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Clinton DC-1 Instruction Manual

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Models DC-1, -10 and -20B DC Spark Testers
Instruction Manual
DCDC-20B/BD-12S shown with optional X3B Horn/Light Tower
Clinton Instrument Company
295 East Main Street
Clinton, CT 06413 USA
DC-1, -10, -20B Instruction Manual – Page 0
Telephone: 860.669.7548 Fax: 860.669.3825
www.clintoninstrument.com

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Summary of Contents for Clinton DC-1

  • Page 1 Models DC-1, -10 and -20B DC Spark Testers Instruction Manual DCDC-20B/BD-12S shown with optional X3B Horn/Light Tower Clinton Instrument Company 295 East Main Street Clinton, CT 06413 USA DC-1, -10, -20B Instruction Manual – Page 0 Telephone: 860.669.7548 Fax: 860.669.3825...
  • Page 2 Models DC-1, -10, -20B DC Spark Testers Rev Null b0002 10/11/17 DC-1, -10, -20B Instruction Manual – Page 1...

  • Page 3: Table Of Contents

    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 ............................
  • Page 4 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 DC-1, -10, -20B Instruction Manual – Page 3...
  • Page 5 ERIODIC NSPECTION TROUBLESHOOTING ..................................50 ..................................51 ETTING ACTORY EFAULTS REPLACEMENT PARTS ..................................52 OPTIONAL ACCESSORIES.................................. 53 FS-4 FLOOR STAND ASSEMBLY ................................. 55 GROUNDING OF CONDUCTORS DURING THE SPARK TEST ....................... 56 DC-1, -10, -20B Instruction Manual – Page 4...

  • Page 6: Declaration Of Conformity

    Models DC-1, -10, -20B DC Spark Testers Declaration of Conformity EU Declaration of Conformity DC-1, -10, -20B Instruction Manual – Page 5...

  • Page 7: Specifications

    Models DC-1, -10, -20B DC Spark Testers Specifications DC-1, -10, -20B Instruction Manual – Page 6...
  • Page 8 Models DC-1, -10, -20B DC Spark Testers DC-1, -10, -20B Instruction Manual – Page 7...

  • Page 9: Safety

    • 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.

  • Page 10: Avoid The Risk Of Fire

    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.
  • Page 11 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, February 1972. DC-1, -10, -20B Instruction Manual – Page 10...

  • Page 12: Installation

    After it is wired, it will plug into the terminal block on the back of the spark tester 6. RS-485 connecting cable 1 Foot Long 7. Quick Start Guide 8. Short Manual DC-1, -10, -20B Instruction Manual – Page 11...

  • Page 13: Site Preparation

    The unit may be mounted on a table or on a Clinton floor stand and should be placed at wire line height and within easy reach of the operator. For detailed dimensions of the spark tester, please see the specification sheet.

  • Page 14: To Install Rc Display Onto The Dc-B

    (preferably green with a yellow stripe) to the crimp terminal. Fasten this to the ground stud and secure with the keps nut. Connect the other end to a safety ground system in accordance with EN 60204-1:1993, Section 5.2, Table 1. DC-1, -10, -20B Instruction Manual – Page 13...

  • Page 15: Terminal Block Wiring

    22 gauge or larger and should be stripped back ¼” (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 terminal. DC-1, -10, -20B Instruction Manual – Page 14...
  • Page 16 ABMS (Any Ba re Wi re Al a rm Ti me) ha s el a ps ed. *When connecting auxiliary equipment to dry relay contact pins 1, 2, 3,or 4, observe maximum ratings of 120VAC at 2 amps, 240VAC at 1 amp. DC-1, -10, -20B Instruction Manual – Page 15...

  • Page 17: Connecting The Serial Rs-485

    BA) The analog interface allows the DC-B to be controlled by a PLC with standard analog and Digital I/O. The connecting cable for this interface is not supplied by Clinton Instrument Company. The cable composition is normally dictated by the PLC, but ordinarily 22 gauge conductors (individually shielded or shielded pairs) are required.

  • Page 18: Unpacking The X3B

    X3B. The functions of pins 5-8 on the spark tester have now been transferred to pins 1-5 on the X3B terminal block. When the wiring is complete, plug in the power cords to both X3B and the spark tester. DC-1, -10, -20B Instruction Manual – Page 17...

  • Page 19: X3B To Spark Tester Connections

    1, 2, 3, 4, or 5, obs erve ma xi mum ra ti ngs of should be suitable for 24V low current 120VAC a t 2 a mps or 240VAC a t 1 a mp. applications. DC-1, -10, -20B Instruction Manual – Page 18...

  • Page 20: Spark Tester Controls

    Pressing the “B” button will momentarily cycle through the 4 additional fault count values. (Pinhole, Metal Contact, Multiple Pinhole, Gross Bare Wire) “CR” COUNT RESET button Pressing the “CR” button will reset all fault count values. DC-1, -10, -20B Instruction Manual – Page 19...

  • Page 21: Fault Light

    Metal end guards on each end of the high voltage test module prevent the operator from reaching into the energized electrode. The test product should be centered in the electrode to avoid damage to the product. DC-1, -10, -20B Instruction Manual – Page 20...

  • Page 22: Definition Of Terms

    (See Latch, Non-Latch, & Remove Voltage on Fault, below). Electrode Voltage- This is a new feature, exclusive to Clinton’s DC-B spark tester, a separate circuit makes a direct connection to the spark tester electrode. The voltage is monitored by a high impedance sensing circuit providing immediate data about the voltage at the electrode.

  • Page 23: New Features

    The bead chains are now arranged at an angle, eliminating gaps between hanging beads, and providing the best coverage around the product at all times. DC-1, -10, -20B Instruction Manual – Page 22...

  • Page 24: Communication Modules

    DC-A and to plug it into the DC-B. The DC-B will function identically to the DC-A if the user does not wish to use any of the additional features. The bolt patterns on the bottom of the DC-B are the same as the DC-A for easy physical replacement. DC-1, -10, -20B Instruction Manual – Page 23...

  • Page 25: Spark Tester Configuration (Front Panel)

    Models DC-1, -10, -20B DC Spark Testers Automatic Calibration with STCAL System: When calibrating with Clinton Model ST-CAL, there is no need to open the equipment, or to make any physical adjustments during the process. The DC-B will communicate with a Tablet and Voltmeter to make all necessary adjustments.

  • Page 26: Configuration Menu Options

    This displays that the Fault Reset “FR” is assigned to the hardware input labeled “IN1”. This input is not re-assignable. This is the password (PIN) configuration menu. For sub menu items press B. DC-1, -10, -20B Instruction Manual – Page 25...
  • Page 27 This configures the unit’s maximum voltage using VLIM as a starting point to allow 2 decimal places. The setting of AUT will allow the maximum the unit will produce. “AUT”: Automatic maximum voltage “x.xx”: The value of the new limit DC-1, -10, -20B Instruction Manual – Page 26...
  • Page 28 See Fault Pulse Length in the “Definition of Terms” section of the manual for more information. “AUT”: Auto mode uses default information to calculate a fault pulse. DC-1, -10, -20B Instruction Manual – Page 27...
  • Page 29 Configures the unit’s RS-485 Baud Rate, where “XXX” is the Baud Rate in bps. This displays the current firmware version for the DC-B and the RC. This information will be useful when contacting Clinton Instrument Company for technical support. Press the “B” Button once to display the DC-B firmware version number.

  • Page 30: Spark Tester Inputs

    1 & 3. When these contacts close, the fault relay will return to a normal state. The interval that the contacts are closed must exceed 50 ms. Spark Tester Outputs DC-1, -10, -20B Instruction Manual – Page 29...

  • Page 31: General Outputs

    Set in kV. If the actual voltage goes above this set point, any “HVL” output will change state. – High Voltage Off Set in kV. If the actual voltage drops below this set point, any “HVL” output will change state. DC-1, -10, -20B Instruction Manual – Page 30...

  • Page 32: High Voltage Watchdog (Wdl)

    “AVWP” is 10%. If the actual voltage is between 9kV and 11kV the output will be high. Actual Voltage Watchdog Percent (AVWP) Set as a percentage. For more information on the Voltage Watchdog or Actual Voltage vs Electrode Voltage, see the “Definition of Terms” section of this manual. DC-1, -10, -20B Instruction Manual – Page 31...

  • Page 33: Percent Load Limit (Pll)

    Any Fault Alarm Time (AFMS) Set in seconds (.01 – 5.0). If “AFMO” is set to “NLC”, this is the time for which the output will change state. DC-1, -10, -20B Instruction Manual – Page 32...

  • Page 34: Pinhole Alarm (Pha)

    This output will operate in 2 different modes, “NLC”,”LCH”. The Multi Pinhole alarm will respond only to a ‘Multi Pinhole’ fault type. See the “Fault Typing” section of the manual for more information. DC-1, -10, -20B Instruction Manual – Page 33...

  • Page 35: Gross Barewire Alarm (Gba)

    This output will change state when the “Any Fault” Count is equal to or greater than the configured “AFLT”. Any Fault Count Limit (AFLT) Amount of counts allowed before the output responds. DC-1, -10, -20B Instruction Manual – Page 34...

  • Page 36: Pinhole Limit (Phl)

    Multi Pinhole Count are equal to or greater than the ‘’MPLT” or “PHLT”. “1”: The output will change state when either the Metal Contact count, or the Gross Bare Wire Count are equal to or greater than ‘GBLT’ or ‘MCLT’ DC-1, -10, -20B Instruction Manual – Page 35...

  • Page 37: Any Barewire Alarm (Abw)

    The output will change state until it is reset at the front panel or remotely. Any Pinhole Alarm Time (APMS) Set in seconds (.01 – 5.0). If “APMO” is set to “NLC”, this is the time for which the output will change state. DC-1, -10, -20B Instruction Manual – Page 36...

  • Page 38: Fault Typing

    Note: Although an accurate line speed is not required for Gross Barewire Fault Typing, the minimum length typed as a Gross Barewire Fault, (2.5 x Electrode Length) is reliant on an accurate line speed. DC-1, -10, -20B Instruction Manual – Page 37...

  • Page 39: Spark Tester Configuration (Usb)

    Models DC-1, -10, -20B DC Spark Testers Spark Tester Configuration (USB) Contact factory for details at support@clintoninstrument.com DC-1, -10, -20B Instruction Manual – Page 38...

  • Page 40: Testing Your Product

    Lateral wire vibration which may be imperceptible can cause phantom faults to register on the spark tester. Properly positioned guides installed at entry to and exit from the electrode can eliminate this condition. DC-1, -10, -20B Instruction Manual – Page 39...

  • Page 41: Rs-485 Interface

    The default Parameters are listed in the table below. Parameter Default Value Baud Rate 19,200 Data Bits Stop Bits Parity None Flow Control None Station Number DC-1, -10, -20B Instruction Manual – Page 40...

  • Page 42: Analog Interface

    Chassis ground, cable This should be used for the cable shield shield ground connection 0-10v remote output This is a 0-10V DC output 1 meg impedance proportional to the spark tester’s high voltage output. DC-1, -10, -20B Instruction Manual – Page 41...

  • Page 43: Fieldbus Communications Interface

    ** On the Profinet module is the Station Name is not set, the MS LED will flash 3 times. This value can be set by the Profinet Master. *** Specify the Output Words first followed by the Input Words. DC-1, -10, -20B Instruction Manual – Page 42...

  • Page 44: Fieldbus Spark Tester Parameter Addresses

    GPI 1 STATUS Bit 13 State of General Purpose Input 1 GPI 2 STATUS Bit 14 State of General Purpose Input 2 GPI 3 STATUS Bit 15 State of General Purpose Input 3 DC-1, -10, -20B Instruction Manual – Page 43...

  • Page 45: Cic Xm Utility

    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 right. Note the Read Only indicator. DC-1, -10, -20B Instruction Manual – Page 44...
  • Page 46 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. DC-1, -10, -20B Instruction Manual – Page 45...

  • Page 47: Calibration

    The following is a list of recommended equipment for use in calibrating the DC-B. • Electrostatic Voltmeter (EVM) – Manufactured by Sensitive Research • ST-CAL with LFVM – Manufactured by Clinton Instrument Company ST-CAL Calibration The DC-B can be calibrated through an automated process using the STCAL system with an LFVM.

  • Page 48: Taking Calibration Readings

    16. Press the “R” button until the Fault Count display does not have the S or *. Adjusting the Spark Tester Voltage Monitor 17. Using the UP/DOWN arrows change the voltage display to read “VMON” DC-1, -10, -20B Instruction Manual – Page 47...

  • Page 49: Maintenance

    ON/OFF power switch on the back panel of the unit. Two additional fuses that could be defective are found on the relay output printed circuit board, behind the back panel. Fuse Relay Fuse DC-1, -10, -20B Instruction Manual – Page 48...

  • Page 50: Periodic Inspection

    The red electrode mounting plate, clear cover, and bead chain assemblies are subject to damage and contamination that is not always visible. They should be replaced if current leakage occurs. Refer to the “Troubleshooting” section for assistance with electrical problems. DC-1, -10, -20B Instruction Manual – Page 49...

  • Page 51: Troubleshooting

    The voltage will need to be re-enabled through that port. The Fault Count Displays “E.HVD” 1. The high voltage will not turn on due to a possible hardware failure. Please contact the Clinton Instrument Company for assistance DC-1, -10, -20B Instruction Manual – Page 50...

  • Page 52: Setting Factory Defaults

    When factory defaults are set from the configuration menu, the unit will restore all settings to the default values. The only exceptions are that Serial Numbers and Calibration Information will be saved so that the unit will not need recalibration. DC-1, -10, -20B Instruction Manual – Page 51...

  • Page 53: Replacement Parts

    BD-22S Bead Chain Assembly 92241i Cover Clear Safety for BD-22 01554 Standoff-Ceramic 90819 Rubber Gasket for 01554 91113 Electrode Mounting Plate for BD-22 91111G End Guard BD-22 92211 Front Panel for RC Display DC-1, -10, -20B Instruction Manual – Page 52...

  • Page 54: Optional Accessories

    Models DC-1, -10, -20B DC Spark Testers Note: Printed circuit boards are carefully constructed and calibrated at the factory. Components are not supplied for field repair of boards. Please return faulty circuit boards to the factory or to your Clinton sales representative for evaluation.
  • Page 55 Warranty The information contained in this document is subject to change without notice. The Clinton Instrument Company makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties or merchantability and fitness for a particular purpose.

  • Page 56: Fs-4 Floor Stand Assembly

    10-1.5 mm Hex Nut 8 x 1.25 mm Hex Nut 8-1.5 x 25 mm Bolt Column Clamp Handle Inner Column Test Module Mounting Plate M6 Split Washer M6 x 16 mm Bolt Hex DC-1, -10, -20B Instruction Manual – Page 55...

  • Page 57: Grounding Of Conductors During The Spark Test

    Models DC-1, -10, -20B DC Spark Testers Grounding of Conductors during the spark test DC-1, -10, -20B Instruction Manual – Page 56...
  • Page 58 Models DC-1, -10, -20B DC Spark Testers DC-1, -10, -20B Instruction Manual – Page 57...

This manual is also suitable for:

Dc-10Dc-20b

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