®
PRECISION INSTRUMENTATION
Operator’s Handbook
for
Compact
High Voltage
P20, P40 & P60
POROSITY (HOLIDAY) DETECTORS
Complies with the requirements of:
Australian Standard AS3894.1-2002,
ASTM G62-87(1998), NACE RP0274-98,
NACE RP0490-2001, NACE RPO188-99, ASTM D4787-93(1999),
JIS G-3491, JIS G-3492, ANSI/AWWA C214-89,
ANSI/AWWA C213-94 and ISO 2746:1998
CE Marked PCWI Compact Detectors comply with the requirements
of EMC Directives 89/336/EEC EMC and its amending directives.
CERTIFICATE OF CALIBRATION
Model : Compact Detector
Manufacturer: PCWI Technology Pty Ltd
Serial No:. ………………..
Tolerance:. ±5%
Offi e:
Postal:
Email:
Web:
Phone:
Intl:
Fax:
c
13 Alhambra Avenue
CARDIFF NSW 2285
Newcastle - Australia
PO Box 900
HUNTER REGION MC
NSW 2310
@
sales pcwi.com.au
www.pcwi.com.au
(02) 4954 3900
+61 2 4954 3900
(02) 4954 3999
Conformance: This detector has been tested at a series of voltages from
0 to 60,000 Volts against a Certified Meter and High
Voltage Probe, Report Number 209852 / Pulse Crest Meter
Report Numbers 01-01851-A, 01-01851-B, 01-01851-C,
01-04258-A, 54019, 54819 and 723 0135/03, using
AS 2886-1986 as a guide. The Detector complies with
PCWI Standards of Manufacture.
PCWI’s Laboratory complies with the requirements of AS
ISO/IEC 17025-1999 ‘general requirements for the
competence of testing and calibration laboratories’. All
calibrations are traceable to National and International
Standards.
Note: It is recommended that the unit be periodically checked
prior to use with a Certified PCWI Crestmeter.
SIGNED: ___________________
Laboratory Technician
PCWI Technology Pty Ltd ABN 96 0 783 373 54
Quality System
Quality
Endorsed
Company
ISO9001
Lic 13066
CONTENTS
1.0 Safety Precautions...................................................................2
2.0 Operation...............................................................................3
3.0 Specifications .........................................................................4
4.0 Control Panel Layout................................................................5
5.0 Voltage Recommendations....................................................6-7
6.0 T roubleshooting...................................................................8-9
7 .0 Optional Accessories.........................................................10-11
8.0 Warranty..............................................................................12
9.0 Service.............................................................inside back page
INTRODUCTION
Thank you for choosing the PCWI Compact for pre-installation and
post installation corrosion detection.
PCWI have designed this instrument with care, to provide ongoing
corrosion detection efficiency under a wide variety of coating
application conditions and to ascertain Porosity for the many protective
coatings currently in use. Under reasonable care in operation, the unit
will provide many years of trouble free detection.
To support the unit, PCWI maintain a comprehensive range of
Electrodes (probes) - extending the versatility of the Compact from
large to small and from accessible to inaccessible surfaces.
PCWI, in a continuing desire to achieve the maximum in corrosion
detection competence, welcomes user enquiries and
recommendations.
Y ours sincerely
Paul V an Gaal
WARNING
Unlike continuous direct current units where the electrical field
drops to zero when contact is made and where the probe is
earthed out via the body, Pulsed Detectors will continue to
shock at full voltage. Caution should be taken to avoid
contact with the live electrode.
Please consult these operating instructions before use.
1
1.0 SAFETY PRECAUTIONS:
All hand-held high voltage test equipment should be operated
by responsible, trained and authorised personnel.
The unit must be earthed to both the item under test and to
ground.
CAUTION
The Detector output can be up to 65,000 volts. Should the
operator accidentally make contact with the test electrode, they
may experience a mild shock or zap, and in order to avoid this
possibility , the wearing of rubber gloves is recommended.
Furthermore, the operator should enjoy good health and not
suffer from a cardiac condition. If the operator has a
pacemaker , then they should not use this equipment.
This equipment should only be used for the purpose for which it
was designed, ie: checking the porosity, or electrical
breakdown, of dielectric or insulating materials.
It is also recommended that testing should be carried out well
clear of personnel not involved in the testing procedure, or in
such a position whereby the surprise of receiving an electric
shock could cause a related accident, if for example, tests
being carried out close to moving or rotating machinery, or in
such an unstable position that the operator could fall and injure
themselves.
DANGER
2
It is recommended that the operator should have an assistant,
to ensure that unauthorised personnel are kept well clear of the
testing area, and generally assist when necessary with the
testing procedure. It is also recommended that the Detector not
be operated within close proximity of sensitive electronic
apparatus, such as computer equipment.
Do not use the test equipment in any combustible or flammable
atmosphere, as a test voltage can cause an arc or spark to be
generated and an explosion could result.
Always consult the plant or safety officer before carrying out a
test procedure.
When testing tank internals, be certain the tank does not
contain solvents remaining from the painting procedure.
Coating Thickness Range
Applied coats should be cured, thickness tested, visually inspected
and accepted – before high voltage porosity testing is carried out.
Coating thickness should be above 150µm; coatings below this
thickness should be tested with a wet sponge unit.
2.0 OPERATION
Connect the probe and earth leads to the unit. Connect the earth
clamp to the metallic substrate of the item to be tested –
substrate should be earthed to ground. Select the probe best
suited for the test and attach to the probe handle.
Fit the Fuse (if not already fitted).
Turn the unit on.
Test the batteries to ensure that they are charged.
Adjust the voltage control to the required test voltage.
Place the probe near the metal substrate.
A spark should occur (if not re-check all leads and connections).
The unit should now be ready for use.
Re-check the output – adjust if necessary.
Place the probe on the coated surface and move at
approximately one metre per four seconds.
A fault is indicated by:
A spark at the probe – this can usually be seen and heard.
A light flashes on the front panel of the unit.
An audible sound – buzzer is mounted inside the unit.
Note: A definite flaw should be made in the coating and located with the
designated test voltage, therefore proving that the unit is locating the
type of fault you wish to find.
Probes must be kept in full contact with the surface, gaps in or between
the probe and the coating may result in flaws going undetected.
Wire brushes, rubber and coil spring probes should all be kept in good
condition.
Probes other than fine wire brushes may require higher voltages.
3
Earthing
Where the item to be tested is not earthed to ground, a ground spike
must be attached.
The unit should always be switched off before removing and
repositioning the earth lead. After the earth is repositioned, the
probe should always be flashed on the substrate to prove a good
contact has been made.
3.0 SPECIFICATION
P20 P40 P60
Unit weight: 2.2kg 2.2kg 2.2kg
Packed weight: 6.0kg 6.0kg 6.0kg
Display: LED LED LED
Voltage: to 20kv 5 to 40kv 10 to 60kv
Resolution: 100v 100v 100v
Alarm range: 1 to 20kV 5 to 40kV 10 to 60kV
Short circuit test current: 1.5mA max 500µa max
Power supply: Gel Cell 3Ah Clip On
Dimensions: 260 x 160 x 70mm
Alarm: Audible
Probe handle: Rubber lead
Battery condition: LED Indicator
Optional coils & brushes available: See accessories pages
STORAGE:
The Detector should be stored in a dry place. Leads should not be
wound tightly . Battery should be fully charged.
4
4.0 CONTROL PANEL LAYOUT
1
40.07
40.07
c
pa tCom
e
s
lP
u
1 LED display
2 On/Battery condition indicator Light
3 Visual alarm indicates when fault is found
4 Voltage Up
5 Voltage Down
6Off
7O n
8 Audible alarm when fault is found
9 Earphone (connected on opposite side)
10 Fuse (4A slow blow) 5 x 20mm
11 Earth connection point
12 Alarm sensitivity ‘wet’ or ‘dry’ conditions
(located in battery compartment of Pulse 20 and Pulse 40 only)
13 Charge connector
14 Clip-on power pack
kV
Pulsed
Porosity
Detector
2
7
6
On Batt
On
Off
Alarm
3
4
5
8
9
FUSE
T
10
4A
250V
11
13
12
14
5
5.0 VOLTAGE RECOMMENDATIONS
AS 3894.1 recommends minimum voltages for testing
specified thickness of film of various Coating Products
Tables 1 and 2 below provide guidance for determination of
minimum voltage for high voltage porosity testing of the indicated
generic types of coating products, at the indicated dry film
thicknesses which may contain residual solvents.
Table 1. Determination of the coating film factor (F)
from coating type and volume solids content.
Generic Type of Coating
Volume Solids %(V/V)
Chorinated rubber, Vinyl 15 to 39 4
Low Build Epoxy, some Tar Epoxy 40 to 59 3 150 3.00 1.50 1.00 0.75
High Build Epoxy, some Tar Epoxy 60 to 79 2 250 4.00 2.00 1.30 1.00
Polyester/Vinyl esters, Solventless
Epoxy, Fusion-bonded Epoxy
Volume Solids
%(V/V)
Factor (F)
80 plus 1
Factor
(F)
Formula 1
Table 2. Determination of the minimum test
voltage (V) from dry film thickness (T)
and coating material factor (F).
Nominal dry film
thickness in microns
400 5.00 2.50 1.60 1.25
600 6.10 3.00 2.00 1.50
800 7.00 3.50 2.30 *
1500 9.70
2500 12.50 * * *
4000 15.80 * * *
Minimum Test Voltage (kV)
F=1 F=2 F=3 F=4
4.80 * *
V = minimum test voltage applied in volts
T = dry film thickness of cured coating in microns
F = a whole number factor which rates a coating’s
generic type and residual solvent content (T able 1)
The above minimum test voltages have been derived from
Australian Standard AS3894.1-2002; the whole of this Standard
should be used. The above voltages relate to the following: the
detector should have a direct earth connection to the substrate and
a fine wire brush electrode must be connected to the probe.
6
International Standards
NACE RP0274-98 derived table
Table 3 below is derived from NACE standards and should be
used as a guide only.
Table 3. kV Values from
NACE RP0274-98
mm kiloVolts
0.51 6
0.79 7
1.6 10
2.4 12
3.2 14
4.0 16
4.8 17
13 28
16 31
19 34
The above table should be taken as a GUIDE only. It is
recommended that the whole of this standard be used.
7
6.0 TROUBLESHOOTING
Alarm Sensitivity Control (for use with P20 and P40 only)
Located on the base of the P20 & P40 compacts, underneath the
battery pack, is an alarm sensitivity control switch.
This switch enables the operator to set the alarm sensitivity by
selecting the most appropriate setting when working in conditions
where the coating surface is wet.
The control “pot” can be adjusted to:
‘Dry’ For normal function in dry conditions
‘Wet’ For alarm function in wet conditions
Note: The P60 is used only for dry coating surfaces. It does not
incorporate a control switch.
8
Symptom Cause Solution
No Display
Display voltage
drops during test
Alarm sounds
continuously
during test
No alarm on fault
Flat battery
No Power - fuse not fitted
Slightly conductive, damp or salty
surface
Coating may not be fully cured
Probe surface area too large
Damp or wet surface
Coating may not be fully cured
Probe moved too fast
Probe surface area too great
Sensitivity adjusted at too low a
setting
Voltage set too low
Recharge battery
Fit fuse
Wash and clean the surface
Set Alarm Sensitivity Control to ‘Wet’
(Control is located in battery compartment
of P20 and P40 only. Not on P60.)
Allow coating to cure
Use a smaller probe, or increase
voltage
Set Alarm Sensitivity Control to ‘Wet’
(Control is located in battery compartment
of P20 and P40 only. Not on P60.)
Allow coating to cure.
Move probe 1 metre every 4 seconds
Use smaller probe
Increase sensitivity
Increase voltage
No spark at
probe tip
Probe voltage
lower than display
voltage
Damaged leads
Poor connections
Flat Battery
Damaged HV lead
Poor Earth connection
Repair or replace leads
Clean and reconnect
Recharge battery
Replace lead
Check all connections
9
7.0 OPTIONAL DETECTOR ACCESSORIES
Crest Meters & Certification.
50mm (2in) to 600mm (24in) wide flat brushes.
25mm (1in) to 500mm (20in) Spiral wound and Disc Internal
circular pipeline brushes.
25mm (1in) to 500mm (20in) External circular pipeline brushes.
10
60mm, 125mm, 200mm, 450mm connectors for flat or external
pipeline brushes.
Fan Brushes
450mm covered probe extensions.
Spare slip-out power packs.
7m Earth lead with clamp.
10m trailing Earth lead (1m plastic encased).
50mm (2in) to 1765mm (72in) Coils complete with ball bearing
ends.
Coil Joiners.
11
8.0 WARRANTY
Subject to the warranty conditions below this PCWI Instrument is warranted by
PCWI International Pty Ltd to be free from defects arising from faulty design,
material, or workmanship for a period of 12 months from the date of original
purchase by the end user or a maximum period of 15 months from dispatch to
authorised distributor.
Probes and leads are warranted for 3 months. They are consumable items, and
subject to wear and deterioration during use. The life of these parts can be much
extended by keeping them in a dry clean condition, and storing them in suitable
protective containers. During use, avoid “scrubbing” the probe along the surface of
the work-piece.
WARRANTY CONDITIONS
During the warranty period listed above PCWI or it’s authorized service
representative will make good any defects covered by this warranty .
PCWI or it’s authorised service representative will decide if there are any defects in
design, material or workmanship.
This warranty only applies provided the instrument has been used in accordance
with the manufacturers operating handbook recommendations.
This warranty does not cover damage, malfunction or failure resulting from misuse,
neglect, abuse or used for a purpose for which it was not designed and no repairs,
alterations or modifications have been attempted by other than PCWI on an
authorized service.
This warranty applies only to the original user buyer.
This warranty does not cover any service that is needed after an accident,
alterations, misuse, fire or floods.
This warranty is the only one given by PCWI and no one has the authority to change,
or add to, the obligations and liabilities listed in it.
This warranty does not cover batteries, probe handle brushes (electrodes) and
leads which are subject to wear.
During the warranty period PCWI or its authorized service representative will bear
the transportation cost of the return of instrument/s repaired under warranty back to
the users premises within the country of purchase.
HOW TO MAKE A WARRANTY CLAIM
Defective goods must be returned to PCWI or an authorized service representative
at the Purchaser’s expense. The goods must be accompanied by the Purchaser’s
written order describing the defect and authorising PCWI or its authorized service
representative to invoice the Purchaser for any charges not covered by the warranty .
The purchasers order must also include the model and serial numbers of the
instrument and address of the distributor and date of purchase.
Upon receipt at the service point the instrument will be examined to determine the
nature and cause of the defect.
If the defect is covered by the warranty, a repair will be effected at PCWI’s or
authorized service representative expense. If the defect is not covered by the
warranty, PCWI or authorized service represent ative will quote the Purchaser for a
replacement or repair, and will not proceed until written accept ance of the quotation
is received.
12
9.0 SERVICE AND MAINTENANCE
AUTHORISED SERVICE REPRESENTATIVE
To enable speedy “return to service” whether under warranty or otherwise, PCWI
have appointed your distributor as a service centre and have provided all relevant
information and recommended parts to be carried to assist distributor’s technical
staff carry out this essential part of the PCWI customer service.
CARE AND MAINTENANCE
This equipment is protected against hostile environments and is designed for
prolonged use in the field without any special maintenance, other than routine
battery recharging. However, the equipment is not totally sealed and appropriate
precautions should be taken. Remember, it is a precision electronic instrument and
should be treated as such. There are no internal user controls.
The equipment should only be operated by qualified personnel.
Some organic materials may attack plastic parts and cause early degradation.
Contact with such materials should be avoided.
Do not operate damaged equipment.
Where the power supply is derived from internally mounted rechargeable cells and
disassembly of the unit is necessary to access those batteries, this action would
void all warranty.
SERVICE REPAIRS AND MAINTENANCE
Repairs not covered by the warranty or carried out after the warranty period, will be
charged at the current hourly or set service rate, plus the cost of materials.
Goods for repair must be sent at the Purchaser’s expense, and be accompanied by
the Purchaser’s written order describing the defect and authorising PCWI to invoice
the purchaser for labour, materials and return delivery cost.
No service or repair will be undertaken until a written order is received.
BEFORE YOU CALL FOR SERVICE
Read the section on “troubleshooting” in this handbook and check the symptom,
cause and solution before you call for service.
AUTHORISED SERVICE AGENT:
P C W I
P C W I
O F F E R S
Strong technical support
In-house development and manufacturing enables us to provide strong
technical support and a quick response to enquiries and orders.
Market and product knowledge
We understand technical specifications demanded by industry and
recognise customer requirements are specific in relation to testing and
measuring instruments.
NATA accredited laboratory in metrology
PCWI’s in-house laboratory can support testing for a range of instruments
enabling Certification Traceable to National Standards.
Quality systems certified to ISO9001
PCWI’s Quality Management System is certified to ISO9001.
Warranties and after sales service
PCWI provides 12 months warranty for its Detectors with detailed operator
instruction handbooks and after sales service. An extension of this PCWI
service is provided by your local distributor.
Office:
Postal:
13 Alhambra Avenue
CARDIFF NSW 2285
Newcastle, Australia
PO Box 900
HUNTER REGION MC NSW 2310
Phone:
Intl:
Fax:
Email:
www:
au - PCWI Compact Pulse Porosity Detectors.cdr (Aug 05)
(02) 4954 3900
+61 2 4954 3900
(02) 4954 3999
@
sales pcwi.com.au
www.pcwi.com.au
©2003 PCWI Pty Ltd
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