Buckleys DCCT User manual

MANUFACTURERS OF SPECIALIST TEST EQUIPMENT
DCCT Pinhole Detector
Operating Instructions
English Version
Please read carefully before use

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Contents Page
Description 4
Unpacking 5
Specifications and symbols 5
Setup 6
Mains, Earth & High Voltage Connections 6
Alarm Circuit 6
Slow Speed 6
Fast Speed 6
Changing pre-set speed 7
Remote operation 8
Operating instructions 9
Maintenance 9
Safety precautions 10
Electromagnetic compatibility 11
Disposal information 13
Output graphs 14
EC declaration of conformity 18
Contact details 19
Distributor details 19

Instruction Manual
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Description
The DCCT range of testers are designed for the automatic testing and
counting of holidays/porosity in coatings of a non-conducting nature.
These units are used for such applications as cable testing (during
manufacture), testing plastic sheet, testing coatings on steel pipes etc.
Fault detection is shown by:
● Audible alarm
● Illumination of a warning lamp on the front panel
● A drop in the pre-set voltage displayed on the output meter.
The duration of the alarm and warning lamp illumination can be adjusted
by inserting a small screwdriver into the aperture on the left hand side of
the front panel marked [ALARM DELAY], to an give audible/visual warning
from 0.5 to 4 seconds duration. The electromagnetic counter adjacent to
the alarm registers each fault passing the sensing electrode. The counter is
inhibited while the alarm is in operation when set in slow speed mode - see
section 4.2.
The test voltage is set by a single multi-turn control with finger operated lock
which prevents accidental alteration of the pre-set test voltage. This voltage
will remain stabilised as set.
Audible/visible alarm Test voltage (kV) Set test voltage
Counter
Alarm delay
Mains
on/off
Alarm
sensitivity
Fig. 1 - DCCT Control Panel

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Unpacking
Remove the DCCT and its accessories from the packaging and check for
any damage. Should any item be damaged, notify the supplier and carrier
immediately. Keep all packing material for inspection. Do not use the
equipment.
Specifications and symbols
DCCT unit Type
Output test voltage (DC neg.)
DCCT 1 –7.5 kV
Adjustable 1kV to 7.5kV
DCCT 2 –15 kV
Adjustable 2kV to 15kV
DCCT 4 –30 kV
Adjustable 4kV to 30kV
DCCT 5 –40 kV
Adjustable 5kV to 40kV
Sensitivity: Variable (factory set for BS EN 62230).
Output current: Maximum continuous output current: <1mA.
Operating time: Continuous
Weight: 17 Kg
Dimensions: 500mm (W), 300mm (H), 330mm (D)
Meter accuracy: <2%.
Mains supply voltage: 110/120V or 220/240V, 50/60Hz.
Standard: Conforms to BS EN 62230 - Electric cables,
Spark-test method.
The following symbols are displayed on the DCCT equipment for your safety
and protection. Failure to comply with the instructions contained in this
manual could result in damage to the equipment or personal injury.
Caution, risk of danger Caution, risk of shock Chassis terminal
NOTE: It is important that you read this manual fully to familiarise yourself
with the DCCT unit.

Instruction Manual
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Setup
Mains, Earth & High Voltage Connections
Set the VOLTAGE SELECTOR switch located on the rear panel (Fig. 3) to the
required mains supply voltage of either 120 volts or 240 Volts AC.
Connect the mains lead to a suitable isolator switch or mains plug fused with
a 3 Amp fuse, using the following colour code:
Brown - Live, Blue - Neutral, Green/Yellow - Earth
Connect the HIGH VOLTAGE cable from the H.V socket at the rear of the
DCCT unit to the sensing electrode.
Connect the EARTH LEAD between the terminal at the rear of the DCCT
unit and the conductive substrate of the item to be tested. This will ensure a
complete earth connection and completes the circuit for detection of faults.
Note: Failure to make a good EARTH connection will render the test
ineffective.
Alarm Circuit
The alarm circuit must be in the correct mode of operation to match the
speed of the material under test as it passes the sensing electrode.
Slow speed: Once the fault has been registered, an inhibitor circuit is
activated to prevent multiple registrations of the same fault while it is
travelling through the sensing electrode.
Fast speed: All faults are registered on the counter unit as they pass through
the sensing electrode at speed.

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Fig. 2 - DCCT Alarm mode switch
The DCCT is factory set to the SLOW SPEED mode.
To change the pre-set speed:
Disconnect the mains supply from the unit and un-screw the four retaining
screws complete with their plastic collars from the front panel and remove
the unit from its case.
The main control circuit board is located just behind the output display
meter. The alarm speed mode switch for changing the mode from
SLOW SPEED to FAST SPEED is at the back of the circuit board (Fig 2).
Replace and secure the unit in its case and re-connect the leads as
necessary.
The ALARM DELAY control (Fig. 1) can be adjusted to give an audible and
visual warning from 0.5 to 4 seconds duration. In the fast speed mode the
electromagnetic counter will register each fault passing the electrode and
will continue to register any further faults even when the audible alarm is
sounding. For slow speed or hand operation, the counter is inhibited while
the alarm is in operation.

Instruction Manual
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Fig. 3 - DCCT Rear panel connections
Remote operation
If required, the high voltage output may be enabled and disabled remotely
via the CON 2 connector. To configure for remote operation:
Remove the plug from ‘CON 2’ connector at the rear of the DCCT unit
(Fig. 3).
Remove the shorting link from inside the plug.
The normally-open contacts of a controlling relay or safety switch may now
be connected in place of the shorting link. Reverse this procedure if remote
operation is no longer required.
A set of heavy duty change-over contacts are provided for operating
exterior contactors, solenoids etc. Connection is made to terminals 1, 2 and
3 of ‘CON 1’ (plug provided) on the rear of the unit.
In the operating NO FAULT condition, the DCCT’s internal alarm relay is
energised, holding contacts 1 & 2 open with contacts 2 & 3 closed.
When a fault is detected the internal relay will be de-energised, closing
contacts 1 & 2 and opening 2 & 3.
This state will be held for the pre-set period determined by the setting of the
alarm delay control as previously mentioned (Fig. 1). Contacts are rated at
240V AC, 5A non-inductive.

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Operating instructions
Follow the Setup instructions detailed on page 6.
Set the OUTPUT control to minimum (anti-clockwise direction).
Switch ON the equipment.
Reset the counter to zero by pressing the reset button on the left-hand side
of the counter.
Rotate the OUTPUT control to the required test voltage.
NOTE: The following is only applicable if a handle is purchased with your
DCCT
Press the Remote ON switch located on the test probe handle to activate
the output of the DCCT. Touch the test electrode to earth or the metal
backing of the article to be tested to ensure the audible and visual alarm
circuits are operating, and also that the test voltage drops to zero.
Ensure that the test area is dry and clean. Sweep test area with an electrode
at a steady speed and observe for any drop of indicated test voltage and
audible/visual warning from the instrument.
Maintenance
The DCCT was designed for minimum maintenance by the user apart
from regular inspection of the accessories and cleaning of the unit as
detailed below:
All leads and cables should be regularly inspected for damage and
checked for continuity.
Operation of all safety switches and devices (if fitted) should be checked.
Fluids should not be allowed to enter the DCCT unit or associated
equipment.
The unit should be kept clean, ensuring all control wording remains legible.
The equipment should be sent back to the manufacturer or their agent for
recalibration at yearly intervals.

Instruction Manual
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Safety precations
All high voltage testing equipment of this type should only be operated
by authorised personnel who have read and understood the instructions
contained in this manual.
The operator should enjoy good health and in particular, not suffer from a
cardiac condition. When the unit is working the operator may experience a
mild shock or ‘zap’ when touching an earthed metal object. This is because
it is possible to build up a static charge in the operator’s body from the
field around the test electrode. The wearing of conductive boots or shoes is
recommended to help to overcome this problem.
The output test voltage of this equipment is derived from a high impedance
source and will collapse under short circuit conditions (See output graphs
- section 9). However, when the equipment is in use, should the operator
accidentally make contact with the test electrode, he will receive an
electric shock. Whilst not in itself hazardous, the involuntary reaction
to an unexpected electrical shock may cause a related accident i.e.
stepping backwards into an adjacent piece of moving machinery. In these
circumstances it is recommended that a guard be placed between the
operator and the test electrode and connected to the unit to turn off the
high voltage when it is opened. Rubber or plastic insulating gloves could be
worn as an alternative.
DANGER: Do not use test equipment of this type in any
combustible atmosphere as the test voltage will cause
an arc or spark, and an explosion could result. Therefore
the plant or site Safety Officer should be consulted before
proceeding with the test.
We cannot stress too strongly that equipment of this type should be operated
only with a secure connection to earth or ground. This applies especially
to the testing of plant or test pieces which do not have a permanent
connection to ground. Failure to comply with this procedure may cause
shock to the operator when adjusting controls whilst the equipment is
switched on.

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Electromagnetic compatibility
Electromagnetic Emissions - European Union Directive
Before operating this equipment it is essential that the following risk
assessment be taken. As this equipment will produce an electromagnetic
emission when actually arcing down through a fault to earth, a risk
assessment of the area in which the unit will be used should be carried out.
For example, the equipment should not be operated where the
electromagnetic disturbance generated may hinder the operation of such
apparatus as:
● Domestic radios and television receivers
● Industrial manufacturing equipment
● Mobile radio equipment; mobile radio and commercial radiotelephone
equipment
● Medical and scientific apparatus
● Information technology equipment
● Domestic appliances and household electronic equipment
● Aeronautical and marine radio apparatus
● Educational electronic equipment
● Telecommunications networks/apparatus. Radio & television broadcast
transmitters
● Lights and fluorescent lamps.
The Directive also requires the above types of equipment to have an
adequate level of electromagnetic immunity from such emissions. However,
it should be borne in mind, when doing an assessment, that the directive
applies to equipment supplied or taken into service after 1st January 1996
and that the equipment you are assessing, although legal, because of age,
may not have this immunity.
Common areas of risk are computers, critical safety equipment (fail/safe
electronics), supply cables, control cables, signaling and telephone cables
above, below and adjacent to the area where the tests are being carried
out. The users of pacemakers and hearing aids should also be considered.
Measuring and calibration equipment may also be susceptible.

Instruction Manual
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To make a comparison: an arc welder, when in use, would create
interference far greater than this type of tester. It would, therefore, be
reasonable to assume that if an arc welder had been used in the area
without problems, then a DC Pinhole Detector would be safe. However, it
would be unwise to use both pieces of equipment on the same site at the
same time as they may interfere with each other.
The test area itself should also be considered. For example, the layout of the
area would affect the distances, which the emissions would travel. Buildings
and metal structures would shield against, or reduce, emissions. If the tester
was being used inside a metal tank, for instance, the tank would act as a very
good shield. This would not, however, have the same effect if you were
testing a plastic tank. If you were testing the circumference of a metal pipe
then the pipe would act as an aerial and transmit the emissions further than
expected. Remember that electromagnetic emissions travel in all directions
and can even be bent or deflected. Neighbouring works or sites should also
be taken into account; there may be equipment in use that could be
affected by your tester’s emissions.
Most of the time this type of tester will be used on outdoor sites and remote
from susceptible equipment, but the SITE SAFETY OFFICER should always
be consulted before any testing is carried out. This is particularly necessary
where electronically controlled equipment is being used.
Timing of the testing should also be considered as a means to avoiding
interference problems. Consider testing when all susceptible equipment in
the test area is switched off.
If your tester is only used in one area, then simple tests will ascertain where
the tester interferes with other equipment and these can be resolved by
scheduling the proper testing accordingly. Again, you should remember
neighbouring works.
The DCCT series are designed to meet the EMC directive therefore all leads
are optimum length. If longer leads are used then they could transmit similar
to aerials and cause interference.

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Always ensure that the tester and test piece is securely earthed as this
reduces any interference generated by the spark. It also prevents static
build-up in the operator. These units have been designed with EMC in mind
and therefore all leads are of optimum length. If longer leads are used they
could transmit, similar to aerials and cause interference.
Wherever you are intending to use equipment of this type, on your site
or on a customers, always obtain clearance from the company safety
officer.
Disposal information
Producer registration number: WEE/HJ0051TQ
This product must be disposed of in accordance with UK WEEE
regulations.
For further information on UK WEEE regulations click on:
www.gov.uk/government/publications/weee-regulations-2013-government-
guidance-notes

Instruction Manual
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Output graphs
The following are the output graphs for the four models of DCCT available.
Please review the graphs associated with your DCCT model.

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Instruction Manual
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Instruction Manual
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EC Declaration of conformity
We:
Buckleys (UVRAL) Ltd
As manufacturer of the apparatus listed,
declare that the product:
DCCT DC Holiday Detector
Is manufactured in conformity with
the following directives:
2014/30/EU
2014/35/EU
Authorised by:
J P Hoveman
CEO, Buckleys (UVRAL) Ltd.

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Contact details
Manufacturer: Buckleys (UVRAL) Ltd
Address: Buckleys House
Unit G, Concept Court
Shearway Business Park
Shearway Road
Folkestone
Kent CT19 4RG, UK
Tel: [phone]
Fax: [phone]
Website: www.buckleysinternational.com
Distributor details

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DCCT/IM/ENG/V.07-18