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Summary of Contents for Clinton TST-10B
- Page 1 TST-10B Wireless DC Spark Tester Model TST-10B Wireless DC Spark Tester Instruction Manual RCW and TSTB Clinton Instrument Company 295 East Main Street Clinton, CT 06413 USA TST-10B Instruction Manual – Page 0 Telephone: 860.669.7548 Fax: 860.669.3825 www.clintoninstrument.com...
- Page 2 TST-10B Wireless DC Spark Tester Rev Null b0010 5/12/2022 TST-10B Instruction Manual – Page 1...
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Page 3: Table Of Contents
“CR” COUNT RESET button ................................19 FAULT light ...................................... 20 “R” RESET button ..................................... 20 RF Status Indicator ..................................20 DEFINITION OF TERMS ..................................21 NEW FEATURES ....................................22 .................................... 22 RONT ANEL ECURITY TST-10B Instruction Manual – Page 2... - Page 4 DIRECT METAL CONTACT ................................37 MULTI PINHOLE ....................................37 GROSS BAREWIRE .................................... 37 SPARK TESTER CONFIGURATION (USB) ............................38 TESTING YOUR PRODUCT ................................39 ..............................39 REPARING YOUR RODUCT FOR ESTING RS-485 INTERFACE ................................... 40 TST-10B Instruction Manual – Page 3...
- Page 5 ........................................49 USES ....................................51 ERIODIC NSPECTION TROUBLESHOOTING ..................................52 ..................................53 ETTING ACTORY EFAULTS REPLACEMENT PARTS ..................................54 OPTIONAL ACCESSORIES.................................. 55 WARRANTY ..................................... 56 GROUNDING OF CONDUCTORS DURING THE SPARK TEST ....................... 57 TST-10B Instruction Manual – Page 4...
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Page 6: Declaration Of Conformity
TST-10B Wireless DC Spark Tester Declara TST-10B Instruction Manual – Page 5... -
Page 7: Specifications
TST-10B Wireless DC Spark Tester Specifications TST-10B Instruction Manual – Page 6... - Page 8 TST-10B Wireless DC Spark Tester TST-10B Instruction Manual – Page 7...
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Page 9: Safety
Risk of electric shock symbol. Earth ground symbol. Warning If the RCW or the TSTB is used in a manner not specified by Clinton Instrument the protection provided by the equipment may be impaired and safety may be compromised Dimensional Specifications RCW : 89mmH x 432mmW x 183mmD (3.5”... - Page 10 TST-10B Wireless DC Spark Tester 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.
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Page 11: Caution: Pacemaker Warning
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 12: Electrical Shock Hazard From Production Line Spark Testers
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. -
Page 13: Installation
5. RS-485 pairing cable 6 Foot Long 6. Antenna cable with magnetic base 7. Antenna with swivel base 8. TSTB Spark tester with Antenna 9. Quick Start Guide 10. Short Manual TST-10B Instruction Manual – Page 12... -
Page 14: Pairing The Rcw And Tstb
If necessary, the TSTB HV Test Module may be located as far as 50 feet from the RCW control unit. However, for best performance the RCW should be located as close to the TSTB as possible. TST-10B Instruction Manual – Page 13... -
Page 15: To Mount The Rcw On A Horizontal Surface
The exhaust of the external air extraction system should be discharged either outdoors or into some area well away from workers. TST-10B Instruction Manual – Page 14... -
Page 16: Power Wiring
Power Wiring Caution The RCW is intended to be powered from a power cord containing 18ga or larger conductors with a ground wire. Reference included Clinton Instrument Co. part number 03780. Mains Power: Note that the spark tester has a self-adjusting power supply with an operating voltage range of 100V to 240V at 47-63 Hz. -
Page 17: Antenna Installation Rcw
22 gauge or larger with double or reinforced insulation. The wires 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. TST-10B Instruction Manual – Page 16... - Page 18 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. TST-10B Instruction Manual – Page 17...
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Page 19: Connecting The Serial Rs-485
RCWA) The analog interface allows the RCW 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 AWG conductors (individually shielded or shielded pairs) are required. -
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. TST-10B Instruction Manual – Page 19... -
Page 21: Fault Light
Green – RF Link Status is Good. This is the optimal RF range for operation. Blue – RF Link Status is Excellent. In this case the RF power could be decreased until the RF Link Status indicator is green. TST-10B Instruction Manual – Page 20... -
Page 22: Definition Of Terms
This data is crucial to differentiate the different fault types. Fault Pulse- The fault pulse is a signal generated by the TST-10B when a defect is detected. This signal causes the front panel fault lamp to light, increments the fault counter, and initiates process control relays to change state. -
Page 23: New Features
Four output relays: One set of form C and three sets of form A relay contacts are located on the back of the RCW for easy connection to external alarms, lights, or machinery that will be TST-10B Instruction Manual – Page 22... -
Page 24: Fault Typing
The TST-10B will communicate with a Tablet and Voltmeter to make all necessary adjustments. Calibration results, Serial information, and other optional information is provided on a Calibration Certificate which can either be printed to a network printer or exported to a USB stick to keep for future records. -
Page 25: Rc Display Security (Pin)
“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. TST-10B Instruction Manual – Page 24... - Page 26 “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. TST-10B Instruction Manual – Page 25...
- Page 27 When “No”, the output will remain inactive. This delay used when voltage is called for till the voltage is output. This is in seconds. This configures the settings associated with fault detection for the unit. TST-10B Instruction Manual – Page 26...
- Page 28 Fault Typing. This configures the RF Module settings in both the RCW and TSTB. This configures the RF module’s channel. It is recommended that each RCW/TSTB pair have a unique channel. TST-10B 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 TST-10B and the RC. This information will be useful when contacting Clinton Instrument Company for technical support.
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Page 30: Spark Tester Inputs
Spark Tester Outputs Output Functions are designed to relay information to an alarm, PLC, etc. The Output functions can be assigned to output pins labeled ‘OUT 0, OUT 1, OUT 2, and OUT 3. TST-10B Instruction Manual – Page 29... -
Page 31: General Outputs
Set in kV. If the actual voltage drops below this set point, any “HVL” output will change state. Note – It is recommended that “HVOF” and “HVON” differ by at least .2kV and that “HVOF” never be set higher than “HVON”. TST-10B Instruction Manual – Page 30... -
Page 32: High Voltage Watchdog (Wdl)
Voltage, see the “Definition of Terms” section of this manual. Percent Load Limit (PLL) This output will change state when the percent load reaches or exceeds the Percent Load Limit PLLT. See the “Definition of Terms” section of the manual for more information. TST-10B Instruction Manual – Page 31... -
Page 33: Fault Output Options
This output will operate in 2 different modes, “NLC”,”LCH”. The Pinhole alarm will respond only to a ‘Pinhole’ fault type. See the “New Features” section of the manual for more information on fault typing. TST-10B Instruction Manual – Page 32... -
Page 34: Metal Contact Alarm (Mca)
‘Multi Pinhole’ fault type. See the “Fault Typing” section of the manual for more information. Multi Pinhole Alarm Mode (MPMO) – Non Latch Mode The output will change state for the configured “MPMS” time. TST-10B Instruction Manual – Page 33... -
Page 35: Gross Barewire Alarm (Gba)
Amount of counts allowed before the output responds. Pinhole Limit (PHL) This output will change state when the “Pinhole” count is equal to or greater than the configured “PHLT”. Pinhole Count Limit (PHLT) Amount of counts allowed before the output responds. TST-10B Instruction Manual – Page 34... -
Page 36: Metal Contact Limit (Mcl)
This output will operate in 2 different modes, “NLC”,”LCH”. The Any Barewire alarm will respond only to a Metal Contact or Gross Barewire fault type. See the “Fault Typing” section of the manual for more information. TST-10B Instruction Manual – Page 35... -
Page 37: Any Pinhole Alarm (Aph)
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. TST-10B Instruction Manual – Page 36... -
Page 38: Fault Typing
TST-10B Wireless DC Spark Tester Fault Typing The TST-10B has the ability to distinguish between four different types of faults. The four types of faults consist of: Pinhole, Metal Contact, Multi Pinhole, and Gross Barewire. PINHOLE A high voltage discharge where the electrode does not make physical contact with the conductor of the product being tested. -
Page 39: Spark Tester Configuration (Usb)
TST-10B Wireless DC Spark Tester Spark Tester Configuration (USB) Contact factory for details at support@clintoninstrument.com TST-10B 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. TST-10B Instruction Manual – Page 39... -
Page 41: Rs-485 Interface
PLC will need to poll REMOTE ENABLE (location 5) at least every 500ms to keep the unit from turning off the voltage. 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 TST-10B 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. TST-10B 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. TST-10B Instruction Manual – Page 42... -
Page 44: Fieldbus Spark Tester Parameter Addresses
* The value for the alarm modes is as follows: AF_ALARM *16 + ABW_ALARM * 4 + APH_ALARM ** The values are: 0 – startup, 1111h – initialization, 5555h- interface online (ready) *** The lower value (GPO_0 or GPO_2) is in the LSB and the upper in the MSB TST-10B Instruction Manual – Page 43... -
Page 45: Cic Xm Utility
To configure any of the active CompactCom™ modules (DeviceNet, Ethernet IP, Modbus RTU, Modbus TCP, Profibus, Profinet), plug in a micro USB cable 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. TST-10B Instruction Manual – Page 44... - Page 46 (DeviceNet, Profibus, Modbus RTU) shown on the right. Note the Read Only indicator. To modify these values, press the Edit Button. The Read Only indicator disappears indicating that the values can be modified. An example is shown below. TST-10B Instruction Manual – Page 45...
- Page 47 TST-10B Wireless DC Spark Tester 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. TST-10B Instruction Manual – Page 46...
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Page 48: Calibration
10B. • Electrostatic Voltmeter (EVM) – Manufactured by Sensitive Research • ST-CAL with LFVM – Manufactured by Clinton Instrument Company ST-CAL Calibration The TSTB can be calibrated through an automated process using the STCAL system with an LFVM. To perform the calibration with the STCAL please follow the instructions for the STCAL system. -
Page 49: Taking Calibration Readings
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 TST-10B Press the “CR” button. The Fault Count display will change to “*.01.0”. 14. Using the UP/DOWN arrows adjust the reading on the EVM until the reading is within the rated tolerance for the TSTB or as close to the value on the Fault count display. -
Page 50: Maintenance
(T2AH), CIC Part Number 92665. Failure to install the proper fuse may cause damage to the equipment. Fuse After the fuse is replaced the RCW shall be tested prior to the equipment being returned to service. TST-10B Instruction Manual – Page 49... - Page 51 Relay Fuse After a fuse is replaced the operation of the RCW as well as the equipment connected to the relay terminals should be checked for proper operation prior to being returned to service. TST-10B Instruction Manual – Page 50...
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Page 52: 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. TST-10B Instruction Manual – Page 51... -
Page 53: Troubleshooting
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 After adjusting the voltage with the product in the electrode, a lower voltage is displayed. -
Page 54: 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. TST-10B Instruction Manual – Page 53... -
Page 55: Replacement Parts
Wire High Voltage 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 56: Optional Accessories
Electrode Brush 0.2” max Prod DIA, 2” L BD-051 Miniature Bead Chain Electrode 92273-DN Module CompactCom DeviceNet 92273-EI Module CompactCom EtherNet/IP 92273-MR Module CompactCom Modbus RTU 92273-MT Module CompactCom Modbus TCP 92273-PB Module CompactCom Profibus 92273-PN Module CompactCom Profinet TST-10B Instruction Manual – Page 55... -
Page 57: Warranty
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 58: Grounding Of Conductors During The Spark Test
TST-10B Wireless DC Spark Tester Grounding of Conductors during the spark test TST-10B Instruction Manual – Page 57... - Page 59 TST-10B Wireless DC Spark Tester TST-10B Instruction Manual – Page 58...
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