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Model HF-15B High Frequency Spark Tester

Instruction Manual

HF-15B/BD-12S shown with optional X3B Horn/Light Tower

295 East Main Street

Clinton, CT 06413 USA

Telephone: 860.669.7548 Fax: 860.669.3825

www.clintoninstrument.com

Clinton Instrument Company

Содержание HF-15B

Страница 1: ...ncy Spark Tester Instruction Manual HF 15B BD 12S shown with optional X3B Horn Light Tower 295 East Main Street Clinton CT 06413 USA Telephone 860 669 7548 Fax 860 669 3825 www clintoninstrument com Clinton Instrument Company ...

Страница 2: ...Model HF 15B High Frequency Spark Tester HF 15B Instruction Manual Page 1 Rev B b0009 7 1 19 ...

Страница 3: ...y onto the HF 15B 13 Provide 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 17 Unpacking the X3B 17 Connecting the X3B 17 X3B to S...

Страница 4: ... Cover Open CVO 29 Unit Malfunction UER 29 VOLTAGE MONITOR OUTPUT OPTIONS 29 High Voltage On Lamp HVL 29 High Voltage Watchdog WDL 30 Electrode Voltage Percent Based Watchdog EVP 30 Actual Voltage Percent Based Watchdog AVP 30 FAULT OUTPUT OPTIONS 31 Fault Pulse FPL 31 Any Fault Alarm AFA 31 Pinhole Alarm PHA 31 Metal Contact Alarm MCA 32 Multi Pinhole Alarm MPA 32 Gross Barewire Alarm GBA 33 Any ...

Страница 5: ...ETERS 41 FIELDBUS SPARK TESTER PARAMETER ADDRESSES 42 CIC XM UTILITY 44 CALIBRATION 46 ST CAL CALIBRATION 46 HF CAL CALIBRATION PROCEDURE 46 Connecting the HF CAL 46 Taking Calibration Readings 47 Adjusting the Calibration 47 EVM CALIBRATION PROCEDURE 48 Connecting the EVM 48 Taking Calibration Readings 48 Adjusting the Calibration 49 MAINTENANCE 50 FUSES 50 PERIODIC INSPECTION 50 TROUBLESHOOTING ...

Страница 6: ...lation 2014 30 EU EMC Directive 2014 35 EU Low Voltage Directive The following Harmonized standards and technical specifications have been applied CISPR 11 Edition 5 0 2009 A1 2010 Conducted Emissions Group 1 Class A CISPR 11 Edition 5 0 2009 A1 2010 Radiated Emissions Group 1 Class A IEC 61000 4 2 2008 Electrostatic Discharge IEC 61000 4 3 2006 A1 2007 A2 2010 Radiated Immunity IEC 61000 4 4 2004...

Страница 7: ...Model HF 15B High Frequency Spark Tester HF 15B Instruction Manual Page 6 Specifications ...

Страница 8: ...Model HF 15B High Frequency Spark Tester HF 15B Instruction Manual Page 7 ...

Страница 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...

Страница 10: ...nd the test product for safety reasons many times this warning is ignored In this situation both the spark tester and the entire length of the wire line will radiate these 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 Caution Ozone Production Ozone is a naturally occurring gas O3 an...

Страница 11: ...acitor discharge energy of 50 Joules watt seconds is regarded as hazardous Clinton DC spark testers are current limited to 5 milliamperes or less Three kilohertz spark testers are limited to 4 milliamperes or less and 60 Hz types to 7 milliamperes Impulse spark testers can deliver a maximum charge of about 2 Joules 248 times per second All these spark testers have current outputs above the reactio...

Страница 12: ...s returned for calibration or service at some future time The following items are packed with the spark tester 1 HF 15B 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 fo...

Страница 13: ...quipment 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 moun...

Страница 14: ...k tester 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...

Страница 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...

Страница 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...

Страница 17: ...linton Instrument 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 HF 15B 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 rega...

Страница 18: ...s shown in the 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 Pri...

Страница 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...

Страница 20: ...cle the Voltage display through the Percent Load and the Set Point Values UP DOWN ARROW VOLTAGE ADJUST buttons The spark test voltage may be adjusted from 0 to 15 000 volts 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 digit fault counter registers a coun...

Страница 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...

Страница 22: ...rmal 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 con...

Страница 23: ...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 The ...

Страница 24: ...oss bare wire conditions and Voltage Watchdog Fault Typing Detecting the flow of current during spark testing has always been the standard in spark testing The HF 15B 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 Pi...

Страница 25: ...uce the test voltage in real time Our old HF 20E units had this in a meter form and people have asked to have it returned Fault output options remove voltage on fault for Alarm Modes Spark 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 th...

Страница 26: ...e Spark Tester Outputs section of this manual This configures the Output Function assigned 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 ...

Страница 27: ...Display 0 Configuration Menu Access 1 Configuration Menu Access Voltage Adjust 2 Configuration Menu Access Voltage Adjust 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 settings associated with fault detection for the unit This configures the unit s fault s...

Страница 28: ... pulse calculation EX 2 Inch Electrode 3333 Feet per minute The Fault Resolution FR may be set to Auto AUT or set to a numeric value in inches between faults AUT Auto mode uses default information 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 Externa...

Страница 29: ...en B is held for no less than 5 seconds a progress bar will be displayed and the unit will enter Manual Calibration mode For more information see the Manual Calibration Section of this manual When B is held for no 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 loc...

Страница 30: ...put will not do anything under any condition Cover Open CVO This output will change state when the safety interlock cover is open If the safety interlock cover is closed the spark tester is able to produce high voltage Unit Malfunction UER This output will change state when there is a hardware malfunction that could cause the unit to operate outside of acceptable limits Voltage Monitor Output Opti...

Страница 31: ...ode Voltage Percent Based Watchdog EVP The EVP 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 t...

Страница 32: ... 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 output will change state until it is reset at the front panel or remotely Remove Voltage on Fault The output will change state and the test voltage will be disabled until it is reset at the front panel or remotely Any Fault Alarm Time AFMS Set in second...

Страница 33: ...pe 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 reset at the front panel or remotely Metal Contact Alarm Time MCMS Set in seconds 01 5 0 If MCMO is set to NLC this is the time for which the output will change state Multi Pinho...

Страница 34: ...wire 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 is set to NLC this is the time for which the output will change state Any Fault Limit AFL This output will change state when the Any Fault Count is equal to...

Страница 35: ...an 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 interface This output will change state when the conditions of the COLT are met Fault Combination Limit Mode COLT 0 The output will change state when either the Pinhole Count or the Multi Pinhole Count are equal to or greater tha...

Страница 36: ...l 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 Latch Mode The output will change state for the configured APMS time Latch Mode The output will change state until it is reset at th...

Страница 37: ...ign 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 re...

Страница 38: ...Model HF 15B High Frequency Spark Tester HF 15B Instruction Manual Page 37 Spark Tester Configuration USB Contact factory for details at support clintoninstrument com ...

Страница 39: ...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...

Страница 40: ...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 PL...

Страница 41: ... 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 ...

Страница 42: ...dbuses that are supported by the HF 15BX 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 Address...

Страница 43: ...sequent changes must use a value that differs from the previous one For example to activate either of these commands again their values could be changed to 0 Command Address R W Notes RESERVED 0 RESERVED 1 REMOVE VOLTAGE COMMAND 2 W Will turn off on the voltage without changing the setpoint AF RESET COMMAND 3 W Will reset All Fault Alarms REMOTE ENABLE 4 RW Enables Data writes from External bus SE...

Страница 44: ...by Fault Count Reset GB COUNT LIMIT STATUS Bit 13 R Set if GB Count GB Count Limit cleared by Fault Count Reset FAULT CO LIMIT STATUS Bit 14 R Set if Fault Co Count Fault Co Count Limit cleared by Fault Count Reset AVSP WD PERCENT STATUS Bit 15 R Set when Actual Voltage is within the AVSP Percent of the Setpoint Below are the individual bits for Status Word 1 EVSP WD PERCENT STATUS Bit 0 R Set whe...

Страница 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...

Страница 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 ...

Страница 47: ... CAL Calibration The HF 15B can be calibrated through an automated process using the STCAL system with an HFVM To perform the calibration with the STCAL please follow the instructions for the STCAL system HF CAL Calibration Procedure The HF 15B can be manually calibrated with the HF CAL Please follow the instructions below Connecting the HF CAL 1 Insert the banana plug on the green colored ground ...

Страница 48: ...he display is locked you will need to unlock the display with the PIN See RC Security section for more information 3 Press the Down Arrow until MCAL is displayed on the voltage display Adjusting the Spark Tester Output voltage 4 Press the B button for several seconds until VOUT is displayed on the voltage display 7 Press the R button The Fault Count display should show S 00 0 representing the set ...

Страница 49: ...s complete press the A button once to exit the Manual calibration mode 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 parall...

Страница 50: ...isplay 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 is not within the rated specification for the HF 15B Press the CR button The Fault Count display will change to 01 0 14 Using the UP DOWN arrows adjust the reading on the ...

Страница 51: ...o 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 not expected to fail in normal operation Their failure may be an indication of equipment malfunction requiring quali...

Страница 52: ...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 always vi...

Страница 53: ... 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 E CV0 1 The cl...

Страница 54: ...rt for the auxiliary equipment to recognize 2 Check 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...

Страница 55: ...sy Bead Chain only for BD 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 92356i Assy Transformer High Voltage 15kV HF 15B Only 03004 Switch Interlock 92283 4 Pin Terminal Block Connector Kit Green 91069 9 Pin Terminal Block Connector Kit Green 03780 Power Cord 91463G End Guard HF 15B BD 12 and BD ...

Страница 56: ... the factory or to your Clinton sales representative for evaluation Optional Accessories Part Number Description FS 4 Floor Stand for HF 15B 39 42 Adjustable wire line height FS 4A Floor Stand for HF 15B with BR 3A or BRTC electrodes X3B W 91224G Plate Horn Light for HF 15B BD 12S X3B W 91223G Plate Horn Light for HF 15B BD 22S STCAL HF STCAL High Frequency Calibration System STCAL SM Sensitivity ...

Страница 57: ...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...

Страница 58: ...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 ...

Страница 59: ...Model HF 15B High Frequency Spark Tester HF 15B Instruction Manual Page 58 Grounding of Conductors during the spark test ...

Страница 60: ...Model HF 15B High Frequency Spark Tester HF 15B Instruction Manual Page 59 ...

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