Clinton DC-1 Manual de usuario

DC-1, -10, -20B Instruction Manual –Page 0

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

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

Clinton Instrument Company

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

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

Rev Null b0002 10/11/17

Models DC-1, -10, -20B DC Spark Testers 
 
DC-1, -10, -20B Instruction Manual –Page 2 
Contents 
DECLARATION OF CONFORMITY........................................................................................................................................................5 
SPECIFICATIONS ................................................................................................................................................................................6 
SAFETY ..............................................................................................................................................................................................8 
SAFETY SYMBOL .........................................................................................................................................................................................8 
ENVIRONMENTAL CONDITIONS...................................................................................................................................................................... 8 
AVOID THE RISK OF FIRE! .............................................................................................................................................................................9 
CAUTION:PACEMAKER WARNING .................................................................................................................................................................9 
ELECTRICAL SHOCK HAZARD FROM PRODUCTION LINE SPARK TESTERS..................................................................................................................9 
INSTALLATION .................................................................................................................................................................................11 
CAUTION:.............................................................................................................................................................................................11 
UNPACKING.............................................................................................................................................................................................11 
SITE PREPARATION....................................................................................................................................................................................12 
Select a suitable location for the spark tester: ................................................................................................................................ 12 
To mount the unit on a horizontal surface: ..................................................................................................................................... 12 
To install the unit on a Clinton floor stand: .....................................................................................................................................12 
To install RC Display onto the DC-B .................................................................................................................................................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) .............................................................................................................................................................16 
Unpacking the X3B ..........................................................................................................................................................................17 
Connecting the X3B ......................................................................................................................................................................... 17 
X3B to Spark Tester Connections.....................................................................................................................................................18 
SPARK TESTER CONTROLS ...............................................................................................................................................................19 
ON/OFF Power Switch ..................................................................................................................................................................... 19 
Voltmeter ........................................................................................................................................................................................ 19 
“A” Button .......................................................................................................................................................................................19 
UP/DOWN ARROW (VOLTAGE ADJUST) buttons............................................................................................................................. 19 
Fault Counter...................................................................................................................................................................................19 
“B” Button .......................................................................................................................................................................................19 
“CR” COUNT RESET button .............................................................................................................................................................. 19 
FAULT light ......................................................................................................................................................................................20 
“R” RESET button.............................................................................................................................................................................20 
High Voltage On Lamp ....................................................................................................................................................................20 
Bead Chain Electrode ......................................................................................................................................................................20 
Clear Protective Cover ..................................................................................................................................................................... 20 
Safety Interlock switch ....................................................................................................................................................................20 
Safety end guards............................................................................................................................................................................20 
DEFINITION OF TERMS ....................................................................................................................................................................21 

Models DC-1, -10, -20B DC Spark Testers 
 
DC-1, -10, -20B Instruction Manual –Page 3 
NEW FEATURES ...............................................................................................................................................................................22 
DISPLAY: ................................................................................................................................................................................................ 22 
FRONT PANEL SECURITY ............................................................................................................................................................................22 
BD-12S DESIGN (PATENT PENDING)..........................................................................................................................................................22 
COMMUNICATION MODULES .....................................................................................................................................................................23 
VOLTAGE WATCHDOG ..............................................................................................................................................................................23 
FAULT TYPING .........................................................................................................................................................................................23 
BACKWARDS COMPATIBLE.........................................................................................................................................................................23 
SPARK TESTER CONFIGURATION (FRONT PANEL) ............................................................................................................................24 
NAVIGATING THE CONFIGURATION MENU..................................................................................................................................................... 24 
RC DISPLAY SECURITY (PIN)....................................................................................................................................................................... 24 
CONFIGURATION MENU OPTIONS................................................................................................................................................................25 
SPARK TESTER INPUTS.....................................................................................................................................................................29 
High Voltage Enable (HVE).............................................................................................................................................................. 29 
Fault Reset (FR) ............................................................................................................................................................................... 29 
SPARK TESTER OUTPUTS .................................................................................................................................................................29 
GENERAL OUTPUTS...................................................................................................................................................................................30 
Output Disabled (OFF) .....................................................................................................................................................................30 
Cover Open (CVO):...........................................................................................................................................................................30 
System OK (SOK)..............................................................................................................................................................................30 
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 
Gross Barewire Alarm (GBA) ...........................................................................................................................................................34 
Any Fault Limit (AFL) .......................................................................................................................................................................34 
Pinhole Limit (PHL) ..........................................................................................................................................................................35 
Metal Contact Limit (MCL) .............................................................................................................................................................. 35 
Multi Pinhole Limit (MPL) ................................................................................................................................................................35 
Gross Barewire Limit (GBL).............................................................................................................................................................. 35 
Fault Combination Limit (FCL) –Must be configured via USB computer interface .........................................................................35 
Any Barewire Alarm (ABW) .............................................................................................................................................................36 
Any Pinhole Alarm (APH) .................................................................................................................................................................36 
FAULT TYPING .................................................................................................................................................................................37 
PINHOLE ..........................................................................................................................................................................................37 
DIRECT METAL CONTACT ................................................................................................................................................................ 37 
MULTI PINHOLE...............................................................................................................................................................................37 

Models DC-1, -10, -20B DC Spark Testers 
 
DC-1, -10, -20B Instruction Manual –Page 4 
GROSS BAREWIRE............................................................................................................................................................................ 37 
SPARK TESTER CONFIGURATION (USB)............................................................................................................................................38 
TESTING YOUR PRODUCT ................................................................................................................................................................39 
PREPARING YOUR PRODUCT FOR TESTING .....................................................................................................................................................39 
RS-485 INTERFACE ...........................................................................................................................................................................40 
RS-485 CONNECTOR ................................................................................................................................................................................ 40 
RS-485 PARAMETERS ...............................................................................................................................................................................40 
ANALOG INTERFACE ........................................................................................................................................................................41 
ANALOG INTERFACE PIN FUNCTIONS ............................................................................................................................................................41 
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......................................................................................................................................................................52 
OPTIONAL ACCESSORIES..................................................................................................................................................................53 
FS-4 FLOOR STAND ASSEMBLY.........................................................................................................................................................55 
GROUNDING OF CONDUCTORS DURING THE SPARK TEST ...............................................................................................................56 
 
 

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

DC-1, -10, -20B Instruction Manual –Page 5

EU Declaration of Conformity

Declaration of Conformity

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

DC-1, -10, -20B Instruction Manual –Page 6

Specifications

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

DC-1, -10, -20B Instruction Manual –Page 7

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

DC-1, -10, -20B Instruction Manual –Page 8

Safety

Safety Symbol

The symbols depicted below are safety symbols placed on spark test equipment.

It is important to understand the meaning of each.

Caution symbol. Caution- refer to the manual to protect against damage to the

equipment or to avoid personal injury.

Indicates Hot Surface. Do not touch.

Risk of electric shock symbol.

Earth ground symbol.

Environmental Conditions

The spark tester is designed to be safe under the following conditions:

• Indoor use.

• Altitude to 2000m.

• Temperatures 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

standards at the National Institute of Standards and Technology (NIST) or derived

by ratio type measurements. 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: support@clintoninstrument.com

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

DC-1, -10, -20B Instruction Manual –Page 9

Avoid the Risk of Fire!

Every time your wire line stops, be sure that the HV in the electrode goes off. If

the HV remains ON while your wire line is stationary, the wire insulation within

the electrode will heat and there is a danger of combustion. Refer to the table in

“Installation” labelled “Terminal Block connections,” under HV Enable on how to

safely install your spark tester.

Caution: Pacemaker Warning

Clinton Instrument Company strongly advises any individual using a pacemaker

or other such medical device to avoid operating or being in the vicinity of spark

testers. Current studies indicate that such medical devices can malfunction in the

presence of electrical and magnetic fields. When a fault occurs in the electrode

of a Clinton spark tester, both high and low frequency electromagnetic fields are

generated. The strengths of these emissions are unknown, since they depend on

test voltage and other variables. The danger is greater when a customer does not

ground the 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 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.

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

milliamperes for males and six milliamperes for females. At 3000 Hz. this value

increases to about 22 milliamperes for men and 15 milliamperes for women, DC

currents do not present the same let-go problems, but a subject can readily let go

at a level of 60 milliamperes. A continuous 60 Hz. current above 18 milliamperes

stops breathing for the duration of the shock only. Ventricular fibrillation may

occur above a level of 67 milliamperes. The reaction current level of 60 Hz. is

about .5 milliamperes. Above this level a muscular reaction can occur which can

cause a secondary accident. The DC and 3 kHz. Levels are probably considerably

higher. Capacitor 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 reaction level, but none above the let-go threshold level. Because of the

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