Buckleys PST-100 User manual

PST-100
High Voltage Spark Tester
Instruction manual
Please read this manual before using the equipment
5830-0012 07/21 │ English

Table of Contents
General Description .......................................................................................... 4
Technical Specification .................................................................................... 5
Unpacking.......................................................................................................... 6
Safety Precautions and Symbols ..................................................................... 6
PST-100 Earth Terminal ............................................................................................... 7
Symbol definitions – IEC61010:2010 .......................................................................... 8
Calculating the test voltage............................................................................ 9
SP-02-74 test voltage formula ................................................................................... 9
Operation......................................................................................................... 10
Setting the Output Voltage .................................................................................... 10
Applications ..................................................................................................... 11
Insulation Testing: ..................................................................................................... 11
Gas Discharge Lamp Testing .................................................................................. 11
Ozone Production.................................................................................................... 11
Risk Assessment ................................................................................................ 12
Maintenance ................................................................................................... 13
Disposal information........................................................................................ 13
EC Declaration of conformity ........................................................................ 14
UKCA Declaration of conformity ................................................................... 14
Contact details ................................................................................................ 15
Distributor details.............................................................................................. 15
Product registration......................................................................................... 16

Instruction Manual
4
General Description
The PST-100 high voltage spark tester is a lightweight, hand held, spark- test pistol.
The PST-100 is primarily used for detecting pinholes or flaws in electrically non-
conductive coatings, linings, membranes, pipe wraps and other plastic coated
metals.
The PST-100 generates a pulsed ring output voltage. The pulse repetition is 20mS @
50Hz or 16.6mS @ 60Hz mains. The ring frequency is approximately 100kHz. The
output voltage is adjustable from 10kV to 55kV.Description
Output voltage characteristics at 50hz mains frequency

PST-100
5
Technical Specification
Operating temperature range: 0 to +45°C
Storage temperature range: -10 to +70°C
Supply voltage:
6000-0002, 6000-0006, 6000-0014 220/240V AC
6000-0003, 6000-0007, 6000-0015 105/120V AC
Supply frequency: 50 to 60 Hz
Max power consumption: 30VA
Output voltage: 10kV to 55kV
Output: Pulsed Ring
Pistol weight: 1.0kg
Altitude: Up to 2000m
Relative humidity: 80% Max (Non-Condensing)
Installation category: Category II
This product has been manufactured under the controls established by a quality
management system that meets the requirements of ISO9001.

Instruction Manual
6
Unpacking
Remove the PST-100 from its packaging and check for damage. If any part is
damaged, the carrier and supplier should be notified immediately.
All packing material should be kept for inspection. The PST-100 should not be used.
The package contains the following items:
•1 x PST-100 pistol unit
•1 x Flexible probe
Safety Precautions and Symbols
Caution, risk of danger
Caution, risk of shock
Category II double
isolation
Earth return (grounding
terminal)
Read the information in this manual carefully before using the equipment.
The PST-100 Spark Tester is intended to generate a high voltage discharge, it is only
to be used by responsible and authorised personnel that have read and
understood this manual.
The probe must NEVER be directed at the body.
There is a potential risk to those who might have an incipient heart condition.
There is also a potential risk from the reflex action when receiving a high- voltage
shock. Injury could also occur if the spark were discharged to sensitive parts of the
body (e.g. eyes).
Note: The works safety officer should approve the use of this equipment.
IMPORTANT: Service and repair of this product and its components MUST ONLY
be undertaken by trained, approved technicians working in full accordance
with Buckleys’ service guidelines. Failure to do so may expose the operator to
potentially lethal voltages.
Under no circumstances should anyone other than trained approved
technicians attempt to dismantle or repair this product.

PST-100
7
In a reasonably ventilated room of a volume greater than 40m3, the exposure to
ozone produced by the high voltage spark should not present a risk to health. In a
‘confined space’ situation it is likely that ozone levels will exceed the exposure limit
and present some risk to health. Under these conditions adequate ventilation must
be provided.
Misuse or failure to comply with the guidelines outlined in this manual may impair
the safety provided by the equipment.
PST-100 Earth Terminal
The PST-100 has been tested and verified by an authorised, independent third
party as meeting the requirements of IEC 61010:2010 - Safety requirements for
electrical equipment for measurement, control, and laboratory use.
The construction methods employed throughout comply with double insulation.
The earth terminal located on the handle is a functional earth terminal, NOT a
Protective Conductor Terminal as defined by IEC61010 and is intended as a high
voltage return point during the operation of the PST-100. This arrangement also aids
suppression of possible EMC interference.
Therefore when conducting an electrical safety test (Portable Appliance Test) to
the PST-100 it should be considered a class 2 appliance and tested accordingly.
WARNING: This equipment must not be used in any combustible
atmosphere; the high voltage discharge will cause a spark from which
an explosion could result.
WARNING: This equipment must not be exposed to damp or wet conditions, or
where the amount of conductive dust is greater than would occur in a normal
situation
WARNING: Never connect or disconnect the electrode with the PST-100
connected to the mains supply.
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.

Instruction Manual
8
Symbol definitions – IEC61010:2010
Functional Earth (ground) Terminal
Terminal by which electrical connection is made directly to a point
of a measuring or control circuit or to a screening part and which is
intended to be earthed for any functional purpose other than
safety.
Double Insulation
Insulation comprising both basic insulation and supplementary
insulation.
Below is a pictorial representation of the PST-100, detailing the functional earth
terminal arrangement.

PST-100
9
Calculating the test voltage
The test voltage needs to be high enough to locate a fault but not so high as to
cause one. With reference to BS EN 60052:2002, (measurement of voltage with
Sphere-Gaps) it can be seen that 32,000 volts will
jump a gap of 1cm between spheres of 5cm diameter, however the same voltage
will jump a gap of nearly 3cm between needles. This is because the shape of the
electrode affects the point at which corona discharge starts. A spark or arc over,
will occur when the voltage is high enough such as to cause localised breakdown
of the air between the electrodes, a spark then forms, ionising the air drastically
reducing its electrical resistance.
For materials with a thickness in the range of 1mm to 30mm, the NACE Standard SP-
02-74 voltage calculation formula is normally used.
SP-02-74 test voltage formula
Alternatively
After the test voltage is calculated it is necessary to check that the voltage is not
so high as to damage the material. The dielectric strength is the voltage at which
the material starts to breakdown, this is expressed in volts per mm, normally with
D.C. As an example, a 2mm thick sheet of P.V.C. would require a voltage of
11.18kV using the above formula.
Referring to the manufacturer’s technical data, the dielectric strength is 8.4kV per
mm. Therefore, 2mm of such material has a dielectric strength of 16.8kV and is safe
to test at 11.18kV.

Instruction Manual
10
Operation
Screw the flexible probe electrode into the red end of the PST-100. Set the output
control knob on the rear fully anti-clockwise. Connect the plug to the mains supply
socket.
Setting the Output Voltage
Hold the end of the flexible probe at the determined distance for a spark to jump
to an earthed metal test piece, squeeze the trigger and turn the output control
knob slowly clockwise until the output voltage is high enough to cause a spark to
jump the gap. Alternatively — for increased accuracy in setting the output voltage
- a Buckleys Spark Gap Setter (part number 6005-0064) may be used.
The probe should always be kept moving when testing as the high voltage and ring
frequency combination may cause heating in the article under test which may
result in burning. The output control should be adjusted for the lowest output at
which an effective test can be carried out.
When testing is complete, release the trigger to switch off the PST-100’s output.
Disconnect the PST-100 from the mains supply before attempting to remove the
flexible probe.
WARNING: NEVER connect or disconnect the electrode with the generator
connected to the mains supply.
WARNING: This equipment must not be used in any combustible atmosphere;
the high voltage discharge will cause a spark from which an explosion could
result.
WARNING: This equipment must not be exposed to damp or wet conditions, or
where the amount of conductive dust is greater than would occur in a normal
situation.

PST-100
11
Applications
Insulation Testing:
The insulation to be tested should have a conductive backing, e.g. if a joint in
plastic or rubber is to be tested, it should be laid on a metal sheet. If this is not
practical, aluminium foil or copper wire can be placed behind the joint. It is
recommended that this should be earthed, although it is not necessary if the area
of the metal backing is very much larger than the area of the probe, e.g. greater
than 1000:1.
Adjust the output of the PST-100 for the item under test (see: Calculating the test
voltage). Slowly sweep the area to be tested, looking at the probe at all times.
When a fault is passed over, the high-voltage probe discharge will change to a
single spark. Remove the probe from the surface and mark the point where the
fault was detected.
Gas Discharge Lamp Testing
The PST-100 can be used to excite gas discharge lamps, to confirm that the
vacuum has not been lost e.g. fluorescent tubes.
The lamp/tube should not be fitted, as the high voltage could contact the fitting
and be passed into the wiring, and could damage other equipment connected to
that wiring.
Hold the probe against the glass of the lamp and increase the output voltage from
minimum, if the lamp is correctly evacuated, the lamp will glow where the probe
touches the glass.
Ozone Production
Small quantities of ozone can be produced from the high-voltage spark, useful for
chemistry lecture demonstrations etc.
NOTE: Electrode size influences the output voltage. For this reason, we recommend a
maximum size of 150mm.

Instruction Manual
12
Risk Assessment
It 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 safety
•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 the test outdoors, or 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?
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 to be tested?
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 – eg industrial processes, measuring equipment,
scientific apparatus, domestic radio and TV?

PST-100
13
Other Risks
•Have you checked that there are no ongoing processes in the area (eg
below the roof you’re working on) that may be dangerous – X-ray
machines, other radiation?
•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?
Maintenance
The PST-100 has been designed to be maintenance free, however the PST-100
should be inspected regularly, checking for damage to the unit. If any damage is
found, the PST-100 must not be used, and should be returned to the manufacturer
for repair.
Two 500mA anti-surge fuses are located on the rear panel. These may be replaced
by the user. Disconnect the PST-100 from the mains supply before attempting to
replace fuses.
Disposal information
Producer registration number: WEE/HJ0051TQ
This Product must be disposed of in accordance with UK WEEE
Producer Responsibility Regulations, or in accordance with your local
WEEE guidance.
For further information on UK WEEE Producer Responsibility regulations click on:
http://www.gov.uk/government/collections/producer-responsibility-regulations
IMPORTANT: Service and repair of this product and its components MUST ONLY
be undertaken by trained, approved technicians working in full accordance
with Buckleys’ service guidelines. Failure to do so may expose the operator to
potentially lethal voltages.
Under no circumstances should anyone other than trained approved
technicians attempt to dismantle or repair this product.
NOTE: Wherever you are intending to use equipment of this type, on your site or on a
customer’s, always obtain clearance from the company safety officer.

Instruction Manual
14
EC Declaration of conformity
We, Buckleys (UVRAL) Ltd., as sole manufacturer of the apparatus listed below,
declare that the product PST-100 High Voltage Spark Tester is manufactured in
conformity with the following directives: 2014/30/EU, 2014/35/EU and
2015/863/EU.
Date: 01/07/2021
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
PST-100 High Voltage Spark Tester 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: 01/07/2021
Authorised by:
J P Hoveman
CEO, Buckleys (UVRAL) Ltd.

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]
Website: www.buckleysinternational.com
Distributor details

Product registration
Thank you for choosing a Buckleys product,
we are sure it will provide you with many years
of reliable service.
Please register this product via Buckleys’
website and download the
Warranty Registration Certificate.
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the following benefits:
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Registering your product helps 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.
We will also send you annual service/calibration reminders by email to help ensure
your product is always in perfect working order.
To register your product, simply visit:
www.buckleysinternational.com/registration
... Complete the online form and click on SUBMIT.
5830-0012~PST-100 Pro’/IM/ENG/V.7-21