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Clinton FL-20A, Instruction Manual

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Page 34 - FL-20A Instruction Manual

Model FL-20A Cable Fault Locator

Troubleshooting

•  An error displays:  “The safety switches were let go.”

The two safety switches were released during the test while the Caged 

Operation setting was OFF.  Press the CANCEL button to return to the 

main menu and begin the test again.  Hold in the safety switches for the 

duration of  the test.
•  During a shorts test, an error displays:  “Inadequate arc rate.”

The voltage may not too low to cause an arc to short from the test con-

ductor to ground.  Increase the voltage.

There may be no fault in the product.  Run a Hi-Pot test to confirm the 

presence of  a fault.
•  During a shorts test, an error displays: “Accuracy:  Low.”

When a test takes a very long time and the report screen says your accu-

racy is low, you may have a multiple fault condition. The FL-20A will find 

the first fault so it can be cut out and the cable retested to locate a second 

short. This setting is not recommended for low loop resistance products, 

because it can give false positives. 
•  An error displays: “Cannot Find Open.”

If  you run the test without attaching the red and blue probes, the error 

message, “Cannot Find Open” will be displayed.
• 

FL-20A cannot find faults.

In a situation where there are multiple direct or high voltage shorts, you 

may not locate any of  them.
•  The ground probe is connected, but it is not detected.

Insure that both contacts of  the ground probe make a good connection 

to the ground wire.
•  The external interlock is not detected in Caged Operation.

Check the connections from the door or latch on your cage to the inter-

lock pins on the back panel of  the FL-20A.
•  Test accuracy is rated Low.

Insure that both contacts of each probe are making a good connection.

Insure that the ground probe is connected to all wires that are not being 

tested.

The test voltage may be too low.
•  The X3F lights are not illuminating when expected.

Check the connections between FL-20A and X3F.

Check the continuity of  the connection of  each of  the testing relay con-

tacts and the connection of  each of  the HV ON relay contacts.  If  there 

is no connection when expected, replace fuses F1 and F2 on PC board 

no. 91496.
•  The FL-20A will not power up.

Check the fuse contained in the ON/OFF switch. (See “Maintenance.”)

Summary of Contents for FL-20A

Page 1: ...Clinton Instrument Company 295 East Main Street Clinton CT 06413 USA Telephone 860 669 7548 Fax 860 669 3825 www clintoninstrument com Model FL 20A Cable Fault Locator Instruction Manual ...

Page 2: ...Rev J 11 19 ...

Page 3: ...robes to each end of the cable under test enters the cable length on the digital touch screen and selects Shorts or Opens to begin the test The unit quickly calculates the distance of the fault site from each test probe displays the location in feet or meters and provides a suggested trim area The failure can then be cut out or repaired and the remaining good product salvaged resulting in great sa...

Page 4: ...X3F 15 W x 14 D x 25 5 H Test Leads 10 standard 20 30 ft available Weight 38 lbs 17 3kg Power Requirements 100 240 volts AC 50 60 Hz 2 amps dependent on accuracy of actual cable footage and product uniformity Specifications subject to change without notice 11 11 EN z Shorts z Typical Lead Connections Opens Green Blue Ground Strap Green Blue Red Red Coaxial Cable Top of Reel Bottom of reel Multi Co...

Page 5: ...g an Open Tests 20 Performing a Hi Pot Test 22 Calibration 24 Maintenance 26 Cable Capacitance Chart 27 Cable Loop Resistance Chart 28 Locating Shorts in Medium and High Voltage Cables 29 How to Use the 91785 FL Test Box 32 Troubleshooting 34 Replacement Parts 35 Optional Accessories 36 Electric Shock Considerations for Electric Vehicle Charging Systems 37 Warranty 44 ...

Page 6: ......

Page 7: ...ns Class A CISPR 11 Edition 4 2003 Radiated Emissions Class A IEC 61000 3 2 2000 Harmonics IEC 61000 3 3 2002 Flicker Conforms with the immunity requirements of EN 61326 2006 Table 1 IEC 61000 4 2 2001 Electrostatic Discharge IEC 61000 4 3 2002 Radiated Immunity IEC 61000 4 4 2004 EFT Burst Power and I O Leads IEC 61000 4 5 2001 Surge Immunity IEC 61000 4 6 2003 Conducted Immunity Power and I O Ca...

Page 8: ......

Page 9: ... observe proper safety precautions can result in severe injury or death Supervisory personnel are strongly advised to use the built in password protection feature to prevent unauthorized persons from defeating safety features or changing test parameters Read the section in Installa tion entitled Password Protection for further information A Warning Note to Operators When cables are being tested wi...

Page 10: ...erably higher Capacitor discharge energy of 50 Joules watt seconds is regarded as hazardous For references see Dalziel Ogden Abbot Effect of Frequency on Let Go Currents Transactions of A I E E Volume 62 December 1943 and Dalziel Electric Shock Hazard I E E E Spectrum Febru ary 1972 Safety Symbols The symbols depicted below are safety symbols placed on the spark test equipment It is important to u...

Page 11: ...libration measurements are traceable to the United States National Institute of Standards and Technology to the extent allowed by the Institute s calibration facility For customer service or technical assistance 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 com email ...

Page 12: ... 3 92100 Probe Clip Assemblies other sizes available An instruction manual If a printer was ordered the following items are included Printer Printer cable Power adapter Roll of paper part no 91901 Remove the FL 20A and accessories from the carton Retain the packing material in the event that the unit is returned for calibration or service at some future time Site Preparation Caution The installati...

Page 13: ... on the rear panel of the FL 20A When the wiring is complete plug the Y power cord into the X3F and the fault locator Ground the chassis Connect a ground wire to the ground terminal on the rear of the FL 20A chassis Connect the other end to earth ground Use 22 gauge wire or larger This is an important safety task that must not be neglected Wire the external safety interlock Caged Operation Wire th...

Page 14: ... defeating safety features and changing voltage settings and test parameters Using password protection will make your work place safer After making necessary changes in the Settings menu go to the Set Admin Password setting The default password is 1111 To change it press the displayed password to access a keypad Enter a new 4 digit password and press OK After entering a new password go to the Lock...

Page 15: ...tand test The purpose of this test is to charge one conductor to determine if high voltage at a predetermined level will discharge to ground through the insulation If too much cur rent flows the conductor is not well insulated and it fails the test Loop Resistance Conductor resistance to the flow of electrical current measured in ohms 1 000 feet Resistance is inversely proportional to the cross se...

Page 16: ...e multiple faults in the cable the cable may have low loop resistance or the fault is judged to be close to either end Standard The test is considered good with good results Exceptional The fault location was easily located and test results are accurate within 1 of the cable length ...

Page 17: ... full test Refer to the section of Caged Operation for wiring details The safety interlock is also required for calibration A two position con nector is supplied for this purpose Refer to the Calibration section for instructions Front panel touch screen The touch screen is used to set test parameters run tests and view test results Never press the touch screen with a tool or sharp object Safety bu...

Page 18: ...e X3F Light Tower When the X3F is properly installed the red High Voltage light will go ON when high voltage is present on the FL 20A test probes The yellow Test In Progress light will flash during a test Warning when the red High Voltage light on the X3F is illu minated do not touch the red and blue probes or the test cable because a charge is present If the cable capacitance is large the light m...

Page 19: ...ettings Calibration Language Caged Operation and Unit of Measure These settings apply to all Opens Shorts and Hi Pot Testing Global Settings Global settings such as Calibration Language Caged Operation and Unit of Measure apply to Opens Shorts and Hi Pot tests They are found in the several pages of the Settings Menu To view or modify a setting press the appropriate button to access the subscreen A...

Page 20: ...d Operation to ON Press ACCEPT Unit of Measure Test cable lengths may be displayed in feet or meters The unit of mea sure cannot be changed during a test Press the displayed choice to toggle between Feet or Meters System Information FL 20A firmware and software version numbers are stored here During troubleshooting you may be asked for this information by a Clinton technician System Errors System ...

Page 21: ...age of the Shorts Parameters settings will appear These settings will apply to all shorts tests that will be done They are saved in memory even when the FL 20A is off Auto Voltage Detect During the shorts test the optimum voltage level is the test voltage required to cause a fault to arc to ground not higher When Auto Volt age Detect is ON the fault locator will begin testing the conductor at 10 o...

Page 22: ...cular cable type are sometimes confident that a partial test is accurate and choose it to reduce test time However this is not recommended without the advice of a Clinton technician Lock Test Voltage When this setting is ON the Shorts Max Voltage setting cannot be changed at test time although the voltage setting is displayed during the test Shorts Max Voltage This setting is found on the second p...

Page 23: ...s point unknown If you instead press NEXT the FL 20A will then proceed to ind the distance of the short from the red probe A summary screen showing the open s location from the red and blue probes as well as the rated accuracy of the test and the sug gested trim area will display The default for Full Test is ON Experienced operators working with a particular cable type are sometimes confident that...

Page 24: ...all Hi Pot tests or at the time of test if Lock Hi Pot Settings is OFF Vramp Time s This setting is found on page 2 of the Hi Pot parameters menu This is the time in seconds up to 60 seconds that the FL 20A will take to per form each Vstep to get to the preset maximum Hi Pot voltage Vmax kV This setting can be changed here to affect all Hi Pot tests or at the time of test if Lock Hi Pot Settings i...

Page 25: ... to personnel Additionally the FL 20A graphics display may not function correctly due to excess electrical noise created by improper grounding Alligator clip assemblies similar to those shown in the photos below are highy recommended when cables to be tested are too large to fit properly in the probes These items are available for purchase Smaller cable sizes can use the enclosed 3 probe clip asse...

Page 26: ...d of the conductor and insert into the blue test probe 3 Ground all untested conductors On one end of the test cable strip back all conductors not under test by 1 carefully bunch them together with the cable shield so that they make a good connection with one another and insert into the green ground probe Be sure that insulation does not obstruct the connec tion between the metal in the probe and ...

Page 27: ...dicating that there is high voltage on the test cable 12 If the Full Test setting is OFF the first test result screen indi cating the fault distance from the red probe will appear Press NEXT to continue the test or press HOME to exit the test If the Full Test setting is ON the unit will proceed through both halves of the test and a complete test summary report will appear The fault distance from t...

Page 28: ...e and the exposed conductor Strip the other end of the conductor and insert into the blue test probe 3 Ground all untested conductors On one end of the test cable strip back all conductors not under test by 1 carefully bunch them together with the cable shield so that they make a good connection with one another and insert into the green ground probe Be sure that insulation does not obstruct the c...

Page 29: ...ash to alert that a test is in progress and the FL 20A touch screen will indicate that the test has begun 8 If the Full Test setting is OFF the first test result screen indicating the fault distance from the blue probe will appear Press NEXT to automatically reverse the leads and continue the test or press HOME to exit the test 9 If the Full Test setting is ON the unit will proceed through both ha...

Page 30: ... metal in the probe and the exposed conductor Strip the other end of the conductor and insert into the blue test probe 3 Ground all untested conductors On one end of the test cable strip back all conductors not under test by 1 carefully bunch them together with the cable shield so that they make a good connection with one another and insert into the green ground probe Be sure that insulation does ...

Page 31: ...arily press safety switches If the Caged Operation setting is OFF the screen will display Hold Safety Switches 10 Press the safety switches as directed 11 The FL 20A touch screen will indicate test progress as it tries to locate the fault The X3F yellow light will flash to alert that a test is in progress and the red High Voltage light will go on indicating that there is high voltage on the test c...

Page 32: ... terminal block which is located on the back of the unit You cannot proceed without installing the connector Press NEXT 3 The number displayed above CURRENT will be chang ing Wait about 10 seconds and press the LOCK button The CURRENT number will be saved to the CENTER number The typical acceptable range is 12 000 to 15 000 Press NEXT 4 Connect the shorted red and blue probes to the input of your ...

Page 33: ...NEXT 11 If the Voltage Reading on the touch screen is not 15 0kV use the DOWN ADJ and UP ADJ buttons until the reading is 15 0 kV If adjustments had to be made press BACK to the previ ous screen 12 Repeat steps 14 and 15 until the Voltage Reading reads within 2 of 15 0 kV 300 volts without further adjustment Press NEXT 13 To record a calibration point press the Voltage Reading number to access a k...

Page 34: ...re not expected to fail in normal opera tion Their failure may be an indication of equipment malfunction requiring qualified repair personnel A fuse is located in the ON OFF power switch To replace it discon nect the power cord from power Use a flathead screwdriver to gain access to it as seen in the pictures below ...

Page 35: ...el FL 20A Cable Fault Locator Cable Capacitance Chart The accuracy of the FL 20A in Opens tests is limited by the test product s capacitance properties Please consult the chart below to determine the results you can expect for your product ...

Page 36: ...le Fault Locator Cable Loop Resistance Chart The accuracy of the FL 20A in Shorts and Hipot tests is limited by the test product s cable loop resistance properties Please consult the chart below to determine the results you can expect for your product ...

Page 37: ...flows the test will give inaccurate results or no results at all Testing Medium and High Voltage Cables Medium and high voltage cables present unique problems in cable fault location Some faults in medium and high voltage cables break down at low voltages As long as the cables are high enough in total loop resis tance 250 milliohms or more the results will be accurate It is those faults that break...

Page 38: ...ge measurement the total resistance of Segment A plus the value of R1 equals the resistance of Segment B This is referred to as balancing the resistances and is the basis of cable fault location of short circuited conductors When there is significant arcing and carbonization there may be mul tiple current pathways each with a different resistance This is illustrated below in Figure 2 Figure 2 The ...

Page 39: ... immediately after failure 16 When hipot testing cables do not allow the hipot tester to keep burning a fault once it is detected This will reduce accuracy in fault location with the FL 20A 17 When using the FL 20A on cables that failed hipot testing above 15 00 kVDC or 10 5 kVAC regard the results as suspect unless the FL 20A reports Standard or Exceptional results ...

Page 40: ...which simulates a break in a conductor of a cable The second is a Metallic Short which simulates a conductor directly connected to another conductor in a cable The last is a High Voltage Short which simulates a conductor with a break in the insulation close to a ground shield drain wire or another conductor with a break in the insulation In this instance high voltage can arc from one conductor to ...

Page 41: ...r within our margin of accuracy from the blue side and 10 from the Red side These two results should total approximately 100 Testing for High Voltage Shorts Accuracy For running a High Voltage Shorts Test connect the probes to the Shorts terminals as shown Note the Green ground probe connects to the terminal labeled HIGH VOLTAGE SHORTS Run the Shorts Test on the cable fault locator at a voltage of...

Page 42: ...s An error displays Cannot Find Open If you run the test without attaching the red and blue probes the error message Cannot Find Open will be displayed FL 20A cannot find faults In a situation where there are multiple direct or high voltage shorts you may not locate any of them The ground probe is connected but it is not detected Insure that both contacts of the ground probe make a good connection...

Page 43: ... Display Color Programmed 91526 Power Supply 24V DC 200W 91175 Power Supply 70W 91497C Stepper Motor 4 wire 91549 Timing Belt 91498 Potentiometer 1K 10 Turn 5W 91494 PC Board Assembly High Voltage Bridge 91496 PC Board Assembly Low Voltage Main 91499 Power Supply 20kV 125W 91627C Rotary Solenoid 10v DC w Connector 02606 Fuse 2 amp 5x20 mm 91610 Transformer 20kV DC 115 230v 91609 Test Lead Assembly...

Page 44: ...ge 36 FL 20A Instruction Manual Model FL 20A Cable Fault Locator Optional Accessories Part Number Description GND SP Ground Probe Assembly PRINTER THERMAL RECEIPT Thermal Printer 91901 Printer paper roll ...

Page 45: ...e small cur rents are harmless but if perceived by a consumer the elec tric 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 an involuntary startle reaction particularly in women The current itself is harmless but the uncontrolled movement of a startled pers...

Page 46: ...or may be unable to breathe while the current flows Tetanization lasts as long as the current flows When the current stops the effect stops and the muscle returns to normal function However the effect can be fatal if breath ing stops long enough If immersed in water an immo bilized person could drown In a manner comparable to perception tetanization occurs at a higher current threshold for DC and ...

Page 47: ...is the peak to peak value of the cur rent if the DC component is low enough so that there is reversal of the current each cycle In fact as long as the cur rent reverses the presence of a DC component is not sig nificant with regard to the ventricular fibrillation threshold If the DC component is high enough to preclude reversal of the current of each cycle of the AC component then the occurrence o...

Page 48: ...siderations are the reliability of the connections and the impedance of the conductors at the frequencies involved Ground monitors that interrupt current and or sound an alarm can enhance reliability Low impedance in the grounding conductor circuitry is important in order to maintain low voltage to ground on accessible conductive parts during a fault before an interrupting device shuts off the cir...

Page 49: ... ampere 60 Hz load Many GFCIs have not been designed or tested for use on circuits involving larger loads higher frequencies non sinusoidal waveshapes and DC components New designs of GFCIs may be needed for use on some of the electric vehicle charging circuits A GFCI discerns load current from possible electric shock current by where the current flows Current flowing both to and from the load thr...

Page 50: ...that the grounded side of the line is connected to those more exposed parts This can involve the use of plugs and connectors that permit mating with only one polarity Interlocks and smart circuits can be used to keep potentially hazardous parts de energized unless specific safety conditions are satisfied Some of these safety conditions include specific covers that must be closed specific connec to...

Page 51: ...the various products including which protective mechanisms or combinations of protective mech anisms are considered satisfactory to meet the need for pro tection against electric shock Manufacturers of electric vehicles charging ports and associated equipment need to consider this information as they design the electric cars of the future If the new vehi cle designs include the appropriate protect...

Page 52: ...bligation 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 charg...

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