PCWI Compact P20, Compact P40, Compact P60 Operator's Handbook Manual

®

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

[phone]

[phone]
[phone]

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.

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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