Buckleys PST-100 User manual

MANUFACTURERS OF SPECIALIST TEST EQUIPMENT
PST-100
Operating Instructions
English Version
Please read carefully before use

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Contents Page
General Description 4
Technical Specification 5
Unpacking 6
Safety precautions and symbols 6
PST-100 Earth Terminal 8
Symbol definitions –IEC61010:2010 8
Calculating the test voltage 9
SP-02-74 test voltage formula 10
Operation 11
Setting the Output Voltage 11
Applications 12
Insulation Testing 12
Gas Discharge Lamp Testing 12
Ozone Production 12
Electromagnetic compatibility 13
Electromagnetic Emissions European Union Directive 2004/108/EC 13
Maintenance 15
Disposal information 16
EC Declaration of conformity 17
Contact details 18
Distributor details 18
Product Registration 19

Instruction Manual
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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.
20ms
100kHz ring
Output voltage characteristics at 50hz mains frequency

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Technical Specification
Operating temperature range: 0 to +30°C
Storage temperature range: -10 to +40°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 controls established by a quality
management system that meets the requirements of ISO9001.

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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 (ground) terminal
Read the information in this manual carefully before using the equipment.
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.

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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).
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.
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 do not use our high-voltage test equipment
under any circumstances.
Misuse or failure to comply with the guidelines outlined in this manual
may impair the safety provided by the equipment.

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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.
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.

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Below is a pictorial representation of the PST-100, detailing the functional
earth terminal arrangement.
Output adjustment pot
L fuse
L
Switch 1
Control
electronics
HT terminal
+ -
N
N fuse
Switch 2
- +
Nose
cone
Y capacitors
PST-100 functional earth terminal arrangement
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.

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coating
coating
SP-02-74 test voltage formula
Test Voltage = 1250 x √ T
Where T
coating is the coating thickness in mils (0.001”).
Alternatively
Test Voltage = 250 x √ T
Where T
coating is the coating thickness in microns (0.001mm).
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.

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Operation
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.
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 A2) 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.

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Applications
Insulation Testing
The insulation to be tested must have a conductive backing, e.g. if a
joint in plastic or rubber is to be tested, it should be laid on a met- al
sheet. If this is not practical, aluminium foil or copper wire can be
placed behind the joint. Ideally this should be earthed, although this is not
necessary if the area of the metal backing is larger than the area of the
probe by a ratio of at least 1000:1.
Slowly sweep the area to be tested, looking at the probe at all times. When
a fault is passed over, the high voltage corona discharge will change to a
single spark. Remove the probe from the surface and mark the point
where the fault was detected.
NOTE: The electrode size has an effect on the output voltage. For this
reason we recommend a maximum size of 150mm.
Gas Discharge Lamp Testing
The PST-100 can be used to excite gas discharge lamps to confirm that
the vacuum has not been lost.
The lamp/tube should not be fitted, as the high voltage could contact
the fitting and be passed into the wiring, which may 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 lamps vacuum is satisfactory, 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 lectures, demonstrations etc.

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Electromagnetic compatibility
Electromagnetic Emissions European Union Directive 2014/30/EU
Before operating this equipment it is essential that the following risk
assessment be taken.
As this equipment will produce an electromagnetic emission when
actually arcingdown 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 radio
telephone 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, signalling and
telephone cables above, below and adjacent to the area where the
tests are being carried out. The wearers of pacemakers and hearing

Instruction Manual
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aids should also be considered. Measuring and calibration equipment may
also be susceptible.
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 an AC Pinhole Detector would be safe. However, it would be unwise to
use both 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 example, 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
considered as there may be equipment in use that could be affected by your
tester’s emissions.
This type of tester will usually 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 PST-100 has been designed with EMC in mind and therefore all leads are
of 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 because this will
reduce any interference generated by the spark. This also prevents static build-
up in the operator and thereby avoiding electric shock.
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.
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
regulations.
For further information on UK WEEE regulations click on:
www.gov.uk/government/publications/weee-regulations-2013-government-
guidance-notes
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.

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EC Declaration of conformity
We:
Buckleys (UVRAL) Ltd
As manufacturer of the apparatus listed,
declare that the product:
PST-100 High Voltage Spark Tester
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

Instruction Manual
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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.
Register your product in 5 minutes
Once your product is registered, you will receive
the following benefits:
•FREE annual service & calibration reminders by email
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We strive to improve the quality of our products and service.
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.

PST-100
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5830-0012 PST-100/IM/ENG/V.6/19