Clinton AC-30B User manual

Models AC-30B and AC-30BHP
Mains Frequency Spark Tester
Instruction Manual
Instruction Manual
295 East Main Street
Clinton, CT 06413 USA
Telephone: [phone] Fax: [phone]
www.clintoninstrument.com
Clinton Instrument Company

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 1
Rev Null b0002 10/22/18

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 2
Contents
DECLARATION OF CONFORMITY........................................................................................................................................................5
SPECIFICATIONS ................................................................................................................................................................................6
SAFETY ..............................................................................................................................................................................................8
SAFETY SYMBOL .........................................................................................................................................................................................8
ENVIRONMENTAL CONDITIONS......................................................................................................................................................................8
AVOID THE RISK OF FIRE! .............................................................................................................................................................................9
CAUTION:PACEMAKER WARNING .................................................................................................................................................................9
CAUTION:OZONE PRODUCTION ....................................................................................................................................................................9
ELECTRICAL SHOCK HAZARD FROM PRODUCTION LINE SPARK TESTERS................................................................................................................ 10
INSTALLATION .................................................................................................................................................................................11
CAUTION:.............................................................................................................................................................................................11
UNPACKING.............................................................................................................................................................................................11
SITE PREPARATION....................................................................................................................................................................................12
Select a suitable location for the spark tester: ................................................................................................................................12
Select a suitable location for the spark tester: ................................................................................................................................12
RC Control Unit:............................................................................................................................................................................... 13
X3B Horn/Light Tower: ....................................................................................................................................................................13
Provide for ventilation of the Test Module......................................................................................................................................13
POWER WIRING .......................................................................................................................................................................................13
Install an external disconnecting device..........................................................................................................................................13
Mains Power....................................................................................................................................................................................14
Ground the Spark Tester.................................................................................................................................................................. 14
TERMINAL BLOCK WIRING..........................................................................................................................................................................14
CONNECTING THE SERIAL RS-485 ...............................................................................................................................................................16
CONNECTING TO THE ANALOG INTERFACE .....................................................................................................................................................16
INSTALLING THE COMPACTCOM™MODULE ..................................................................................................................................................16
CONNECTING THE X3B ..............................................................................................................................................................................17
Unpacking the X3B ..........................................................................................................................................................................17
Connecting the X3B .........................................................................................................................................................................17
X3B to Spark Tester Connections.....................................................................................................................................................18
SPARK TESTER CONTROLS ...............................................................................................................................................................19
ON/OFF Power Switch .....................................................................................................................................................................19
Voltmeter ........................................................................................................................................................................................ 19
“A” Button .......................................................................................................................................................................................19
UP/DOWN ARROW (VOLTAGE ADJUST) buttons.............................................................................................................................19
Fault Counter...................................................................................................................................................................................19
“B” Button .......................................................................................................................................................................................19
“CR” COUNT RESET button ..............................................................................................................................................................19
FAULT light ...................................................................................................................................................................................... 20
“R” RESET button............................................................................................................................................................................. 20
High Voltage On Lamp ....................................................................................................................................................................20
Safety Interlock switch ....................................................................................................................................................................20
Protective Cover ..............................................................................................................................................................................20
Bead Chain Electrode ......................................................................................................................................................................20
DEFINITION OF TERMS ....................................................................................................................................................................21

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 3
NEW FEATURES ...............................................................................................................................................................................22
DISPLAY: ................................................................................................................................................................................................ 22
FRONT PANEL SECURITY ............................................................................................................................................................................22
COMMUNICATION MODULES .....................................................................................................................................................................22
VOLTAGE WATCHDOG ..............................................................................................................................................................................23
FAULT TYPING .........................................................................................................................................................................................23
BACKWARDS COMPATIBLE......................................................................................................................................................................... 23
SPARK TESTER CONFIGURATION (FRONT PANEL) ............................................................................................................................24
NAVIGATING THE CONFIGURATION MENU.....................................................................................................................................................24
RC DISPLAY SECURITY (PIN)....................................................................................................................................................................... 24
CONFIGURATION MENU OPTIONS................................................................................................................................................................25
SPARK TESTER INPUTS.....................................................................................................................................................................30
High Voltage Enable (HVE) ..............................................................................................................................................................30
Fault Reset (FR) ............................................................................................................................................................................... 30
SPARK TESTER OUTPUTS .................................................................................................................................................................30
GENERAL OUTPUTS...................................................................................................................................................................................31
Output Disabled (OFF) .....................................................................................................................................................................31
Cover Open (CVO):........................................................................................................................................................................... 31
Unit Malfunction (UER) ...................................................................................................................................................................31
VOLTAGE MONITOR OUTPUT OPTIONS.........................................................................................................................................................31
High Voltage On Lamp (HVL)........................................................................................................................................................... 31
High Voltage Watchdog (WDL) .......................................................................................................................................................31
FAULT OUTPUT OPTIONS ...........................................................................................................................................................................32
Fault Pulse (FPL) .............................................................................................................................................................................. 32
Any Fault Alarm (AFA) .....................................................................................................................................................................32
Pinhole Alarm (PHA) ........................................................................................................................................................................33
Metal Contact Alarm (MCA)............................................................................................................................................................33
Multi Pinhole Alarm (MPA) .............................................................................................................................................................33
Gross Barewire Alarm (GBA) ...........................................................................................................................................................34
Any Fault Limit (AFL) .......................................................................................................................................................................34
Pinhole Limit (PHL) ..........................................................................................................................................................................35
Metal Contact Limit (MCL) .............................................................................................................................................................. 35
Multi Pinhole Limit (MPL) ................................................................................................................................................................ 35
Gross Barewire Limit (GBL)..............................................................................................................................................................35
Fault Combination Limit (FCL) –Must be configured via USB computer interface ......................................................................... 35
Any Barewire Alarm (ABW) ............................................................................................................................................................. 36
Any Pinhole Alarm (APH) ................................................................................................................................................................. 36
FAULT TYPING .................................................................................................................................................................................37
PINHOLE ..........................................................................................................................................................................................37
DIRECT METAL CONTACT ................................................................................................................................................................37
MULTI PINHOLE...............................................................................................................................................................................37
GROSS BAREWIRE............................................................................................................................................................................37
SPARK TESTER CONFIGURATION (USB)............................................................................................................................................38
TESTING YOUR PRODUCT ................................................................................................................................................................39
PREPARING YOUR PRODUCT FOR TESTING .....................................................................................................................................................39

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 4
RS-485 INTERFACE ...........................................................................................................................................................................40
RS-485 CONNECTOR ................................................................................................................................................................................ 40
RS-485 PARAMETERS ...............................................................................................................................................................................40
ANALOG INTERFACE ........................................................................................................................................................................41
ANALOG INTERFACE PIN FUNCTIONS ............................................................................................................................................................41
FIELDBUS COMMUNICATIONS INTERFACE.......................................................................................................................................42
FIELDBUS COMMUNICATIONS PARAMETERS...................................................................................................................................................42
FIELDBUS SPARK TESTER PARAMETER ADDRESSES ...........................................................................................................................................43
CALIBRATION ..................................................................................................................................................................................44
STCAL CALIBRATION ................................................................................................................................................................................44
EVM MANUAL CALIBRATION PROCEDURE (OR OTHER HIGH VOLTAGE DIVIDER) ....................................................................................................44
Connecting the EVM........................................................................................................................................................................44
Taking Calibration Readings............................................................................................................................................................45
Adjusting the Calibration.................................................................................................................................................................45
MAINTENANCE ................................................................................................................................................................................47
FUSES.....................................................................................................................................................................................................47
PERIODIC INSPECTION................................................................................................................................................................................47
TROUBLESHOOTING ........................................................................................................................................................................48
SETTING FACTORY DEFAULTS ......................................................................................................................................................................49
REPLACEMENT PARTS......................................................................................................................................................................50
OPTIONAL ACCESSORIES..................................................................................................................................................................51
FS-4 FLOOR STAND ASSEMBLY.........................................................................................................................................................53
GROUNDING OF CONDUCTORS DURING THE SPARK TEST ...............................................................................................................54

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 5
EU Declaration of Conformity
Declaration of Conformity
ration of Conformity

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 6
Specifications

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 7

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 8
Safety
Safety Symbol
The symbols depicted below are safety symbols placed on spark test equipment.
It is important to understand the meaning of each.
Caution symbol. Caution- refer to the manual to protect against damage to the
equipment or to avoid personal injury.
Indicates Hot Surface. Do not touch.
Risk of electric shock symbol.
Earth ground symbol.
Environmental Conditions
The spark tester is designed to be safe under the following conditions:
• Indoor use.
• Altitude to 2000m.
• Temperatures from 5ºC to 40ºC.
• Humidity to 80% R.H. at 31ºC, decreasing linearly to 50% R.H. at 40ºC
The Clinton Instrument Company certifies that this equipment met its published
specifications at the time of shipment. The calibrations of the equipment are
checked against Measurement Standards (Reference) maintained by the Clinton
Instrument Company. The accuracy of these standards is traceable to the
national standards at the National Institute of Standards and Technology (NIST)
or derived by ratio type measurements. For customer service or technical
assistance with this equipment, please contact:
The Clinton Instrument Company
295 East Main Street, Clinton, CT 06413 USA
Telephone: [phone] Fax: [phone]
Website: www.clintoninstrument.com
Email: [e-mail]

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 9
Avoid the Risk of Fire!
Every time your wire line stops, be sure that the HV in the electrode goes off. If
the HV remains ON while your wire line is stationary, the wire insulation within
the electrode will heat and there is a danger of combustion. Refer to the table in
“Installation” labelled “Terminal Block connections,” under HV Enable on how to
safely install your spark tester.
Caution: Pacemaker Warning
Clinton Instrument Company strongly advises any individual using a pacemaker
or other such medical device to avoid operating or being in the vicinity of spark
testers. Current studies indicate that such medical devices can malfunction in
the presence of electrical and magnetic fields. When a fault occurs in the
electrode of a Clinton spark tester, both high and low frequency
electromagnetic fields are generated. The strengths of these emissions are
unknown, since they depend on test voltage and other variables. The danger is
greater when a customer does not ground the inner conductors of a test
product. While Clinton cautions its customers to ground the test product for
safety reasons, many times this warning is ignored. In this situation, both the
spark tester and the entire length of the wire line will radiate these emissions.
There is also a serious risk of electrical shock if an individual comes into contact
with an ungrounded test product.
Email: [e-mail].
Caution: Ozone Production
Ozone is a naturally occurring gas (O3) and is produced when there is an
electrical discharge through Oxygen (O2). Whatever generates arcing will
produce Ozone (electric motors and office photocopiers for example).
High frequency spark testers produce ozone because the AC test voltage
generates a corona field, ionizing the air surrounding the cable within the
electrode. Ozone is produced in proportion to the surface area of this corona
field, which varies in size primarily due to the capacitance of the specific cable
under test. Other factors include the length and condition of the spark tester
electrode, and test voltage level.
When Ozone is noticeable and problematic, ventilation should be added to the
workstation to exhaust the air and to provide fresh air. To gauge exposure levels
in a given setting, operators can wear Ozone sensitive badges during a working
day. Thus total exposure can be assessed and appropriate actions taken.
Email: [e-mail].

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 10
Electrical Shock Hazard from Production Line Spark Testers
By Henry H. Clinton
The commonly accepted maximum values of 60Hz. current passing through the
human adult body which permit a subject to let go of electrodes are nine
milliamperes for males and six milliamperes for females. At 3000 Hz. this value
increases to about 22 milliamperes for men and 15 milliamperes for women, DC
currents do not present the same let-go problems, but a subject can readily let
go at a level of 60 milliamperes. A continuous 60 Hz. current above 18
milliamperes stops breathing for the duration of the shock only. Ventricular
fibrillation may occur above a level of 67 milliamperes. The reaction current
level of 60 Hz. is about .5 milliamperes. Above this level a muscular reaction can
occur which can cause a secondary accident. The DC and 3 kHz. Levels are
probably considerably higher. Capacitor discharge energy of 50 Joules (watt-
seconds) is regarded as hazardous.
Clinton DC spark testers are current limited to 5 milliamperes or less. Three
kilohertz spark testers are limited to 4 milliamperes or less, and 60 Hz. types to
7 milliamperes. Impulse spark testers can deliver a maximum charge of about .2
Joules 248 times per second. All these spark testers have current outputs above
the reaction level, but none above the let-go threshold level. Because of the
possibility of secondary accidents caused by muscular reactions, operators
should be protected against accidental shock. Electrodes are supplied with
interlock switches, and these should not be disabled. The conductor under test
should be grounded. If an operator must inspect the product by touching its
surface while it is being spark tested, he should be electrically insulated from his
environment, and any possible cause of a secondary accident caused by reaction
should be eliminated.
For references, see: Dalziel, Ogden, Abbot, “Effect of Frequency on Let-Go
Currents,” Transactions of A.I.E.E., Volume 62, December 1943, and Dalziel,
“Electric Shock Hazard,” I.E.E.E., Spectrum, February 1972.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 11
Installation
CAUTION:
The installation procedures listed below are to be performed by qualified
service personnel only. Failure to follow these procedures may result in danger
to personnel and equipment damage.
Unpacking
Remove the spark tester from the carton. Retain the packing material in the
event that the unit is returned for calibration or service at some future time.
The following items are packed with the spark tester:
1. AC-30B Spark tester
2. RC Display With mounting bracket (when ordered)
3. A power cord
4. A 9-Pin green terminal block connector for process control connec-
tions. After it is wired, it will plug into the terminal block on the
back of the spark tester
5. A 4-Pin green terminal block connector for process control connec-
tions. After it is wired, it will plug into the terminal block on the
back of the spark tester
6. RS-485 connecting cable 3 Feet Long
7. FS-6G Floor Stand Components and hardware
8. X3B Horn/Light Tower with power cord and connecting cable kit
9. Quick Start Guide
10. Short Manual

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 12
Site Preparation
Select a suitable location for the spark tester:
The Floor Stand consists of 4 legs, 4 feet, 8 rails, a control unit mounting
bracket, and a set of hardware. Before assembling the stand, determine the
height of the wire line center. The wire line center of the electrode may be
positioned from 39” to 42” (99.1 to 106cm) from the floor. Using the hardware
supplied, bolt each Floor Stand foot to a leg at the appropriate height to provide
the required height for the wire line center. Assemble the Floor Stand as shown.
The Floor Stand must be securely mounted to the floor. Locate it in its desired
position along the wire line and anchor the feet securely to the floor system
using four (4) 1/2” or 12mm diameter bolts.
Remove the AC-30B Electrode from the shipping carton and place it on the
stand, aligning the four holes on the bottom of the Electrode chassis with four
holes on the top lip of the stand. Insert four (4) 1/4-20 x 1/2” long bolts
(supplied) through the Electrode chassis and secure with keps nuts.
Select a suitable location for the spark tester:
The AC-30B Spark Tester is designed for use in a fixed location, permanently
connected to its power source. The unit may be mounted on the supplied
Clinton floor stand and should be placed at wire line height and within easy
reach of the operator. For detailed dimensions of the spark tester, please see
the specification sheet.
The spark tester should be adjusted so that the product runs centered in the
electrode in both the vertical and horizontal axes and parallel to the mounting
plate. Vertical and horizontal dimensions for wire centers for standard
electrodes can be found on drawings supplied with this manual. For non-
standard electrodes, or for copies of the required drawings, contact the
Engineering Department of The Clinton Instrument Company.
When the spark tester is to be placed on a primary or jacketing (sheathing)
extrusion line, it is desirable to locate the equipment as close to the extruder
cross-head as practical, this generally means locating it just after the water
cooling trough. In this case it is important to wipe the water off of the product
thoroughly before it enters the spark tester electrode containment. Failure to
adequately dry the surface of the wire or cable can cause false-counting, and
can cause premature failure of the equipment.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 13
FS-6G Floor Stand
AC-30B Electrode
RC Control Unit
RC Control Unit:
The RC control unit is supplied with a rack mount bracket to mount the RC on
the Floor Stand beneath the AC-30B Electrode. If preferred, the RC can be
installed on top of the AC-30B Electrode or in a rack or panel as far as 200 feet
away from the AC-30B spark tester. RS-485 cables for connection of the AC-30B
to a computer or PLC must be purchased separately. Refer to the section
entitled “Programming Through the RS-485 Interface.”
X3B Horn/Light Tower:
An X3B Horn/Light Tower is supplied with the AC-30B Spark Tester. The red
lamp of the X3B alerts the operator that HV is present in the electrode, and
when a fault is found, the yellow lamp flashes and an alarm sounds.
Four (4) mounting bolts are provided on the side of the AC-30B Electrode to
mount the X3B. If another location is preferred, a longer connecting cable may
be required.
Provide for ventilation of the Test Module
As with any apparatus producing a spark or electrical corona, the AC-30B Spark
Tester produces ozone in the electrode region. While ozone reverts harmlessly
to oxygen within a few minutes, an external air extraction system is
recommended and should operate whenever the spark tester is in use. The
exhaust of the external air extraction system should be discharged either
outdoors or into some area well away from workers.
Power Wiring
Install an external disconnecting device
Install an external switch or circuit breaker in close proximity to the spark tester
and within easy reach of the operator. The switch or circuit breaker must meet
the relevant requirements of IEC 947-1 and IEC 947-3 and should be marked as
the disconnecting device for the equipment. The rating of the circuit breaker or
fuse should be no greater than 5 amperes.
Caution: Be sure the external disconnecting device is OFF and locked out before
continuing.
X3B Horn/Light Tower

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 14
Mains Power
The AC-30B operating voltage is factory set for 120/240 volts or
100/200 volts. Note the spark tester’s operating voltage (WARNING!
120V OR 240V), which is marked beneath the ON/OFF switch on the
back panel. If it does not match the power line voltage you will be using
to energize the spark tester, contact the factory.
Ground the Spark Tester
Locate the ground stud on the back panel of the spark tester. Remove
the outer nut and crimp terminal. Crimp a 16 awg. (1, 29 mm2 , 1, 31
cross section) stranded insulated wire (preferably green with a yellow
stripe) to the crimp terminal. Fasten this to the ground stud and secure
with the keps nut. Connect the other end to a safety ground system in
accordance with EN 60204-1:1993, Section 5.2, Table 1.
Terminal Block Wiring
Refer to the following table for information on pin functions. Locate the green
terminal blocks on the back of the spark tester and its companion green
terminal block connectors that came with the unit.
Conductors connecting auxiliary equipment, relays and switches should be
shielded 22 gauge or larger and should be stripped back ¼” (6mm) and fed into
the green terminal block connector at the proper pin number. Shields from con-
ductors connecting auxiliary equipment should be grounded to the safety
ground terminal.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 15
Pin
No.
Designation Conductor
1GND
2
HV ENABLE
3
RESET
4 not used
5
NO
6
COM
7NO
8
COM
9
NC
Pin
No.
Designation Conductor
1
NO
2
COM
3
NO
4
COM
9 - Pin Terminal Block Connections
HV Enable (IN0):
CAUTION: For HV on the electrode, ins tall a norma lly clos ed switch or
relay conta ct** between pins 1&2. This s wi tch or rel ay s houl d open
automati call y when the wi rel ine stop swi tch is a ctivated or be opened
manua l ly by the s ystem operator when the l ine stops. FAILURE TO DO SO
COULD RESULT IN A FIRE HAZARD If the HV rema i ns ON i n the el ectrode
when your l ine i s s tationa ry, the wi re ins ul a tion in the electrode wi ll
hea t and there is a danger of combus tion.
External Reset (IN1):
To reset the spark tes ter fault relay wi th an external s wi tch, wire a
momentary swi tch** between pi ns 1&3. When thes e contacts cl os e, the
fa ul t rel ay wil l return to a norma l s ta te. The i nterval tha t the contacts
are cl os ed must exceed 50 ms .
(3) 22 ga. stranded
conductors rated
250V, less than 10
meters in length,
contained in a
common insulating
sheath
*When connecting auxiliary equipment to dry relay contact pins 1, 2, 3,or 4, observe maximum ratings of
120VAC at 2 amps, 240VAC at 1 amp.
4 - Pin Terminal Block Connections
Watch Dog (OUT2):
Dry rela y conta ct pins 1&2 wi ll cl ose when the tes t voltage i s between
the VWDL (Voltage Wa tchdog Low Threshold) a nd the VWDH (Vol tage
Wa tchdog Hi gh Threshol d) values .
Bare Wire (OUT3):
To activate external lights, al arms or relays* when a Ba re Wire type
fa ul t occurs , wi re the m between dry relay conta ct pi ns 3 & 4. If the
output function is set LCH or RVF, the dry rel ay contacts wi ll remai n
closed until the RESET button is press ed or when pi ns 1&3 are closed by
remote s witch or rela y output function is set to NLC, the dry re l ay
contacts wil l return to norma l s tate after the interval known as the
ABMS (Any Ba re Wire Ala rm Ti me) has el a ps ed.
(3) 22 ga. stranded
conductors rated
250V, less than 10
meters in length,
contained in a
common insulating
sheath
HV ON Indication (OUT0):
Dry rela y conta ct pins 5&6 wi ll cl ose when the tes t voltage exceeds
500v. For a n i ndicati on tha t HV is ON in the electrode, wi re a l amp or
auxil iary device* here.
(3) 22 ga. stranded
conductors rated
250V, less than 10
meters in length,
contained in a
common insulating
sheath
Process Control (OUT1):
To activate external li ghts, a l arms or relays* when a fa ult occurs, wire
them between dry relay conta ct pi ns 9,8 & 7. If the output function is set
to LCH or RVF the dry rela y conta cts wil l rema in cl osed until the RESET
button i s pres sed or when pins 1&3 are closed by remote s witch or
relay. If the output function i s set to NLC, the dry rel ay contacts wi ll
return to normal s tate a fter the i nterva l known a s the AMFS (Any Fa ul t
Ala rm Ti me) has elapsed.
* When connecting auxiliary equipment to dry relay contact pins 5, 6, 7, 8 or 9, observe maximum ratings of
120VAC at 2 amps, 240VAC at 1 amp.
**Switches and relays connected to pins 1,2, & 3 should be suitable for 24V low current applications.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 16
Connecting the Serial RS-485
The model AC-30B is equipped with an RS-485 serial interface allowing the spark
tester to receive commands and exchange information with a PLC or computer.
Programming and control of voltage settings, which can be done manually on
the AC-30B display, can also be done through this interface. Control display
buttons can be disabled when the serial interface is in use. See the section
entitled “RS-485 Interface” for connection and communication information.
The “RS-485” interface connector is located on the rear of the AC-30B directly
under the “Display” connector.
Connecting to the Analog Interface
The model AC_30B comes standard with an analog interface. The analog
interface allows the AC-30B to be controlled by a PLC with standard analog and
Digital I/O. The connecting cable for this interface is not supplied by Clinton
Instrument Company. The cable composition is normally dictated by the PLC,
but ordinarily 22 gauge conductors (individually shielded or shielded pairs) are
required. The maximum length of the cable is also determined by the
equipment the AC-30B is being connected to. However, it is recommended that
the cable length not exceed 10 meters.
See the section entitled “Analog Interface” for the details regarding this
interface.
Installing the CompactCom™Module
The model AC-30B comes standard a Fieldbus Communications Interface. This
interface will allow the installation of several fieldbus options. (DeviceNet,
Ethernet IP, Modbus RTU, Modbus TCP, Profibus, Profinet) Modules purchased
separately.
To enable the Fieldbus Interface the proper CompactCom™ module will need to
be installed into the AC-30B spark tester.
•First remove the Anybus Slot Cover from the rear of the spark tester.
•Remove the CompactCom™module from the packaging.
•Slide the CompactCom™module into the open slot on the rear of the
spark tester.
•Secure the CompactCom™module by tightening the 2 screws.
See the section entitled “Fieldbus Interface” for the details regarding this
interface.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 17
Connecting the X3B
Unpacking the X3B
Remove the following items from the carton:
1. X3B Horn/Light Tower with mounting plate.
2. Power Cord (part #03780)
3. A 4 conductor cable, with a 9-pin terminal block connector on one end
and a 10-pin connector on the other. (part #91247)
Connecting the X3B
1. Mount the X3B to the side of the AC-30B using the (4) bolts that are pre-
installed into the side of the spark tester, as shown in the picture to the
left.
2. Make sure the spark tester is off before wiring to the X3B.
3. Locate the 10-pin green terminal block on the back of the X3B and the 9-
pin terminal block on the back of the spark tester. The X3B is supplied
with a 4 conductor cable. The 10-pin connector will plug into the X3B
terminal block and the 9-pin connector will connect to the spark tester
terminal block. Prior to inserting them, pins 1-5 of the 10-pin connector
should be wired to accessory equipment with 22 gauge or larger, stripped
back 1/4” (6mm) and fed into the green terminal block connector at the
proper pin numbers, as described on the following page. Pins 1-3 of the 9-
pin connector should be wired as described on the following page.
4. When wiring the two units, notice that pins 5-8 on the spark tester are
now being used to communicate with the X3B. The functions of pins 5-8
on the spark tester have now been transferred to pins 1-5 on the X3B
terminal block. When the wiring is complete, plug in the power cords to
both X3B and the spark tester.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 18
X3B to Spark Tester Connections
Conductor
Termi na l Block
Connections
Pin
No.
Pin
No.
Termi na l Block
Connections
Conductor
COM 10 9 Not Us ed NC
COM
8 7 NO
6 5 NO
NC 5 4
COM
2
Des igna tion
4-Conductor
Cable
Suppl ied
with X3B (22
ga uge or
hi gher)
NO
NO
Fault Relay
HV ON Relay
To Spark Tes ter:
Wi re pins 10-7 to
spark
tester pins 8-5 on the
spark
tester termi na l bl ock
connector
GND
(3) 22 ga .
stranded
conductors
rated 250V,
les s than
10 meters
in length,
contained
in a
common
insulating
sheath
Spark Tester Terminal Block Connections
X3B Horn/Light Tower Terminal Block Connections
Not Us ed
(3) 22 ga .
stranded
conductors
rated 250V,
les s than
10 meters
in l ength,
contained in
a common
insulating
sheath
Fault Relay
RESET
HV
ENABLE
8
6
Not Us ed
To X3A:
Wi re pins 8-5 to X3A
pi ns 10-7 on X3A termi -
na l block connector
HV ON Relay
(OUT0)
Fault Relay (OUT1)
Des igna tion
COM
COM
4-conductor
cable
supplied
with X3A
(22 ga uge or
hi gher)
9
7
**Switches and relays connected to pins 1,2, & 3
should be suitable for 24V low current
applications.
NO
22 ga .
stranded
conductors
rated 250V,
les s than
10 meters
in l ength,
contained in
a common
insulating
sheath
HV ON Indica tion:
Dry relay contact pi ns
1&2 wi l l close when
the tes t voltage
exceeds 500v. For an
indica tion tha t HV is
ON i n the el ectrode,
wire a l amp or
auxil iary device* here.
HV ON Relay
*When connecti ng a uxil i ary equipment to dry relay
contacts pins 1, 2, 3, 4, or 5, observe maximum rati ngs of
120VAC at 2 amps or 240VAC at 1 amp.
External Res et:
To reset the s pa rk tes ter fault
relay wi th an external swi tch,
wire a momentary switch**
between pi ns 1&3. When
thes e contacts close, the fa ult
relay wi l l return to a norma l
sta te. The i nterva l tha t the
contacts a re closed must
exceed 50 ms .
HV Enable:
CAUTION For HV on the
electrode, i ns tall a normal ly
closed swi tch or rela y
contact** between pins 1&2.
This s wi tch or relay s hould
open automatical l y when the
wireli ne s top s wi tch is
activated or be opened
manua l ly by the system
operator when the line stops.
FAILURE TO DO SO COULD
RESULT IN A FIRE HAZARD If
the HV rema ins ON in the
electrode when your li ne is
sta tionary, the wi re
insulation in the el ectrode
wil l hea t and there i s a
da nger of combus tion.
COM
NO
4
3
1
3
2
1
Process Control:
To activate external
lights,alarms or relays*
when a fault occurs, wire
them between dry relay
contact pins 5,4 & 3.
If the Lch function is ON
(set on the front panel),
the dry relay contacts will
remain closed until the
RESET button is pressed or
when pins 1&3 are closed
by remote switch
or relay. If the Lch
function is OFF, the dry
relay contacts will return
to normal state after the
interval known as the
PCd (Process Control
Duration, set on the front
panel) has elapsed.

Models AC-30B and AC-30BHP Mains Frequency Spark Tester
AC-30B Instruction Manual –Page 19
Spark Tester Controls
ON/OFF Power Switch
This switch is located on the rear panel of the spark tester.
Voltmeter
The voltmeter will indicate the high voltage present at the electrode.
The voltage is displayed in kV. When the output is set to 1,000V the
display will read 1.0. A reading of 10.2 indicates that the test voltage at
the electrode is 10.2kV RMS.
This display can also display a “Percent Load” value and the “Set Point”
value by pressing the “A” Button. These values will be displayed
momentarily on the Voltmeter display and then will return to displaying
the spark tester voltage at the electrode.
“A” Button
Pressing the “A” button will momentarily cycle the Voltage display
through the “Percent Load” and the “Set Point” Values.
UP/DOWN ARROW (VOLTAGE ADJUST) buttons
The spark test voltage may be adjusted from 0 to 15,000 volts in 100
volt increments by pressing the up and down arrow buttons under the
voltmeter. Press and hold a button to increase the speed at which you
change the voltage setting.
Fault Counter
The 3-digit fault counter registers a count each time any fault type is
detected in the electrode. This display can also momentarily show 4
additional fault counts by pressing the “B” button. These fault counts
are Pinhole, Metal Contact, Multiple pinhole, Gross Bare wire. Press the
CR button to reset the number of faults on the counter to 0.
“B” Button
Pressing the “B” button will momentarily cycle through the 4 additional
fault count values. (Pinhole, Metal Contact, Multiple Pinhole, Gross Bare
Wire)
“CR” COUNT RESET button
Pressing the “CR” button will reset all fault count values.