30V DC Max Current 150mW 8 Remote Fault pulse emitter Max Voltage 30V DC Max Current 150mW 9 Ground 0 10v reference ground 10 Ground 11 Count Reset 12 Count Preset Open Collector Current sinking NPN open collector output Max Voltage 30V DC Max Current 150mW 13 DC output This is a ...

Page 43: ...ous fieldbuses that are supported by the DC BX Spark Tester See the section entitled CIC XM Utility for the steps required to modify these parameters Note the Data Sizes are fixed and cannot be changed Interface Types Parameter Default Modbus RTU Station Number 40 Modbus RTU Interface RS 232 or RS 485 RS 232 Profibus Station Address 40 DeviceNet Node Address 40 Modbus TCP Ethernet IP Profinet IP A...

Page 44: ... STATUS Bit 3 R Set when the fault is detected and cleared at end of fault pulse duration AF ALARM STATUS Bit 4 R State of the AF Alarm cleared by Fault Reset PH ALARM STATUS Bit 5 R State of the PH Alarm cleared by Fault Reset MC ALARM STATUS Bit 6 R State of the MC Alarm cleared by Fault Reset MP ALARM STATUS Bit 7 R State of the MP Alarm cleared by Fault Reset GB ALARM STATUS Bit 8 R State of t...

Page 45: ...and run the CIC XM Utility If the USB cable is not connected the CIC XM Utility will prompt for the USB cable as shown Once the cable is connected you will get one of two edit screens The first is for Ethernet based fieldbus types Ethernet IP Modbus TCP and Profinet shown on the left The second type of edit screen is for non Ethernet based fieldbuses DeviceNet Profibus Modbus RTU shown on the righ...

Page 46: ... press the Edit Button The Read Only indicator disappears indicating that the values can be modified An example is shown below Once edits are complete press the Save Button The following screen will be shown indicating a power cycle is required Once power has been cycled the new values will be used ...

Page 47: ...tions for the STCAL system EVM Calibration Procedure The EVM has a mirrored area to assist in eliminating errors in reading The correct way to read the meter is to move the viewing position your eye until the reflection of the needle in the mirror is directly behind the needle itself and observe the needle position on the scale This eliminates any parallax error that might result from viewing the ...

Page 48: ... Adjusting the Spark Tester Output voltage 10 Press the B button for several seconds until VOUT is displayed on the voltage display 11 Press the R button The Fault Count display should show S 00 0 representing the set point value 12 Using the UP DOWN arrows adjust the output voltage up so that the Fault Count display shows S 01 0 for 1kV 13 Check the actual output voltage on the EVM if this value ...

Page 49: ...alue on the EVM 22 Once the Voltage monitor value matches the output voltage value on the EVM press the R button to return the Fault Count Display to read the set point value 01 0 23 Repeat these steps until the all calibration values are within tolerance 24 Once calibration is complete press the A button once to exit the Manual calibration mode Maintenance Fuses The fuses in this equipment are no...

Page 50: ...loth Bead chain assemblies contaminated with insulation residue should be removed from the high voltage test module and cleaned with a wire brush Broken safety covers and mounting plates and electrode assemblies with worn brushes or missing beads should be replaced immediately The red electrode mounting plate clear cover and bead chain assemblies are subject to damage and contamination that is not...

Page 51: ... setting in the Configuration menu from NOR to RED Note that your spark tester will no longer meet the BS Standard for sensitivity but will still meet the NEMA Standard for sensitivity The Fault Count Displays E EXI 1 There is no switch or relay contact between Pins 1 2 GND and HV ENABLE Refer to the table in Installation labelled Terminal Block Connections under HV ENABLE The Fault Count Displays...

Page 52: ...eck fuse on main pc board The spark tester controls are on but the equipment does not 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 GND and HV ENABLE Refer to the table in Installation labelled Terminal Block Connections under HV ENABLE I forgot my P...

Page 53: ...12S Requires 2 91048 Electrode Mounting Pate for BD 12 BD 13 92240i Cover Clear Safety for BD 12 BD13 92264 Hinge Surface Mount 40 Series Requires 2 92xxxi 92xxyi 92xxzi High Voltage 1kV DC Supply High Voltage 10kV DC Supply High Voltage 20kV DC Supply 03004 Switch Interlock 92283 4 Pin Terminal Block Connector Kit Green 91069 9 Pin Terminal Block Connector Kit Green 03780 Power Cord 91463G End Gu...

Page 54: ... boards to the factory or to your Clinton sales representative for evaluation Optional Accessories Part Number Description FS 4 Floor Stand for DC B 39 42 Adjustable wire line height FS 4A Floor Stand for DC B with BR 3A or BRTC electrodes X3B W 91224G Plate Horn Light for DC B BD 12S X3B W 91223G Plate Horn Light for DC B BD 22S STCAL LF STCAL Low Frequency Calibration System STCAL SM Sensitivity...

Page 55: ...r obligation under this warranty being limited to repair or replacement of the defective parts This warranty does not apply to fuses lamps or any normally expendable parts Any part appearing to have defects in material or workmanship upon our examination only and as determined by us and providing the equipment has not been subject to abuse misuse or alteration will be repaired or replaced at no ch...

Page 56: ...st Module 1 2 6 mm Split Lock Washer 4 3 M6 x 16 Hexhead Screw 4 Item No Item Description Qty 1 Base 1 2 Outer Column 1 3 10 1 5 x 30 mm bolt 2 4 10 1 5 mm Hex Nut 2 5 8 x 1 25 mm Hex Nut 2 6 8 1 5 x 25 mm Bolt 2 7 Column Clamp 1 8 Handle 1 9 Inner Column 1 10 Test Module Mounting Plate 1 11 M6 Split Washer 2 12 M6 x 16 mm Bolt Hex 2 ...

Page 57: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 56 Grounding of Conductors during the spark test ...

Page 58: ...Models DC 1 10 20B DC Spark Testers DC 1 10 20B Instruction Manual Page 57 ...

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Clinton DC-1, Instruction Manual, Page: 1 / 58

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