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Clinton DC-50B Instruction Manual

Dc spark testers
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Models DC-50B DC Spark Testers
Instruction Manual
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-50B

  • Page 1 Models DC-50B DC Spark Testers Instruction Manual 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...
  • Page 2 Model DC-50B DC Spark Testers Rev Null b0003 11/8/23 DC-50B Instruction Manual – Page 1...
  • Page 3 Select a suitable location for the spark tester: ..........................13 To mount the unit on a horizontal surface: ..................Error! Bookmark not defined. To install the unit on a Clinton floor stand: ..................Error! Bookmark not defined. To install RC Display onto the DC-B ..................... Error! Bookmark not defined.
  • Page 4 Fault Combination Limit (FCL) – Must be configured via USB computer interface ................. 39 Any Barewire Alarm (ABW) ................................39 Any Pinhole Alarm (APH) ................................. 39 FAULT TYPING ....................................41 PINHOLE ......................................41 DIRECT METAL CONTACT ................................41 MULTI PINHOLE ....................................41 DC-50B Instruction Manual – Page 3...
  • Page 5 ....................................53 ERIODIC NSPECTION TROUBLESHOOTING ..................................54 ..................................55 ETTING ACTORY EFAULTS REPLACEMENT PARTS ..................................56 OPTIONAL ACCESSORIES.................................. 56 FS-4 FLOOR STAND ASSEMBLY ................................. 58 GROUNDING OF CONDUCTORS DURING THE SPARK TEST ....................... 59 DC-50B Instruction Manual – Page 4...
  • Page 6 Model DC-50B DC Spark Testers Specifications DC-50B Instruction Manual – Page 5...
  • Page 7 Model DC-50B DC Spark Testers DC-50B Instruction Manual – Page 7...
  • Page 8 Risk of electric shock symbol. Earth ground symbol. Warning If the DC-50B is used in a manner not specified by the Clinton Instrument Co the protection provided by the equipment may be impaired and safety may be compromised. Dimensional Specifications RC/RM: 89mmH x 483mmW x 46mmD (3.5”...
  • Page 9 Model DC-50B DC Spark Testers 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.
  • Page 10 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-50B Instruction Manual – Page 11...
  • Page 12 6. FS-6G Floor Stand Components and hardware 7. X3B Horn/Light Tower with power cord and connecting cable kit 8. RS-485 connecting cable 1 Foot Long 9. Quick Start Guide 10. Short Manual DC-50B Instruction Manual – Page 12...
  • Page 13 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 Floor Stand beneath the DC-50B Electrode. If preferred, the RC can be installed on top of the DC-50B Electrode or in a rack or panel as far as 200 feet away from the DC-50B spark tester. RS-485 cables for connection of the DC-50B DC-50B Electrode to a computer or PLC must be purchased separately.
  • Page 15 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-50B Instruction Manual – Page 15...
  • 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-50B Instruction Manual – Page 16...
  • Page 17 Model DC-50B DC Spark Testers Connecting the Serial RS-485 The model DC-50B is equipped with an RS-485 serial interface allowing the spark tester to receive commands and exchange information with a PLC or computer. Programming and control of voltage settings, which can be done manually on the DC-B display, can also be done through this interface.
  • Page 18 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-50B Instruction Manual – Page 18...
  • Page 19 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-50B Instruction Manual – Page 19...
  • Page 20 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-50B Instruction Manual – Page 20...
  • Page 21 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-50B Instruction Manual – Page 21...
  • Page 22 (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 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-50B Instruction Manual – Page 23...
  • Page 24 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-50B Instruction Manual – Page 24...
  • Page 25 Model DC-50B 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 This displays that the High Voltage Enable “HVE” is assigned to the hardware input labeled “IN0”. This input is not re-assignable. This displays that the Fault Reset “FR” is assigned to the hardware input labeled “IN1”. This input is not re-assignable. DC-50B Instruction Manual – Page 26...
  • Page 27 RC 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. DC-50B Instruction Manual – Page 27...
  • Page 28 When “No”, the output will remain inactive. DBMS 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. DC-50B Instruction Manual – Page 28...
  • Page 29 See the “New Features” section of this manual for more information on Fault Typing. FLT1 Fault Filtering Mode. This mode is to prevent specific false counting problems. Consult the Factory for details at support@clintoninstrument.com “ON” Filter is Enabled “OFF” Filter is Disabled DC-50B Instruction Manual – Page 29...
  • Page 30 IP Address (1—255), Default (10) Ex. 10.10.10.101 IP Address (1—255), Default (10) Ex. 10.10.10.101 IP Address (1—255), Default (10) Ex. 10.10.10.101 IP Address (1—255), Default (10) Ex. 10.10.10.101 SUB0 Subnet Mask (1—255), Default (10) Ex. 10.10.10.101 DC-50B Instruction Manual – Page 30...
  • Page 31 Gateway (1—255), Default (10) Ex. 0.0.0.0 Gateway (1—255), Default (10) Ex. 0.0.0.0 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. FWTY Press the “B” Button once to display the DC-xxB firmware version number.
  • Page 32 Input functions are assigned to input pins labeled IN0 and IN1 located on the terminal block, so that the unit will perform the required task. High Voltage Enable (HVE) To enable high voltage, install a wire jumper, normally closed switch, or relay between pins 1 & 2. DC-50B Instruction Manual – Page 32...
  • Page 33 0 and disabled when the voltage is set to 0 or the voltage is disabled. High Voltage Enable (HVE) This output will change state when the unit meets all conditions to generate high voltage. DC-50B Instruction Manual – Page 33...
  • Page 34 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 the “New Features” section of this manual. DC-50B Instruction Manual – Page 34...
  • Page 35 See the “Definition of Terms” section of the manual for more information. Any Fault Alarm Mode (AFMO) – Non Latch Mode (NCL) The output will change state for the configured “AFMS” time. DC-50B Instruction Manual – Page 35...
  • Page 36 ‘direct metal contact’ fault type. See the “Fault Typing” section of the manual for more information. Metal Contact Alarm Mode (MCMO) – Non Latch Mode (NLC) The output will change state for the configured “MCMS” time. DC-50B Instruction Manual – Page 36...
  • Page 37 – Non Latch Mode (NLC) The output will change state for the configured “GBMS” time. – Latch Mode (LCH) The output will change state until it is reset at the front panel or remotely. DC-50B Instruction Manual – Page 37...
  • Page 38 Gross Barewire Limit (GBL) This output will change state when the “Gross Barewire” count is equal to or greater than the configured “GBLT”. Gross Barewire Count Limit (GBLT) Amount of counts allowed before the output responds. DC-50B Instruction Manual – Page 38...
  • Page 39 – Non Latch Mode (NLC) The output will change state for the configured “APMS” time. – Latch Mode (LCH) The output will change state until it is reset at the front panel or remotely. DC-50B Instruction Manual – Page 39...
  • Page 40 Model DC-50B DC Spark Testers 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-50B Instruction Manual – Page 40...
  • Page 41 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-50B Instruction Manual – Page 41...
  • Page 42 Model DC-50B DC Spark Testers Spark Tester Configuration (USB) Contact factory for details at support@clintoninstrument.com DC-50B Instruction Manual – Page 42...
  • Page 43 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-50B Instruction Manual – Page 43...
  • Page 44 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 DC-50B Instruction Manual – Page 44...
  • Page 45 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 proportional to the 1 meg impedance spark tester’s high voltage output. DC-50B Instruction Manual – Page 45...
  • Page 46 ** 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-50B Instruction Manual – Page 46...
  • Page 47 * 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 DC-50B Instruction Manual – Page 47...
  • Page 48 Profinet), plug in a micro-USB (shown on below left) or USB “B” (on below right) cable and run the CIC XConfig Utility. If the USB cable is not connected the CIC XConfig Utility will prompt for the USB cable as shown. DC-50B Instruction Manual – Page 48...
  • Page 49 (DeviceNet, Profibus, Modbus RTU) shown on the right. Update the IP Address information or the Node Address. Once edits are complete, press the Finish Button. The following screen will be shown indicating a power cycle is required. DC-50B Instruction Manual – Page 49...
  • Page 50 Model DC-50B DC Spark Testers Once power has been cycled the new values will be used. DC-50B Instruction Manual – Page 50...
  • Page 51 0 using the VOLTAGE ADJUST down arrow button. Turn OFF the spark tester. 2. With the power to the RC and DC-50B Spark Tester turned off connect the high voltage input on the EVM to the Spark Tester electrode. Use the shortest high voltage lead possible.
  • Page 52 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 DC-50B 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 DC-50B 15.
  • Page 53 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-50B Instruction Manual – Page 53...
  • Page 54 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-50B Instruction Manual – Page 54...
  • Page 55 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-50B Instruction Manual – Page 55...
  • Page 56 Front Panel for RC Display 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 57 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 Rail Floor Stand 91331G Carriage Bolt 5/16-18 x 3/4 91352 Foot Floor Stand Adjuster 91336G Nut Keps 5/16-18 90780 Washer #10 Lock Internal Tooth SS 02812 Screw 10-32 x 3/8 Truss hd Phillips SS 01933 DC-50B Instruction Manual – Page 58...
  • Page 59 Model DC-50B DC Spark Testers Grounding of Conductors during the spark test DC-50B Instruction Manual – Page 59...
  • Page 60 Model DC-50B DC Spark Testers DC-50B Instruction Manual – Page 60...