Buckleys DCCT PRO2 User manual

High-voltage DC Test Instruments
User Manual
Please read this manual before using theequipment
5830-0063 06/23 │English

Instruction Manual
2 06/23
Contents
Safety Warnings – VERY IMPORTANT...........................................................................................................................3
EC Declaration of Conformity.....................................................................................................................................4
UKCA Declaration of Conformity ...............................................................................................................................4
Specifications................................................................................................................................................................4
Maintenance ................................................................................................................................................................5
Register Your Product...................................................................................................................................................5
Kit Contents ...................................................................................................................................................................5
Risk Assessment .............................................................................................................................................................6
Factory Settings.............................................................................................................................................................6
Overview........................................................................................................................................................................7
HV Testing Basic Physics ...............................................................................................................................................8
Corona Discharge & Material Current Draw ............................................................................................................8
Instrument Output Limits ..............................................................................................................................................9
Instrument Range .......................................................................................................................................................10
Multi-instrument Configuration Examples ................................................................................................................11
Electrodes....................................................................................................................................................................12
Installation Setup - General .......................................................................................................................................13
Setup (continued) ......................................................................................................................................................17
Instrument Setup – User Menus .................................................................................................................................19
Useful Advice ..............................................................................................................................................................27
Product registration ....................................................................................................................................................27
Contact Details...........................................................................................................................................................28

06/23 3
Safety Warnings – VERY IMPORTANT
IMPORTANT: We strongly advise that
individuals with pacemakers, cochlear
implants, or trans-dermal electronic implants -
e.g., glucose monitors do not use our high-
voltage test equipment under any
circumstances.
IMPORTANT: This product must not be
used in combustible atmospheres or
ATEX Hazardous Areas, such as fuel stations or
in proximity to any combustible gas (and/ or
oxygen concentrations exceeding normal
atmosphere).
IMPORTANT: This instrument must be
connected to an appropriate earth
(ground) before a high voltage is
applied.
All high-voltage testing equipment
must be operated by suitably trained,
responsible, authorised personnel only.
IMPORTANT: This product may cause
radio interference, which may interfere
with other processes.
Observe all safety precautions;
operators will be exposed to high
voltages when using this instrument. Avoid
contact with live components.
This instrument creates sparks in use,
which cause the formation of ozone
(O3). Ozone is a known irritant and therefore -
particularly when using the instrument in
confined spaces - the user must ensure
adequate ventilation so that established
workplace exposure limits are not exceeded.
Safety Warning: DO NOT USE this
equipment in the event of it being
immersed in water. It must be immediately
returned to Buckleys for service, calibration
and/or repair.
A high voltage will always take the easiest route
to earth. The risk of electrical shock is inherent
when operating high-voltage equipment and
extreme caution must be taken at all times.
The output voltage of this equipment is derived
from a high-impedance source and is current
limited. However, when the equipment is in use,
should the operator accidentally contact the
test electrode they will receive an electric
shock. If this situation is unavoidable, we
recommend that suitable rubber or plastic
insulating gloves, apron and boots be worn.
Furthermore, the operator should be in good
health and - in particular - not suffer from any
cardiac condition.
During testing, a static charge may accumulate
on the surface under test. If an operator
touches the surface, they may also become
‘charged- up’. When discharged to earth, this
charge could result in a static electric shock,
such as may be experienced in the home under
certain weather conditions.
Whilst such a shock does not normally present
any danger to the user, it can be unpleasant,
and may cause the operator to react in a way
which may place them in danger. In most
cases, the operator can avoid this by wearing a
blue electrostatic discharge wristband and
ensuring it is connected by the blue cable to
the grounding terminal (4mm socket) on the
instrument’s enclosure, or any other suitable
grounding point.
In all cases it is essential to ensure that the
instrument is correctly earthed.

Instruction Manual
4 06/23
EC Declaration of Conformity
We, Buckleys (UVRAL) Ltd., as sole manufacturer of the apparatus listed below, declare that the
product
DCCT Pro2 is manufactured in conformity with the following directives: 2014/30/EU , 2014/35/EU ,
2015/863/EU and 2011/65/EU (RoHS) .
Date: 01/06/2023
Authorised by:
J P Hoveman
CEO, Buckleys (UVRAL) Ltd.
UKCA Declaration of Conformity
We, Buckleys (UVRAL) Ltd., as sole manufacturer of the apparatus listed below, declare that the
product
DCCT Pro2 is manufactured in conformity with the following UK legislation: Electronic
Compatibility Regulations 2016
, The Electrical Equipment (Safety) Regulations 2016 and Restriction of the
Use of Certain Hazardous Substances in Electrical and Electronic Equipment Regulations 2012
.
Date: 01/06/2023
Authorised by:
J P Hoveman
CEO, Buckleys (UVRAL) Ltd.
Specifications
Note: Due to ongoing technical developments, all stated information is typical and is subject to change
without notice or obligation.
• Mains Supply Voltage: 90-250VAC
(via IEC C13 “Kettle Plug” lead)
• Output voltage range: 0.9kV – 40kV
• Max. output current: <1mA (continuous)
• Alarm sensitivity range: 10μA to 450μA
(factory-set to 200μA)
• Unit: 3.8kg, 420mm x 240mm x 90 mm
• Packed weight: 4.1kg
• Dimensions (packed): 580mm x 420mm x
220mm
• Meter accuracy: <10kV: +/- 10V. >=10kV +/-
100V
• Current meter FSD: 450μA
• Maximum relative humidity: 80% non-
condensing
• Temperature range: 0ºC - +40ºC
Output voltage range:
Model Low Range Increment High Range Increment
DCCT Pro2 0.9kV-10kV 10V 10.1kV-40kV 100V

06/23 5
Maintenance
The Buckleys Pro2 instruments are designed for minimum maintenance by the user, however the
following periodic checks/actions are recommended:
The exterior of the unit should be cleaned
regularly. Stubborn dirt may be removed with a
moistened cloth (99% water +1% mild
detergent). Mild solutions may be used to
remove greasy dirt. Do not allow cleaning fluid
to enter the unit. The use of other cleaning
agents may lead to damage to the detector’s
surface areas.
Periodically inspect all wiring connections to
ensure that they are sound, properly installed
and undamaged.
Our service team will ensure your detector’s
performance is within our strict tolerances and
carry out a thorough inspection of the entire kit;
advising you of any repairs required.
NOTE: The DCCT Pro2 should be calibrated annually by an approved provider. For more
details, visit:
www.buckleysinternational.com/repairs
Register Your Product
Please register this product via Buckleys’
website and download the Warranty
Registration Certificate.
Once your product is registered, you will receive
the following benefits:
• Annual service & calibration reminders by
email
• Latest industry news relating to yourproduct
• Be the first to hear about our new products
We strive to improve the quality of our products
and service. By registering your product, you
can help us monitor overall quality of our
products, service and dealer network.
Additionally, if we ever need to contact you
regarding your product, we are able to do so
immediately.
To register your product, simply visit:
www.buckleysinternational.com/registration
... complete the online form and click on ‘ SUBMIT ’
Kit Contents
Upon delivery of your Pro2 instrument, please take the time to ensure that the kit is complete, and all
components shown below are present and undamaged:
Item Description 6002-0098 6002-0099 6002-0101 6002-0102 6002-0100
A DCCT Pro2 Integral - single channel

B DCCT Pro2 Integral - dual channel

C DCCT Pro2 Output Module - single channel

D DCCT Pro2 Output Module - dual channel

E DCCT Pro2 Command + Module

F Mains power supply cable
    
G Terminator Plug (6005-0497)
  
H Calibration certificate
   
I Carry Case (6005-0497)
    
A B C D E F G H I

Instruction Manual
6 06/23
Risk Assessment
It is the user’s responsibility to complete a risk assessment before using Buckleys equipment. The following
points offer some guidance but must not be assumed to be complete or sufficient.
Personal Safet
y
• Have all users been trained in the correct
and safe use of the instruments?
• Are they aware that the instrument
produces high voltages, and can give
electric shocks if used incorrectly?
• Is the instrument in good condition,
undamaged? Is the instrument dry? Are the
accessories similarly in good condition, dry
and undamaged?
• Is it possible to ensure that persons with
pacemakers, cochlear implants or trans-
dermal implants of any kind are sufficiently
far from the instrument & test site to be safe?
• Ozone is an irritant gas which will be
produced when the instrument produces
sparks – is there sufficient, suitable
ventilation in place to ensure that this is not
hazardous?
• Is the access route to the area of the test
safe? Is fall protection necessary? If so, is it
in place?
• Has the instrument been properly grounded
to a metallic grounding point?
• Should you use the anti-static wristband to
prevent static charge build-up?
Explosion & Fire Risk
• Buckleys high-voltage instruments will
produce sparks - Are you certain that there
is no risk of an explosive atmosphere?
• Have all easily-ignited and/or flammable
materials been removed from the area in
which testing will take place?
EMC & RFI
• Buckleys high-voltage instruments will
produce sparks which may create
interference in nearby electronic apparatus,
particularly communication and computer
equipment.
• Are you certain that there is no risk of such
interference causing a danger to others –
particularly medical or life support
equipment?
• Are you sure that there is no risk of such
interference causing costs or inconvenience
to others – e.g., industrial processes,
measuring equipment, scientific apparatus,
domestic radio and TV?
Other Risks
• Have you checked that there are no
ongoing processes in the area that may be
hazardous?
• Are you certain that the instrument has not
been immersed, dropped or otherwise
damaged in a way that is not obvious?
• Have you verified that the ground
connection is actually grounded?
• Is the person responsible for site safety
aware of / fully understanding the testing
you are going to do, and has it been
reviewed in line with the site procedures?
Factory Settings
In order to use the DCCT Pro2, you will need to adjust the instrument settings to suit your specific
application – see page 9. The following is a summary of the settings as set in the factory:
Output voltage: 5kV
Testing standard: Manual
Sensitivity: 200µA
Alarm volume: 5
Screen contrast: 5
Alarm Mode: Fast
ON time 30ms
OFF time 30ms
HV Pause 250ms
This setting is suitable for tests carried out in line with the BS standard
Electric Cables – Spark-test
method
.
NOTE: Wherever you are intending to use
equipment of this type, always obtain
clearance from the company safety officer.

06/23 7
Overview
High voltage pinhole detection has been commonplace for nearly half a century. The principle of such
testing is that the material being tested has a greater breakdown voltage (in kilovolts) than the
equivalent “thickness” of air, and this resistance to breakdown prevents current flowing between
electrodes placed either side of the material being tested.
If there is a flaw or fault in the material being tested (which may be a microscopic hole, or one so large
that it is easily visible, or a significant reduction in thickness even without a hole) a current will pass,
either as a spark which may be audible and visible, or as an ionisation current which is unlikely to be
visible. Buckleys High Voltage test equipment incorporates detection circuits which will detect the flaw
in either case. Sparks will always be detected. Ionisation currents will be detected providing they
exceed the user-defined current threshold.
Therefore, there are two electrodes – the first will be connected to the High Voltage (HV) output of the
instrument, and the second to the ground connection. This second, ground electrode may also be
connected to grounding points for the installation and/or building.
Fig 1 – A typical DCCT installation.
As shown in Fig 1, it is necessary to arrange the test electrodes so that the material passes between
them, and ideally the electrodes should always be in contact with the material. If this is not possible, it is
beneficial to minimise the air gap between electrodes and material as much as possible.
Buckleys DCCT instruments are purpose designed, based on over forty years’ production of HV Non-
Destructive Test (NDT) equipment for industry. The instrument provides a highly stable user-controlled
HV DC output, from 0.9-40kV, and an adjustable sensitivity alarm whose threshold may be set between
10 and 450µA. Both may be easily adjusted by the user, and the settings can be locked by means of a
manager-defined passcode.
Additionally, these instruments are fitted with software-controlled zero-volt relay connections which
operate in synchronisation with the alarm, allowing interconnection with PLC controllers, or a variety of
other devices, such as a paint spray for marking. Additionally, the instrument is fitted with interlock
connections allowing the HV output to be remotely controlled and disabled, should the safety case
require it. There is also a fault counter.
Mains
Supply
90-250V AC
Instrument
Ground
Material to be
tested, being
drawn between
electrodes.
Ground Electrode
connection to
Instrument
DCCT Instrument
HV Connection
HV Electrode
Ground Electrode
Optional Local
Ground
Connection

Instruction Manual
8 06/23
HV Testing Basic Physics
AS noted above, the principle of this method is that the material being tested has a greater breakdown
voltage (in kilovolts) than the equivalent “thickness” of air. Air has a breakdown voltage of
approximately 3kV/mm (approx. 76kV/inch) so it is easy to calculate the voltage necessary for a spark
to form in a hole through a membrane of any similar thickness. There are other effects that will change
this simple calculation at very small gaps, or much larger ones, but in the range of thicknesses of typical
materials being tested, this approximation is appropriate.
The maximum voltage that can be used is dependent on the thickness, and the dielectric strength (or
breakdown voltage), of the material. Most plastics have breakdown voltages in the range of 10 to 100
kV/mm and some exotic materials are rather higher.
Accordingly, there is generally a significant difference between the voltage required to breakdown the
thickness of the material being tested, and that required to breakdown the air within a flaw in the
material. This means that when a flaw passes between the electrodes, a current will pass, and this
current can be detected by the DCCT.
Test voltages are specified somewhat higher than the minimum limit, in order to ensure detection of non-
perpendicular faults in the material, whilst being somewhat lower than the breakdown voltage of the
material being tested. This is to reduce the risk of the test inadvertently damaging the material being tested.
The ideal approach is to identify an appropriate calculated voltage (Buckleys are happy to provide
advice) and then to test this in a range of scenarios to ensure that the desired detection level is
achieved without causing unwanted material damage.
There are published test standards to which users may refer which provide guidance on test voltages
often based on material thickness. Most standards do not provide guidance on current thresholds.
Publishers include the BSI, NACE, ASTMs and the ISO.
Corona Discharge & Material Current Draw
Whilst we associate air as being an extremely effective electrical insulator, we are also familiar with
sparks travelling through the air. Lightning is an obvious example, but the spark plugs of petrol engines
and piezoelectric gas lighters are perhaps more relevant. In these cases, the design of the system
ensures that the electrode voltage rises very rapidly, and decays almost instantly when the spark
occurs. This is not very useful for a continuous inspection system as we need the voltage to exist at all
times, with the spark to only occurring when a flaw passes between the test electrodes. Accordingly,
the HV system must produce and maintain a significant voltage difference between the test
electrodes.
There are two physical phenomena which counteract the maintenance of this voltage difference.
The first of these is
Corona Discharge . This is a process by which the air surrounding a charged body,
such as the electrode, becomes ionised, and in so doing, moves away from the charged body. This is
often visible as a blue glow (the corona) around sharp edges. It causes a continuous flow of current
from the electrode, the magnitude of which is largely dependent on the voltage applied. The other
factor which significantly affects corona discharge is the shape of the body. Pointed items will cause a
more significant discharge than spherical ones. Electrodes with metallic brushes are particularly
susceptible to this effect.
The second is
Material Draw . Highly insulating materials are typically able to act as capacitors, and will
hold a dielectric charge on their surface, particularly if there is a counter charge on the opposite
surface. As the material passes through the electrodes, there will be deposition of charge on the
material surface, which is drawn away from the electrode by the material passing, and this represents a
further flow of current from the electrode. The magnitude of this current is dependent on the material
being tested, the width of the electrode, as well as the velocity of the material passing the electrode.

06/23 9
Therefore, as the thickness of the test material is increased, the required voltage also increases, and this
in turn leads to an increase in the Corona Discharge current. As the width of the material is increased,
or the speed of the material is increased, the Material Draw current is also increased. These physical
factors must be considered when specifying an HV system. The sum of the Corona Current and
Material Draw Current is the Total Quiescent Demand Current, Iq for convenience.
Buckleys have material testing capability and are pleased to offer advice on the expected Corona
and Material Draw currents for planned installations, however, due to the nature of discharges and their
very specific dependence on the surroundings and environment, this advice can only ever be general
in nature.
Instrument Output Limits
Buckleys DCCT instruments are designed to provide a limited output current, primarily to ensure that the
output remains within the limits specified by the IEEE to prevent a lethal shock to anyone accidentally
touching the HV electrodes or wiring. This has the effect of limiting the output power at any given
voltage, as can be seen in the graph in Fig 2.
Fig 2 - Typical Output Performance at 40kV
The red line on the graph in Fig 2 shows the performance limit as a limit for continuous current across the
range of output voltage of the DCCT instrument. Ideally, the current demand Iq at the required
voltage will fall in the zone outlined in green. However, if the demand current Iq is sufficiently high, it will
cause the output voltage to drop. Provided that the resultant voltage remains sufficiently high to carry
out the test reliably, this is acceptable. However, if it leads to a voltage below the necessary minimum,
the test may not detect flaws. This inevitably leads to a situation where some combinations of material
thickness, extrusion width, and extrusion speed, will exceed the output of a single instrument.
In order to counteract this constraint, Buckleys have introduced a range of multi-channel instruments in
which a user interface is able to control more than one generator. Each generator can supply sufficient
current to energise an electrode of a given size, and multiple generators can then be used to ensure
the total electrode width is sufficient to carry out the test on the full width of material, at the desired
extrusion speed.
This approach provides economic and ergonomic advantages:
• It is cheaper than providing several complete instruments.
• It is considerably simpler to install, particularly if interlocking and remote control are require.
• It is easier to control, with a single setting process controlling all outputs simultaneously.
• The instruments each provide individual alarm counters and outputs, and these can be grouped
into a single overall alarm if required.
0
50
100
150
200
250
300
350
400
0 5 10 15 20 25 30 35 40 45
Maximum Output Current
Output Voltage
Continuous Output Current Capability

Instruction Manual
10 06/23
Instrument Range
To meet the needs of different industrial users, a selection of DCCT instruments has been created in the
Pro2 range.
• All instruments are installed in a robust powder-coated aluminium housing.
• They are mains (90 – 250V AC) powered and can output from 900V to 40kV.
• The alarm threshold range is from 10 to 450µA.
• All units are fitted with an interlock loop facility and an internal alarm sounder, coupled with an
alarm triggered DPDT relay which allows interconnection with PLC or other parts of the
installation.
• User-settable software controls enable selection from a range of responses to alarms to suit the
installation requirements.
• All instruments are capable of networking, allowing up to four output units to be connected to a
single command station.
DCCT Pro2 Integral – Single Output (6002-0098)
This is the basic instrument which replaces the previous generation of DCCT. It provides a digital user
interface, and a single channel output assembly. In addition to offering a greater, and more stable,
output over the whole range, visual alerts are provided on-screen, the backlight will be blue if HV is
energised, and red if a fault is detected, along with an audible alarm. Faults are counted on a
resettable digital counter, and a remote button connection is provided for HV on-off control. The
instrument is installed in a rack-mountable (19” 2U) case and provided with rack mounting accessories.
DCCT Pro2 Integral – Dual Output (6002-0099)
This is identical to the above, but as the name suggests, it provides two DCCT output channels which
are controlled in parallel from the same digital user interface. It provides identical features as the
previous instrument, and likewise, is installed in a rack-mountable (19” 2U) case and provided with rack
mounting accessories.
DCCT Pro2 Command + (6002-0100)
This instrument provides the same command, control and reporting capabilities as the preceding
instruments, but does not include an output assembly. The instrument is mounted in a smaller case and
provides a means of remotely operating other instruments. As above, visual alerts are provided on-
screen, the backlight will be blue if HV is energised, and red if a fault is detected, along with an audible
alarm. Faults are counted on a resettable digital counter, and the relay outputs are also provided in
this instrument. The Command + unit is connected to other units via a 4-core network cable, which
may be up to 100m long.
DCCT Pro2 Single Channel Output Unit (6002-0101)
This comprises a mains-powered output unit, mounted in a 19” 2U powder-coated housing. The
specifications & capabilities are identical to the single channel Integral unit, but there is no command
interface within the instrument – it must be networked with one of the preceding instruments.
DCCT Pro2 Dual Channel Output Unit (6002-0102 )
This is identical, however as with the Dual Output Integral unit, the instrument contains two output
channels.

06/23 11
In summary, the Pro2 range comprises the following instruments:
Instrument Part Number User Interface Output
DCCT Pro2 Integral – Single Output 6002-0098 5-button, 4-colour digital 1 output 0.9-40kV 340µA
DCCT Pro2 Integral – Dual Output 6002-0099 5-button, 4-colour digital 2 outputs 0.9-40kV 340µA
DCCT Pro2 Command + unit 6002-0100 5-button, 4-colour digital none
DCCT Pro2 Single Channel Output Unit 6002-0101 3 indicator leds & sounder 1 output 0.9-40kV 340µA
DCCT Pro2 Dual Channel Output Unit 6002-0102 6 indicator leds & sounder 2 outputs 0.9-40kV 340µA
The digital interface is configured to control and monitor up to four output stages. The output stages
will automatically have the same set output voltage, and the same alarm threshold. The alarm settings
are likewise common to all output stages.
The interface incorporates a digital counter for each output stage, and these may be cleared
individually or collectively. A flaw detected by any output stage will trigger its own alarm, and relay,
and will trigger the counter and alarm on the user interface. Further details of alarm settings are
provided below.
Multi-instrument Configuration Examples
Given the inherent flexibility and networking capability of the Buckleys Pro2 instrument range, the
following examples may be helpful:
This simple arrangement of the Integral Single Channel
(6002-0098)
replaces previous generation units, but offers significantly greater
output power, and enhanced control and interface options. The
unit is provided with two zero-volt relay outputs to control external
alarms, paint markers or other peripherals. See Fig 3.
This Integral Dual Channel
(6002-0099) instrument provides two output
modules within the same housing, meeting the demand for higher
currents, or where it is necessary or convenient to use two separate
electrodes.
The output voltage and alarm threshold are identical for both
channels, but the fault counter and output control functions of each
channel are independent. See Fig 4.
Where multiple DCCT output stages are required without remote
control, the integral unit can be connected to single or dual output
stages.
This example comprises an Integral Dual Channel
(6002-0099) and a
Dual Channel Output module
(6002-0102) , and this arrangement
allows the system to be extended to provide three or four outputs.
The controller and the output stages are each provided with
independent interface capability to drive alarms / paint markers /
etc. See Fig 5.

Instruction Manual
12 06/23
Use of a Command+ module, (6002-1000) permits the remote
management of a DCCT output stage, in this example a Single
Channel Output Unit
(6002-0101) is used, and this offers the same
capabilities as the Integral Single Channel unit described above.
The controller and the output stage(s) have interlock inputs, and the
interface capability to drive alarms / paint markers / etc. The
network cable may be up to 100m long. See Fig 6.
In this final example, the network arrangement permits the remote
control of two Dual Channel Output Modules
(6002-0102)
It is possible to construct a remotely managed network with one,
two, three or four output channels.
Whilst the output voltage and alarm threshold are identical for all
channels, the controller and the output stages are provided with
independent fault counters, and individual interface capability to
drive alarms / paint markers / etc. See Fig 7.
Electrodes
A wide range of rollers, metallic or carbon fibre brushes, conductive rubber, metallic gauze or mesh
can be used to form electrodes. Ideally, the electrodes will be in contact with the material being
tested. If this is not possible then any airgap between the material and electrodes should be minimised.
Of course, it is important that the electrodes do not damage the material being tested, so the form and
material used for their construction should be chosen with this in mind. It is also likely that the surface of
these electrodes will be damaged over time, so functional parts, such as cores for mould tools, should
not be used in this way.
In cable-testing applications, the ground electrode is normally formed by the core (or cores) of the
cable itself, and arrangements must be made to ensure a low resistance path from the cable core to
the instrument, either in the supply, or take-up reel. Similarly in pipe insulation testing, a ground
connection to the metal tube itself will be necessary. This may be arranged by means of a travelling
contact, or a static brush, which is able to make contact with the tube as it passes through the HV
electrode assembly.
It is recommended that the HV cable length between instrument output and electrode should always
be minimised, and it is most important not to exceed 2m of armoured cable.
Buckleys has considerable experience in the design and manufacture of HV and Grounding electrodes
and we are happy to advise, and to quote for custom installations including extrusion of films and
membranes, and a wide range of coated components including wires, cables and flexible and rigid
pipes.

06/23 13
Installation Setup - General
Should you have any concerns or difficulties after having thoroughly read the guidance in this manual,
please refer to the guide provided on our website at https://www.buckleysinternational.com.
If these resources do not resolve your query, Buckleys will provide support and guidance in the use and
set-up of the instrument by phone and email. However, please understand that we cannot control the
circumstances of operation, and it remains the user’s responsibility to ensure safe and satisfactory
operation at all times.
The instrument and its accessories should be unpacked and inspected. If there is any damage, or any
parts missing, please advise us immediately. Do not use the instrument if it is damaged.
Determine a suitable location for the instrument(s) ensuring access for cabling and connections, as well
as taking ergonomic considerations into account. The location should be protected from rain and
water, and it is not recommended to install these instruments outdoors.
Apart from the Command+ module, the instruments are housed in a 2U 19” rack mount compatible
case. Rack mount “ears” are provided, along with fixing screws, in the instrument kit.
Install the network cable or Terminator Plug in the network socket. Once aligned, red dot to
red dot, it is a PUSH fit. Do NOT twist. To see our instructional video here, scan the QR code
or visit: https://youtu.be/Sl4dJxWDtxs
Ensure the Run-Off-Cal switch on the rear panel is in the RUN position.
Please refer to Fig 1 above. Connect the ground/earth terminal to a suitable grounding point electrically
connected to the ground plane or structure of the test area. It is necessary to provide a low resistance
return path for the test current, and this is not a substitute for proper and sufficient protective earthing of
the structure itself. If in any doubt, consult a suitably qualified electrician before making this connection.
Connect the HV cable between the instrument and the HV test electrode. We recommend that this
cable is kept as short as practicable, and that it is
not installed within metallic conduit. If a conduit is
required, it is most important to limit the length to less than 2m. Ensure that the cable, and any
electrode to which it is attached are properly supported and protected from accidental damage.
We recommend that the area surrounding the HV test electrode is secure and that personnel cannot
enter the area when HV is enabled. The instrument is provided with an interlock loop connection which
may be connected through a series of switches (see Fig 15) to ensure that HV is disabled if the interlock
loop is opened. If this is not practical, the interlock loop connections may be joined by a short,
insulated wire. Please refer to Fig 13 below.
If required, a remote operation button may be fitted to integral instruments, please refer to Fig 12 below.
Additionally, the instrument is provided with two independent change-over relay switches, allowing the
user to interconnect this unit with process or factory automation, or to connect an Andon light and/or
sounder. The contacts will change over whenever an alarm state is generated and will revert once the
alarm state is cleared. The timing of these state changes is introduced under Alarm Mode below.
Please refer to Fig 14 below.
Once the instrument has been installed, and the ground and HV cables fitted, the mains supply cable
can be connected, and after ensuring no risk of shock to any personnel, the instrument can be turned on.
We recommend disconnecting the mains supply when making adjustments or alterations to electrodes,
or the HV cables supplying them.
The green switch will illuminate when turned on. The on-off button on the front panel should be pressed
briefly and the screen will illuminate.
The instrument, as supplied, is set with default parameters to comply with BS 62230. These settings may
be suitable, but there is a wide range of adjustments which may be customised to tailor the instrument

Instruction Manual
14 06/23
performance to suit your application. Further detail is provided below and in the on-line user manual.
The button at the top right of the screen will provide access to the following settings via the on-screen menus:
Test Voltage
The instrument will generate a voltage between 0.9kV and 40kV. In general, the test voltage should be
set to a level that will ensure the detection of flaws through the thickness of the material under test, but
not so high as to risk causing damage to the material itself. Various standards are available, and
Buckleys can provide guidance. However, in all cases, it is recommended to first test on sacrificial
samples to confirm the theoretical approach.
Alarm Threshold
The instrument sensitivity may be set from 10µA (most sensitive) up to 450µA, and to Spark Only mode
(least sensitive). The preferred approach is to set the alarm threshold at the lowest (and most sensitive)
level that avoids false alarms, with some allowance for variability. The actual setting will be critically
dependent on the material being tested and the environmental conditions under which the tests are
conducted. Again, sacrificial samples are recommended to validate the setting, particularly in process
control applications.
Alarm Mode
There are four settings for the alarm mode which are located in the Alarm Menu . These affect the way
the counter increments when a flaw is detected.
When an alarm state is generated, the screen of the unit will change from Blue (HV Active) to Red
(Alarm), and the internal buzzer will sound.
The internal relay will change state whilst the alarm is active and will return to the rest state when the
alarm state concludes.
Depending on the operating conditions, and particularly in process applications, the time during which
a flaw may be within the area covered by the test electrode might be extremely brief, potentially only
a few microseconds. However, the alarm indication must persist long enough for the user to observe it,
typically at least a few seconds. If the relays are used, it must also be maintained for a sufficient period
for the relay to physically change state. Similarly, there must be a finite time period following an alarm
state to permit the relay to return to the rest state.
In order to control the way in which alarms are managed, the
Alarm Mode may be selected from these options:
FAST MODE
In FAST mode, the counter will increment whenever a flaw is detected, even if an alarm is already
active. There is an effective hardware limitation of approximately 10 microseconds during which a
second flaw will not be registered.
Fig 8 – FAST MODE

06/23 15
SLOW MODE
In SLOW mode, the counter will not increment if a flaw is detected during a pre-existing (user
adjustable) alarm ON period but will do so if a flaw is detected immediately following an alarm
indication.
Fig 9 – SLOW MODE
VERY SLOW MODE
In VERY SLOW mode, the counter will not increment during a pre-existing alarm indication, nor during a
(user adjustable) OFF period thereafter.
Fig 10 – VERY SLOW MODE
RESTART MODE
In RESTART mode, detection of a flaw will prolong the existing alarm by the user-set alarm ON period,
but the counter will not increment.
Fig 11 – RESTART MODE

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16 06/23
These modes are supported by three user-adjustable timer settings.
Alarm (ON) Period
This is the period of time that an alarm will remain active. It may be adjusted from 0 to 5000ms. A
period less than 15ms may not provide adequate time to ensure that the relay changes state.
No-Alarm (OFF) Period
This is the period of time following an alarm that a further alarm is inhibited in VERY SLOW MODE . It may
be adjusted from 0 to 5000ms. A period less than 20ms may lead to the relay remaining closed
between successive alarms.
HV Pause
This is the period of time following an alarm during which the HV output is disabled. It may be adjusted
from 0 to 5000ms. During the pause, the instrument will not generate HV and cannot detect flaws. This
may be considered as a way of extending the hardware delay noted in the description of
FAST MODE
above.
Additionally, the following user comfort features may be configured:
Alarm Volume
(Main menu) as described. The unit incorporates a sounder whose volume is adjustable.
Warning Tick
(Main menu) the instrument can be set to emit a “tick” noise whenever HV is active. This may be
disabled.
Display Brightness
(Display Menu) the screen brightness can be adjusted.
Display Contrast
(Display Menu) the screen contrast can be adjusted.
For convenience, the instrument is provided with the following pre-set Operating Modes:
BS EN 62230
This mode pre-sets the Test voltage to 5kV, the alarm current threshold to 200µA, sets FAST MODE , the
ON and OFF times to 30ms, and HV Pause to 250ms. This setting is suitable for tests carried out in line
with the BS standard
Electric Cables – Spark-test method .
If the
Full Custom Operation Mode is selected, all functions may be adjusted by the user, unless
Manager Lock has been activated.
Other pre-set Operation Modes may be added to this list in due course.
All function settings and selections will be retained when the instrument is shut down, provided the O/1
button on the front panel is operated, followed by turning the instrument off by use of the mains switch.
Turning off by the mains switch or unplugging will not retain any software settings made since the
instrument was last switched off using the O/1 button on the front panel.

06/23 17
Setup (continued)
Network Cable Connection
The network provides a low voltage connection between instruments, as shown in the diagrams on
page 11 above. The network requires a terminator plug
(6005-0497) which is supplied with all Integral and
Command+ units. If your installation does not require a network, align and insert the plug into the
integral unit. The plug fits by a straight
PUSH , and is removed by a straight PULL ; do NOT twist.
If you are connecting multiple instruments, the network cables must be daisy-chained – a cable from
the command unit to the first output unit, and from the first to the second output unit if applicable. The
terminator should be fitted to the remaining socket in the last unit.
Fig 12 – Network Connections
Interlock Loop Connection
Buckleys always recommends that HV electrodes should be installed in an area from which staff are
excluded when they are energised. This is particularly important where the Command+ module is used,
and it may not be possible to verify visually that the area is safe before energising HV. To facilitate this,
the instruments are provided with interlock connections which will disable the HV generator if the loop is
not closed. This loop can be connected to door switches or guarding. The precise connections
depend on whether one, or two modules are used:
Fig 13 – Interlock Loop Connections

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18 06/23
Remote HV Energise Connection
Many existing customers use a DCCT connected via an HV cable to a passive HV handle. This handle is
fitted with an
ON button to enable HV generation, and the facility to connect such a handle is
provided for with the Integral Pro2 versions of the instrument.
Integral Instruments are fitted with a remote-control connection which allows
a handle button or other remote switch to control the generation of HV. An
adaptor
(5700-1076 / 6005-0496) is available to connect a Buckleys DCCT handle
to the necessary connections on the rear of the instrument. The remote-
control button should be connected between pins 11 & 12 of the green 12-
way connector.
Buckleys do not recommend the use of a latching switch or button in this
application.
A remote-button handle should not be used in multi-channel applications.
Fig 14 – Remote Switch Connections
Alarm Relay Connections
Within each output channel of the DCCT instruments, a dual-pole, dual-throw relay is fitted. The relay
contacts are zero-volt; there is no electrical connection to them within the instrument. The contacts are
rated at 250V & 5A.
The contacts are pins 1-6 of the 12-way connector on all units. In the case of dual channel instruments,
the second channel has a dedicated connector for its independent relay. Relay pins are as tabulated.
Fig 15 – Alarm Relay Connections

06/23 19
Instrument Setup – User Menus
The DCCT instruments are controlled via the on-screen menus, and the soft keys on the front panel. The
metal button marked with the yellow warning symbol is used to energise the HV output.
Access on-screen menu by pressing
the
b button which is also used to
select menu options and/or confirm
adjustment of set values.
The d and e buttons are used to
scroll up and down the menus, and
to increase or decrease set values.
The c button is used to close menu
items without modification and to
return to the home screen.
The instrument is turned on and off
with the
a button. When this is
used, the settings will be retained.
Fig 16 – User Interface Controls
Home Screen
The home screen display shows the overall status of the instrument and any connected output units.
The set-point voltage is 10kV and the alarm threshold current has been set to 200µA. The unit is currently
not generating HV.
Each connected channel will display the Unit ID (80 in this case) and the status, the detected current
and the fault counter in a box.
Fig 17 – Home Screen – HV Not Energised
Energising HV, by pressing the metal button, will change the backlight to blue to signify that HV is
present on the output of the instrument and the Command Status will indicate
Output ON .
The connected channel(s) will change to show the output voltage, which will normally match the set-
point, and the actual current will be displayed. The Menu option is disabled.

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20 06/23
Fig 18 – Home Screen – HV Energised
Pressing the button again will turn HV off and the screen will return to the previous version.
The symbol indicates that the
b button will access the Main Menu.
Use of the
d and e buttons will highlight through the Voltage set point, Alarm Threshold set point and
the windows for each connected output unit in turn. When an item has been selected, the text will
invert (white on black) or the selected window border will be bold.
Fig 19 – Voltage Set Point Select on Home Screen