PCWI DC15 Service manual

High Voltage
C15 & DC30
POROSITY (HOLIDAY) DETECTORS
D
CE Marked PCWI Compact Detectors comply with the requirements
of EMC Directives 89/336/EEC EMC and its amending directives.
®
PRECISION INSTRUMENTATION
Operator’s Handbook
for
Compact
www. .com [e-mail]1.800.561.8187

Postal:
Offi e:
c
Phone: [phone]
PO Box 900
HUNTER REGION MC
NSW 2310
Fax: [phone]
Web:
Email:
www.pcwi.com.au
@
sales pcwi.com.au
Intl: [phone]
13 Alhambra Avenue
CARDIFF NSW 2285
Newcastle - Australia
CONTENTS
1.0 Safety Precautions ....................................................................2
2.0 Operation ................................................................................3
3.0 Specifications...........................................................................4
4.0 Control Panel Layout .................................................................5
5.0 Voltage Recommendations .....................................................6-7
6.0 Troubleshooting ....................................................................8-9
7.0 Optional Accessories ..........................................................10-11
8.0 Warranty ...............................................................................12
9.0 Service ..............................................................inside back page
CERTIFICATE OF CALIBRATION
Model : Compact Detector
Manufacturer: PCWI Technology Pty Ltd
Serial No:. ………………..
Tolerance:. ±5%
Conformance: This detector has been tested at a series of voltages from
0 to 60,000 Volts against a PCWI Certified Meter and High
Voltage Probe, Report Number 213823 / Pulse Crest Meter
using AS2886-1986 as a guide and complies with PCWI
Standards of Manufacture.
PCWI’s Laboratory has also been assessed to ISO/IEC
17025 ‘general requirements for the competence of
testing and calibration laboratories’. All calibrations are
traceable to National and International Standards.
Note: It is recommended that the unit be periodically checked
prior to use with a Certified PCWI Crestmeter.
SIGNED: ___________________
Laboratory Technician
Quality
Endorsed
Company
ISO9002
Lic 13066
Quality System
1
www. .com [e-mail]1.800.561.8187

WARNING
This Equipment generates a high voltage and should be used
with care. Please consult these operating instructions before
use.
INTRODUCTION
Thank you for choosing the PCWI Compact for pre-installation and
postinstallationcorrosiondetection.
PCWI have designed this instrument with care, to provide ongoing
corrosion detection efficiency under a wide variety of coating
applicationconditionsandtoascertainPorosityforthemanyprotective
coatingscurrentlyin use. Underreasonablecareinoperation, theunit
willprovidemanyyearsoftroublefreedetection.
To support the unit, PCWI maintain a comprehensive range of
Electrodes (probes) - extending the versatility of the Compact from
largetosmallandfromaccessibletoinaccessiblesurfaces.
PCWI, in a continuing desire to achieve the maximum in corrosion
detection competence, welcomes user enquiries and
recommendations.
Yourssincerely
PaulVanGaal
CONTENTS
1.0 Safety Precautions
2.0 Operation
3.0 Specifications
4.0 Control Panel Layout
5.0 Voltage Recommendations
6.0 Troubleshooting ................................................
7.0 Optional Accessories
8.0 Warranty ................................................
9.0 Service
CERTIFICATE OF CALIBRATION
Model : Compact Detector
Manufacturer: PCWI Technology Pty Ltd
Serial No:. ………………..
Tolerance:. ±5%
Conformance: 0 to 60,000 Volt
Volt
using
Standards of Manufacture.
PCWI’
17025 ‘general requirement
testing and calibration laboratories’.
traceable to National and International St
Note: prior to use with a Certified PCWI Crestmeter
SIGNED: ___________________
Laboratory Technician
1
www. .com [e-mail]1.800.561.8187

1.0 SAFETY PRECAUTIONS:
All hand-held high voltage test equipment should be operated
byresponsible,trainedandauthorisedpersonnel.
The unit must be earthed to both the item under test and to
ground.
CAUTION
The Detector output can be up to 35,000 volts. Should the
operatoraccidentallymakecontactwiththetestelectrode,they
may experience a mild shock or zap, and in order to avoid this
possibility,thewearingofrubberglovesisrecommended.
Furthermore, the operator should enjoy good health and not
suffer from a cardiac condition. If the operator has a
pacemaker,thentheyshouldnotusethisequipment.
Thisequipmentshouldonlybe used for the purposeforwhichit
was designed, ie: checking the porosity, or electrical
breakdown,ofdielectricorinsulatingmaterials.
It is also recommended that testing should be carried out well
clear of personnel not involved in the testing procedure, or in
such a position whereby the surprise of receiving an electric
shock could cause a related accident, if for example, tests
being carried out close to moving or rotating machinery, or in
such an unstable position that the operator could fall and injure
themselves.
It is recommended that the operator should have an assistant,
toensurethatunauthorisedpersonnelarekeptwellclearofthe
testing area, and generally assist when necessary with the
testingprocedure. Itisalsorecommended thattheDetectornot
be operated within close proximity of sensitive electronic
apparatus,suchascomputerequipment.
DANGER
Donotusethetestequipmentinanycombustibleorflammable
atmosphere, as a test voltage can cause an arc or spark to be
generatedandanexplosioncouldresult.
Always consult the plant or safety officer before carrying out a
testprocedure.
When testing tank internals, be certain the tank does not
containsolventsremainingfromthepaintingprocedure.
ge
sshouldbecured, thickness tested, visuallyinspected
allic substrate of the item to be tested –
robe best
ach to the probe handle.
age control clockwise to the required test voltage.
.
al substrate. nnections).
. Turn alarm sensitivity
f.
ard.
anel of the unit. the unit.
age drops drastically.
A definite flaw should be made in the coating and
act with the surface, gaps in or
ages.
aminated coatings should not be tested until dry
ages).
3
2
www. .com [e-mail]1.800.561.8187

1.0 SAFETY PRECAUTIONS:
All hand-held high volt
ground.
CAUTION
operatoraccidentallymakecont
possibility
suffer from a cardiac condition.
pacemaker
breakdown,ofdielectricorinsulatingmaterials.
being carried out close to moving or rot
such an unst
themselves.
apparatus,suchascomputerequipment.
DANGER
atmosphere, as a test volt
generatedandanexplosioncouldresult.
Always consult the plant or safety of
testprocedure.
When testing tank internals, be cert
containsolventsremainingfromthep
Coating Thickness Range
Appliedcoatsshouldbecured,thicknesstested,visuallyinspected
and accepted – before high voltage porosity testing is carried out.
Coating thickness should be above 150µm; coatings below this
thicknessshouldbetestedwithawetspongeunit.
2.0 OPERATION
Connect the probe and earth leads to the unit. Connect the earth
clamp to the metallic substrate of the item to be tested –
substrate should be earthed to ground. Select the probe best
suited for the test and attach to the probe handle.
Fit the Fuse (if not already fitted).
Turn the unit on.
Check the batteries to ensure that they are charged.
Turn the voltage control clockwise to the required test voltage.
Note:Iftheneonisinplaceallowanadditional200v.
Place the probe near the metal substrate.
A spark should occur (if not re-check all leads and connections).
Place the probe on the surface to be tested.
Re-check the output – adjust if necessary. Turn alarm sensitivity
until the alarm is just off.
Place the probe on the coated surface and move at
approximately one metre per four seconds.
A fault is indicated by:
A spark at the probe – this can usually be seen and heard.
A light flashes on the front panel of the unit.
An audible sound – buzzer is mounted inside the unit.
Digital test voltage drops drastically.
The neon in the probe flashes.
Note:A definite flaw should be made in the coating and
located with the designated test voltage, therefore proving that
the unit is locating the type of fault you wish to find.
Probes must be kept in full contact with the surface, gaps in or
between the probe and the coating may result in flaws going
undetected.
Wire brushes, rubber and coil spring probes should all be kept in
goodcondition.
Probesotherthanfinewirebrushesmayrequirehighervoltages.
Wet and contaminated coatings should not be tested until dry
andclean(seealsotroubleshootingpages).
3
2
www. .com [e-mail]1.800.561.8187

13
8
10
9
11 12
13
8
10
9
11 12
7
FUSE
T
1.6A
250V
ector
ON
ALARM
Sensitivity
Voltage
OFF
Test
23
1
5
4
6
Batt
kV
F
Batt
kV
F
Earthing
Wheretheitemtobetestedisnotearthedtoground,agroundspike
mustbeattached.
The unit should always be switched off before removing and
repositioning the earth lead. After the earth is repositioned, the
probe should always be flashed on the substrate to prove a good
contacthasbeenmade.
Leads
Carboncored22kWHighVoltageleadsmustbeused.
Useofcoppercoredleadswillvoidwarranty.
3.0 SPECIFICATIONS
Weight: 2.2kg
Display: LCD 3¾ digits with battery indicator
Voltage 0 to: DC15:15kv DC30: 30kv
Resolution: 10v 10v
Short circuit: Test current less than 0.5mA
Power supply: 3Ah Slide-off
Recharge Time: 400mA for 10hrs.
Battery Test: When Porosity (Holiday) Detector is switched on, the
result is displayed on the LCD.
Dimensions: 260 x 160 x 70mm
Alarms: Audible – with sensitivity adjustment.
Visual – front panel light.
Neon in probe – 360° visibility
Probe lead: 2m carbon-cored high-voltage silicon-rubber.
Earth lead: 7m with a clamp fitted to one end.
Probes: 250mm Flat Brass Wire brush, trim length of 50mm
Carry Case: 130 x 355 x 465mm
Optional coils & brushes available: See accessories pages
STORAGE:
The Detector should be stored in a dry place. Leads should not be
woundtightly.Batteryshouldbefullycharged.
ack
OUT
Carbon Cored Lead “O” Rings
Screw Fitting
Neon
Lock Nut
End Cap
Neon Holder
Screw
Probe Handle Washer
Spring
5
4
www. .com [e-mail]1.800.561.8187

13
8
10
9
11 12
13
8
10
9
11 12
7
FUSE
T
1.6A
250V
High Voltage
Porosity Detector
ON
ALARM
Sensitivity
Voltage
OFF
Test
23
1
5
4
6
29.00
Batt
kV
EF
29.00
Batt
kV
EF
Earthing
mustbeattached.
The unit should always be switched of
repositioning the earth lead. Af
contacthasbeenmade.
Leads
Carboncored22kWHighVoltageleadsmust
Useofcoppercoredleadswillvoidwarranty.
3.0 SPECIFICATIONS
Weight: 2.2kg
Display: LCD 3¾ digits with battery indicator
Voltage 0 to: DC15:15kv DC30: 30kv
Resolution: 10v 10v
Short circuit: Test current less than 0.5mA
Power supply: 3Ah Slide-off
Recharge Time: 400mA for 10hrs.
Battery Test: result is displayed on the LCD.
Dimensions: 260 x 160 x 70mm
Alarms: Audible – with sensitivity adjustment.
Visual – front panel light.
Neon in probe – 360° visibility
Probe lead: 2m carbon-cored high-volt
Earth lead: 7m with a clamp fitted to one end.
Probes:
Carry Case: 130 x 355 x 465mm
Optional coils & brushes available: See accessories p
STORAGE:
woundtightly.Batteryshouldbefullycharged.
1 LCD display (including battery condition
indicator)
2 Voltage control (10 turn)
3 Visual alarm indicates when fault is found
4 On switch
5 Off/test switch
6 Sensitivity control for the alarm
7 Audible alarm when fault is found
8 High Voltage probe connector
9 Fuse (1.6A slow blow) 5 x 20mm
10 Earth connection point
11 Charge connector – allows operation while
charging is in progress
12 Slide-off power pack
13 Earphone jack
4.0 CONTROL PANEL LAYOUT
Probe Handle Diagram
Carbon Cored Lead “O” Rings
Screw Fitting
Neon
Lock Nut
End Cap
Neon Holder
Screw
Probe Handle Washer
Spring
5
4
www. .com [e-mail]1.800.561.8187

Table 3. kV Values from
NACE RP0274-98
mm kiloVolts
0.51 6
0.79 7
1.6 10
2.4 12
3.2 14
4.0 16
4.8 17
13 28
16 31
19 34
andards and should be
.
able should be taken as a GUIDE only. It is
andardbeused.
ALLOW AN ADDITIONAL 200 VOLTS IF THE NEON IN THE PROBE HANDLE IS IN USE.
The above minimum test voltages have been derived from
Australian Standard AS3894.1-2002; the whole of this Standard
should be used. The above voltages relate to the following: the
detector should have a direct earth connection to the substrate and
afinewirebrushelectrodemustbeconnectedtotheprobe.
V= minimumtestvoltageappliedinvolts
T= dryfilmthicknessofcuredcoatinginmicrons
F= a whole number factor which rates a coating’s
generictypeandresidualsolventcontent(Table1)
Table 1. Determination of the coating film factor (F)
from coating type and volume solids content.
Table 2. Determination of the minimum test
voltage (V) from dry film thickness (T)
and coating material factor (F).
Generic Type of Coating
Volume Solids %(V/V)
Volume Solids
%(V/V)
Factor (F)
Factor
(F)
Nominal dry film
thickness in microns Minimum Test Voltage (kV)
Chorinated rubber, Vinyl 15 to 39 4 F=1 F=2 F=3 F=4
Low Build Epoxy, some Tar Epoxy 40 to 59 3 150 3.00 1.50 1.00 0.75
High Build Epoxy, some Tar Epoxy 60 to 79 2 250 4.00 2.00 1.30 1.00
Polyester/Vinyl esters, Solventless
Epoxy, Fusion-bonded Epoxy 80 plus 1 400 5.00 2.50 1.60 1.25
600 6.10 3.00 2.00 1.50
800 7.00 3.50 2.30 *
1500 9.70 4.80 * *
2500 12.50 * * *
4000 15.80 * * *
Tables 1 and 2 below provide guidance for determination of
minimum voltage for high voltage porosity testing of the indicated
generic types of coating products, at the indicated dry film
thicknesseswhichmaycontainresidualsolvents.
5.0 VOLTAGE RECOMMENDATIONS
AS 3894.1-2002 recommends minimum voltages for
testing specified thickness of film of various Coating
Formula 1
7
6
www. .com [e-mail]1.800.561.8187

Table 3. kV Values from
NACE RP0274-98
mm kiloVolts
0.51 6
0.79 7
1.6 10
2.4 12
3.2 14
4.0 16
4.8 17
13 28
16 31
19 34
International Standards
NACE RP0274-04 derived table
Table 3 below is derived from NACE standards and should be
used as a guide only.
The above table should be taken as a GUIDE only. It is
recommendedthatthewholeofthisstandardbeused.
ALLOW AN ADDITIONAL 200 VOLTS IF THE NEON IN THE PROBE HANDLE IS IN USE.
The above minimum test volt
Australian Standard
should be used. The above volt
V= minimumtestvoltageappliedinvolts
T= dryfilmthicknessofcuredcoatinginmicrons
F= a whole number factor which rates a coating’s
generictypeandresidualsolventcontent(Table1)
Table 1. Determination of the coating film factor (F)
from coating type and volume solids content.
Table 2. Determination of th
voltage (V) from dry film t
and coating material
Generic Type of Coating
Volume Solids %(V/V)
Volume Solids
%(V/V)
Factor (F)
Factor
(F)
Nominal dry film
thickness in microns Minim
Chorinated rubber, Vinyl 15 to 39 4 F=1
Low Build Epoxy, some Tar Epoxy 40 to 59 3 150 3.00
High Build Epoxy, some Tar Epoxy 60 to 79 2 250 4.00
Polyester/Vinyl esters, Solventless
Epoxy, Fusion-bonded Epoxy 80 plus 1 400 5.00
600 6.10
800 7.00
1500 9.70
2500 12.50
4000 15.80
Tables 1 and 2 below provide guidance for de
minimum voltage for high volt
generic types of coating product
thicknesseswhichmaycontainresidualsolvents.
5.0 VOLTAGE RECOMMENDATIONS
Formula 1
7
6
www. .com [e-mail]1.800.561.8187

HV Lead
Neon
Holder
18
to
22kW
resistance
6.0 TROUBLESHOOTING
In order to ensure that your Compact Porosity Detector is operating to
specification, the Detector handle and lead should be checked prior to use.
Use the following procedure:
Unscrew the neon holder from the handle.
Using a multi-meter, complete the circuit and check the resistance at both the
handle Êand the high voltage plug Ë.
If resistance is outside the 18,000 to 22,000 ohm range, or is open circuit:
(a) Check Êand Ëfor either poor connection or damage;
(b) Check for break or damage to the HV lead Ì.
Replace/rectify connection and leads and then re-test.
Cause Solution
Flat battery
No Power - fuse not fitted
Recharge battery
Fit fuse
Voltage higher than display capacity Decrease voltage
Display drops to -1 when fault found Normal operation
Slightly conductive, damp or salty
surface
Coating may not be fully cured
Probe surface area too large
Wash and clean the surface
Allow coating to cure
Use a smaller probe, or increase
voltage
Poor Earthing Make positive earth connections
Slightly conductive, damp or salty
surface
Coating may not be fully cured
Probe moved too fast
Probe surface area too great
Wash and clean the surface
Allow coating to cure.
Move probe 1 metre every 4 seconds
Use smaller probe
Sensitivity adjusted at too low a
setting
Voltage set too low
Increase sensitivity
Increase voltage
Neon in handle damaged
Damaged leads
Poor connections
Flat Battery
Replace neon (or use a metal
conductor piece)
Repair or replace leads
Clean and reconnect
Recharge battery
Neon in handle can use up to 200
volts
Damaged HV lead
Poor Earth connection
Turn up voltage control to
compensate for neon
Replace lead
Check all connections
9
8
www. .com [e-mail]1.800.561.8187