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FL-8A Instruction Manual - Page 1

Model FL-8A Portable Cable Fault Locator

Safety

Danger! High Voltage Safety Hazards 

Caution--Read before using this equipment.  

DISCHARGE  ALL  CONDUCTORS  OF  THE  TEST  CABLE 

PRIOR  TO  CONNECTING  TO  THE  FL-20A.    YOU  MUST 

REMOVE  ANY  STORED  CHARGE  FROM  THE  PREVI-

OUS  OPERATION,  SUCH  AS  A  HI-POT  TEST.  A  STORED 

CHARGE IN THE CABLE CAN KILL!!!

The FL-20A employs high voltage to locate cable faults.  It is imperative 

that only personnel trained in the dangers of  high voltage operate this 

equipment. 

A stored charge in the TEST PRODUCT can be lethal,  

even when the cable is no longer attached to the FL-20A.  Please read 

and understand the manual prior to operating this equipment.

A Warning to Supervisors! 

The FL-8A is equipped with such safety features as internal safety inter-

locks, a red High Voltage Present warning light, grounding sensors, and 

password  protection.    Do  not  attempt  to  defeat  or  bypass  any  safety 

feature.  Failure to 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 with this or any high voltage equipment, 

the possibility of  leaving a dangerous charge in the cable is always pres-

ent.  Always bunch together and ground all conductors not under test, 

including to the cable shield and to the earth ground, using the provided 

ground probe.  Make sure the test is complete, that the high voltage indi-

cator lamp is off, and that 

all leads are shorted to ground before touching 

any part of  the cables.  

Although the high voltage output of  the FL-8A is not in itself  capable 

of  delivering a truly dangerous shock, a stored charge in the cable can, if  

proper safety precautions are not taken.  For this reason, operators and 

supervisors should establish rigid safety procedures for the use of  this 

and all high voltage equipment. 

Summary of Contents for FL-8A

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 8A Portable Cable Fault Locator Instruction Manual ...

Page 2: ...Rev D 2 15 ...

Page 3: ...The operator simply connects the FL 8A test probes to each end of the damaged cable 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 g...

Page 4: ... Ground Strap Green Blue Red Red Coaxial Cable Top of Reel Bottom of reel Multi Conductor Cable Green Ground Strap Green Coaxial Cable Top of Reel Bottom of reel Multi Conductor Cable Blue Red Blue Red 1 1 2 2 3 3 4 4 A A B B C C D D DWG NO ALL DIMENSION IN INCHES TOLERANCES FRACTIONAL 1 64 DECIMAL 2 PLACES 015 3 PLACES 010 ANGULAR 1 UNLESS OTHERWISE NOTED USED IN APPROVED 11 4 2011 DRAWN tlane 15...

Page 5: ...Performing a Shorts Test 14 Performing an Open Tests 16 Performing a Hi Pot Test 18 Calibration 20 Maintenance 22 How to Use the 91785 FL Test Box 23 Cable Capacitance Chart 25 Cable Loop Resistance Chart 26 Replacement Parts 27 Troubleshooting 28 Electric Shock Considerations for Electric Vehicle Charging Systems 29 Warranty 36 ...

Page 6: ......

Page 7: ...o 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 w...

Page 8: ... considerably 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 importa...

Page 9: ...alibration 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 10: ...time Password Protection The FL 8A offers password protection that can prevent unauthorized individuals from 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 passwo...

Page 11: ...withstand 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 current 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 cros...

Page 12: ...ay be 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 13: ...the opposite end Review the instructions in the Installation section on how to properly strip back the conductors and insert them into the probes This is an important safety procedure Green ground probe The green ground probe is used to make connections to the reference conductor and to ground the test cable Review the instructions in the test sections on how to properly strip back the conductors ...

Page 14: ...w pages of the Settings menu to access the following global settings Calibration Language and Unit of Measure These settings apply to all Opens Shorts and Hi Pot Testing Global Settings Global settings such as Calibration Language 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 but...

Page 15: ... ON a password is required to access the Set tings menu Reserving global setting access to supervisory personnel prevents unauthorized individuals from changing test parameters or defeating safety features The default password is 1111 To change it press the displayed password to access a keypad Enter a new 4 digit password and press the check mark accept button After changing the password turn Loc...

Page 16: ... will first locate the distance of the short from the red probe and then find its distance from the blue probe A summary screen showing the distance of the fault from each probe will display The total of the two distances should equal the length of the test cable By pressing MORE the operator may view the rated accuracy of the results as well as a suggested cable area to remove The full report may...

Page 17: ...When this setting is ON the FL 8A will automatically find the optimum frequency at which to test When the setting is OFF it will test at the Set Frequency which may not give you correct results The default set ting is ON Full Test When this setting is ON the equipment will first locate the distance of the open from the blue probe and then find its distance from the red probe A summary screen showi...

Page 18: ...the operator cannot change the parameters during the test The default setting is OFF Vmax kV This is the maximum Hi Pot test voltage The range is 1 0kV to 8 0kV This setting can be changed here to affect all Hi Pot tests or at the time of test if Lock Hi Pot Settings is OFF Vsteps This is the number of steps the Hi Pot test will take to get to Vmax kV the maximum Hi Pot voltage The number is betwe...

Page 19: ...ous to personnel Additionally the FL 8A 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 as...

Page 20: ...uct the connection between the 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...

Page 21: ... test cable 10 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 the blue probe plus the fault distance from...

Page 22: ...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 con...

Page 23: ... 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 8 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 the blue probe plus the fault distance from the red pro...

Page 24: ...rip 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 connec tion between the metal i...

Page 25: ...s to locate the fault The yellow Test in Progress light will flash and the red High Voltage Present light will go on indicating that there is high voltage on the test cable 10 If the hi pot test is successful the touch screen will dis play Pass A Pass indicates that the tested conduc tors were able to withstand the preselected voltage for the preselected amount of time without any arcing If there ...

Page 26: ... 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 DC multimeter 5 Connect the green ground probe to earth ground Check that the ground connection on the rear of the FL 8A is secure and connected to earth ground Press NEXT 6 The red High Voltage Present light on the FL 8A front panel will illumin...

Page 27: ...til the reading is 6 0 kV If adjustments had to be made press BACK to the previous screen 12 Repeat steps 10 and 11 until the Voltage Reading reads within 2 of 6 0 kV 300 volts without further adjustment Press NEXT 13 To record a calibration point press the Voltage Reading number to access a keypad Enter a new Voltage Reading a number from 5kV to 8 0kV and press OK Record the voltage output on the...

Page 28: ...hours of use or earlier if the indicator is at 1 bar or below Charging should be done with the cover open and in an open area Allow 6 hours for the battery to receive a full charge Aviod charging the unit in areas with temperatures exceeding 110 degrees Fahrenheit If after 6 hours of charging the battery indicates a level below 2 bars contact the factory for a replacement The factory will provide ...

Page 29: ...en 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 ...

Page 30: ...t is 90 or 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 v...

Page 31: ...L 8A Portable Cable Fault Locator Cable Capacitance Chart The accuracy of the FL 8A 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 32: ... Cable Fault Locator Cable Loop Resistance Chart The accuracy of the FL 8A 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 33: ...r repair and cali bration Part Number Description 91501P8 Touchscreen Display Color Programmed 91497C Stepper Motor 4 wire 91498 Potentiometer 1K 10 Turn 5W 91494I PC Board Assembly High Voltage Bridge 91496I PC Board Assembly Low Voltage Main 91857 Power Supply 8kV 6 mA 91609 FL8 Test Lead Assembly 10 91684I PC Board Assembly Battery Monitor 91930I Battery Case Assembly 92100 Probe Clip Assembly ...

Page 34: ...ult condition The FL 8A 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 8A cannot find faults In a ...

Page 35: ...These 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 ...

Page 36: ...zen 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 ...

Page 37: ...on 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 occurrenc...

Page 38: ...considerations 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 ...

Page 39: ... 20 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 ...

Page 40: ...uch 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 conne...

Page 41: ...of 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 prot...

Page 42: ...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...

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