PCWI DC15, DC30 Operator's Handbook Manual

Can be used in accordance with:

Australian Standard AS3894.1

ASTM G62, ASTM D5162, ASTM D4787, NACE SP0274,

NACE SP0490, NACE SP0188, ANSI/AWWA C213,

ANSI/AWWA C214, ISO 2746

CE Marked PCWI Compact Detectors comply with the requirements
of EMC Directives 89/336/EEC EMC and its amending directives.

Operator’s Handbook

For

Compact

High Voltage

DC15 & DC30

POROSITY (HOLIDAY) DETECTORS

®

POROSITY DETECTOR ACCURACY:

+5% of reading or + 50V below 1kV
(Note: at the time PCWI tested the Porosity Detector
at the reference temperature & humidity).

Refer to the PCWI Manufacturer’s Calibration
Certificate provided with the Porosity Detector.

Range: 0kV to 30kV
Recertification available.

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CONTENTS

1.0 Safety Precautions 4

2.0 Operation 5-6

3.0 Specifications 6

4.0 Control Panel Layout 7

5.0 Voltage Recommendations 8-9

6.0 Troubleshooting 10-11

7.0 Optional Accessories 12-13

8.0 PCWI NiMH Battery & Charger Clip 14-15

9.0 Warranty 16

10.0 Service & Maintenance 17

WARNING

This Equipment generates a high voltage and should
be used with care. Please consult these operating
instructions before use.

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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.

Yours sincerely

Paul Van Gaal

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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 35,000 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.

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.

DANGER

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.

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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.
Check the batteries to ensure that they are charged.
Turn the voltage control clockwise to the required test voltage.

Note: If the neon is in place allow an additional 200v.

Place the probe near the metal substrate.
A spark should occur (if not re-check all leads and connections).
Place the probe on the surface to be tested.
Re-check the output – adjust if necessary. Turn alarm sensitivity until
the alarm is just off.
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.
Digital test voltage drops drastically.
The neon in the probe flashes.

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.

Wet and contaminated coatings should not be tested until dry and
clean (see also troubleshooting pages).

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