SPY 780 User manual

Spy® model 780
portable dc
holiday detector
o p e r at i n g
instructions
PIPELINE INSPECTION COMPANY
picltd.com

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welcome
Thank you for purchasing the SPY®Model 780 DC Holiday Detector.
Pipeline Inspection Company and our SPY®brand of coating inspection,
jeep meter and pig tracking equipment has been serving companies
all over the world since 1953. With the purchase of this high precision
instrument you can now enjoy access to worldwide service and support
only SPY®and our vast Distributor network can offer.
For more information about SPY®brand equipment please visit our
website at www.picltd.com.
The SPY®Model 780 DC Holiday Detector meets the Electromagnetic
Compatibility Directive and the Low Voltage Directive. This product is a
Class A, Group 1 ISM equipment according to CISPR 11. Group 1 ISM
product: A product in which there is intentionally generated and/or used
conductively coupled radio-frequency energy which is necessary for the
internal functioning of the equipment itself. Class A products are suitable
for use in all establishments other than domestic and those directly
connected to a low voltage power supply network which supplies
buildings used for domestic purpose.
is a registered trademark of Pipeline Inspection Company,
Houston, Texas 77055, United States.
A copy of this Operating Instructions Manual can be downloaded on our
website at www.picltd.com.

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Table of contents
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Principles of Holiday Detector Operation . . . . . . . . . . . . . . 7
SPY®Model 780 DC Holiday Detector Overview . . . . . . . . . . 8
Connecting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Controls and Voltage Adjustments . . . . . . . . . . . . . . . . . . . 12
DC Paddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Field Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Charging and Storage Instructions . . . . . . . . . . . . . . 16
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . 20
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrode Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Related Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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operator safety
PLEASE READ THESE INSTRUCTIONS CAREFULLY PRIOR TO
USING THE EQUIPMENT!
WARNING! This is a HIGH VOLTAGE device capable of producing
an electrical shock if not properly grounded and/or operated in accordance with
instructions and procedures prescribed in this manual! If you have a pacemaker
or other life critical electronic medical device DO NOT use this device.
Only trained and responsible personnel should operate high voltage equipment.
Display warning labels prominently prior to and during testing. Portable holiday
detectors are designed to operate and maintain an electric current output well
below levels which could cause injury. However, you may experience a mild shock
if the test electrode or ground is touched while the equipment is activated. Wear
rubber or plastic gloves and non-conductive footwear to minimize potential shock.
Keep in mind that the shock prevention effectiveness of the rubber or plastic glove
and footwear is limited to the condition of their protective surface. Make sure your
gloves and footwear are void of tears and holes and are in good condition.
Use of Portable Holiday Detectors is limited to finding defects in insulating
materials. Testing should be conducted clear of personnel not involved in the
testing procedure. Personnel operating Portable Holiday Detectors should
be aware of the safety limitations imposed by their environment at all times.
Operator should have an assistant to ensure that unauthorized personnel are kept
clear of the testing area.
DANGER! Portable Holiday Detectors create an arc or spark.
Use of a Portable Holiday Detector in or around combustible or flammable
environments can result in an explosion. When operating in any potentially
hazardous area, consult with the plant or site safety officer before proceeding
with a holiday detection test in any potentially hazardous or suspect area.
DANGER! If you have a pacemaker DO NOT use this device.

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DO NOT CUT the ground cable to a shorter length.
CAUTION! DO NOT TOUCH the bare ground wire when the detector
is turned on.
WARNING! DO NOT USE WHEN RAINING. If it is raining then
there is a safety concern for the operator. Pure water is non-conductive, but
almost any contaminant will cause water to become conductive (dust in the air,
salt from an operator’s hands). If this conductive water covers the wand (black
plastic part of the detector where the electrode is attached) and the orange case
then the operator will become the return path for the high voltage. While this is
NOT LETHAL, it does hurt. Also the unit may become damaged.
If it isn’t raining, but the coating surface is wet, the problem becomes one
of accurately locating the coating defect (holiday). Again, the water will conduct
the electricity and you may get false holiday indications many feet from the actual
holiday(s). In this case it is recommended that you dry the testing area prior to
inspection.
CAUTION! DON’T USE AROUND SENSITIVE ELECTRONICS
OR RADIO EQUIPMENT. When in standby the SPY®Model 780 DC Holiday
Detector will generate radio frequency emissions which are within the limit
defined by the Electromagnetic Compatibility Directive. Due to its method of
operation however, the SPY®Model 780 DC Holiday Detector will generate
broadband RF emissions when the unit is generating high voltage or when a
spark is produced at the electrode. It is therefore recommended that the user
does not activate the high voltage within the vicinity of sensitive electronics or
radio equipment.
ELECTRODES/ACCESSORIES: It is imperative for the accurate operation of
unit that electrodes (Spring & Brush) and accessory attachments (Spring & Brush
Wands & Ground Cable) be kept clean and free of dirt and debris. Please clean
with a damp cloth before storing them for future use.

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unit calibration
As the operator of this unit you require accurate, safe, and reliable
equipment to perform coating inspections at the proper output voltage.
Prior to leaving our manufacturing facility Pipeline Inspection Co. certifies
that SPY®Model 780 Holiday Detector has been calibrated and demonstrates
the output voltage, which appears on the display of the detector within +/-
5% of indicated setting over the range of 1000 - 5000 volts. Since output
voltage is regulated, this tolerance is maintained regardless of load.
Your unit comes with a Factory Calibration Certificate and a
Factory Authorized Calibration Decal applied to the side of the unit
both with the date your unit was calibrated.
Our units do not tend to drift but it is recommended that this unit be
calibrated at least once per year or more frequently based on heavy
usage. Recalibration of our equipment should be performed ONLY
at a SPY®Authorized Service Center due to the unique calibration
process; test equipment utilized and properly trained SPY®
technicians.
We DO NOT recommend using any other calibration service other
than a SPY®Authorized Service Center; using an outside service with
technicians not trained to work on SPY®brand equipment could damage
the unit and if the enclosure is opened will void the warranty.
When calibration is needed please return your unit to a SPY®Authorized
Service Center or SPY®manufacturing facility located at:
Pipeline Inspection Company
Attn: Calibration
1919 Antoine Dr.
Houston, TX 77055
Please include: Company Name and Contact info. For a complete
list of Authorized Service Centers please visit our website at
www.picltd.com. If a copy of the Calibration Certificate on file is
needed it may be obtained by emailing a request to [e-mail].

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principles of holiday
detector operation
Holiday detectors are devices that are used to detect the presence of
defects in the non-conductive coatings applied to surfaces in order to
minimize ion flow from a conductive substrate. This is accomplished
by attempting to create an electrical circuit by passing an electrode
over the non-conductive coating. A sufficient voltage is generated in
the electrode to cause a spark that will jump from the electrode to the
substrate if a defect is found. When a defect is found a horn will sound
and a LED light will turn off.
Metal objects such as pipelines, reinforcing bar (rebar), storage tanks
or structural steel are normally covered with a protective coating to
prevent corrosion. Holiday detectors are used to inspect these coatings
for pin holes, scratches or other coating faults. They work by generating
a voltage high enough to jump a gap that is longer than the thickness of
the coating.
The laws of physics determine the required voltage level to jump a given
distance, or gap. Coating type also affects voltage level requirements.
Environmental Conditions such as humidity, temperature, and other
environmental factors will also affect voltage required to jump a given
distance.
A holiday detector simply applies a voltage to the outside of the coating.
With the pipe connected to ground and with the holiday detector
connected to ground, a hole in the coating will allow a spark to jump
or “arc” from the electrode to the pipe to complete the circuit. When a
complete circuit is formed, an audible and visual signal is activated on
the holiday detector.

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spy®model 780 dc holiday
detector overview
The Model 780 DC Holiday Detector is a low voltage (1-5kv) detector
designed specifically for thin film epoxy coatings. The output voltage of
this detector is normally D.C. (direct current). However, if light moisture
is encountered on the pipe, the detector output starts to fast pulse. Fast
pulse enables continued operation whereas with older type thin film
detectors the operator either had to wait until the moisture evaporated
or the pipe had to be dried.
The Model 780 DC Holiday Detector incorporates circuitry allowing the
detectors to maintain a selected voltage, regardless of different pipe
diameters, coating thickness variations and battery wear (unless the
battery is totally discharged). Keep in mind that the voltage can decrease
slightly depending on ground losses and/or conditions.

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1 Spring or Brush Electrode
2 Electrode Accessory
Connection Point
3 Electrode Wand
4 Wand Release
5 Easy Carry Top Handle
6 Shoulder Strap Connection
7 Built In Digital LCD Jeepmeter
(Voltage meter)
8 Control Knob (3 positions:
Off / Voltage Set / On)
9 Voltage Set Access Hole
10 Comfort Grip
11 Ground Cable Connection Point
12 8 Hour Battery
13 Quick Release Battery Button
14 Horn
15 Model & Serial Number
10
11
12
4
3
13
14
78
9
5
15
6
6
2
1

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connecting accessories
CAUTION! DO NOT TOUCH Make sure the switch is in the OFF position
prior to connecting any accessory.
STEP 1. CONNECTING THE ELECTRODE WAND. Plug into “front” of
the detector. Push the wand in until it locks in place. It can be released by
pressing the release (located near the front / bottom of the unit) upwards until
the wand pops out.
STEP 2. CONNECTING THE ELECTRODES. Connect the electrode to the
wand. The wand comes with the spring adapter attached to the wand. If spring
or full circle brush electrode attach to pipe.
CAUTION! DO NOT TOUCH THE ELECTRODE WHILE THE DETECTOR
IS OPERATING.
Battery
Control Knob
Shoulder Strap
Electrode Wand
Caution! - High Voltage
Cuidado! - Voltaje Alto
1 2 3
Clip Installation
1
4
5
3

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OPTIONAL: BRUSH ADAPTER KIT. The Model 780 Kit comes with a
brush adapter kit for use in connecting flat brush/neoprene electrodes, half
circle electrodes and full circle electrodes.
STEP 3. CONNECTING THE GROUND CABLE. The ground cable plugs
into the bottom side of the rear handle. It uses a quarter turn fastener, so insert
the cable as far as possible, and then rotate it at least a quarter clockwise turn
until it locks in place.
DIAGRAM 1
TO JEEP PIPE ON SKIDS OR WHEN HANGING FROM PIPE SLINGS –
GROUND DIRECTLY TO THE PIPE CUTBACK
EXTEND GROUND CABLE TO PIPE
PROPER GROUNDING. Make sure the ground cable is uncoiled and
extended.
DIAGRAM 1: Shows the method when the pipe is on wood skids or hanging
from pipe slings; attach the holiday detector ground cable directly to the
uncoated substrate (pipe cutback) with a clamp to complete the circuit.
CAUTION! DO NOT TOUCH THE GROUND CABLE WHILE DETECTOR
IS OPERATING.

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STEP 4. CONNECTING THE CLIP \ SHOULDER STRAP. First attach strap
clip on the black handle by placing the tab portion of the strap clip into the top
groove on the back side of the handle that faces the unit display. Then push up
on the bottom of the strap clip in the direction of the opposite side of the black
handle until the strap clip snaps into place around the black handle. Next attach
the shoulder strap to the front handle clip and the pin on top of the rear handle.
The front clip can slide to the left or right on the handle to allow hand placement
while using the detector.
STEP 5. BATTERY. The battery will only install one way (from the front side).
It is keyed to prevent insertion in an incorrect fashion. One end of the battery
is flat and the other has a step. The flat end goes towards the rear of the unit.
Push the battery on until it snaps in place (the spring will be almost completely
compressed when properly installed). To remove the battery, press the orange
release on the bottom left side of the unit. Newer batteries can be a bit resistant
when trying to remove the battery because of the newness of the battery and
the tight fit on the slide path; if so give a gentle tap with your palm on the battery
in the direction of removal.
DIAGRAM 2: Shows the method of attaching a grounding cable from a
grounding rod (earth ground) to the pipe cutback (substrate). Next attach the
holiday detector ground cable to the second grounding rod (earth ground) to
complete the circuit.
CUSTOM LENGTH GROUND CABLES AVAILABLE FROM SPY®
DIAGRAM 2
USE A GROUND ROD WITH A GROUNDING CABLE CLAMPED TO THE PIPE
CUTBACK WHILE HOLIDAY DETECTOR GROUND CABLE IS ALSO CONNECTED TO
A SEPARATE GROUNDING ROD
DETECTOR
GROUND CABLE
GROUND ROD

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controls and
voltage adjustments
The control knob has three positions: OFF, VOLTAGE SET, and ON. In the
OFF position all power is off, including the high voltage output.
POWER ON
RIGHT
POWER OFF
LEFT
STEP 6. SETTING THE VOLTAGE OUTPUT. Turn the knob clockwise
to the middle position (voltage set) this turns on the high voltage output and
activates the internal Jeepmeter (voltage meter), the LCD display turns on,
the red LED light will blink and the horn tone will pulse on and off.
Using the SPY®provided flathead screwdriver place the flat screwdriver
head through the hole on the bottom side of the knob to change the voltage
setting, the voltage (shown on display) is in kilovolts (thousands of volts.).
Turning the screwdriver clockwise will increase the voltage and counter
clockwise will decrease the voltage.
NOTE: Voltage setting can only be viewed in the middle set position.
This is to prevent confusion during detection of holidays as the voltage will
drop when the unit discharges to substrate. Static electricity on protective
coatings can be picked up and can cause fluctuations in Voltage reading.
VOLTAGE SE T
MIDDLE

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STEP 7. TURNING ON UNIT FOR HOLIDAY DETECTION. Turn the
unit clockwise to the ON position. In this position the unit is in the normal
running mode with the red LED on steady, the horn tone will be steady, and
the display will turn off.
DISPLAY IN "VOLTAGE SET" ONLY
KILOVOLTS VOLTAGE
SET
ONOFF
PIPELINE INSPECTION CO., LTD.
CHARGE BATTERY AFTER EACH USE
KEEP ELECTRODES FREE OF TAR
DO NOT CUT OR KINK GROUND CABLE
PIPE SHOULD BE GROUNDED TO EARCH
DON'T TOUCH ELECTRODE WITH UNIT ON
Voltage Adjustment Hole
Power ON LED

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dc paddle
The Model 780 DC Holiday Detector comes with a DC Paddle to assist in
the location of Holidays (defects in the coating). Due to the low voltage
of the Model 780 DC Holiday Detector the spark that jumps the gap
from the electrode to the substrate when a holiday (defect in the coating)
is found can sometimes be hard to see as opposed to using a higher
voltage detector which produces a larger brighter spark. The DC Paddle
acts as an extension of the spring electrode giving the user a wider path
to test areas the user suspects are producing the holiday but can’t see
during standard detecting travel speed.
Immediately after holiday detector indicates a fault, roll spring electrode
back approximately 2-3 inches. Place the edge of the conductive
rubber paddle against the spring and wipe the paddle around the entire
circumference of the pipe until detector signal activates indicating the
exact location of the coating flaw.
PIPE

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field calibration
instructions
Prior to each use of the Model 780 DC Holiday Detector it is important to
perform a Field Calibration to verify that the required voltage setting for the
coating thickness will accurately detect defects (Holidays) in the coating.
There are two methods to performing a Field Calibration:
METHOD 1: ADDING TEST DEFECTS TO THE COATING.
1. Prior to turning on and setting the voltage on the detector manually add one
pinhole size defect on the coating surface, make sure the defect goes down
to the substrate (bare metal).
2. Set the voltage on the detector to the minimum voltage based on the
coating thickness 525 x sqrt (mils) and using the spring or brush electrode
travel over the test defects.
3. If you see the spark jump the gap from the electrode to the substrate in the
defect and the horn on the detector changes from a running tone to a loud
signal horn and the light on the display turns off then you have successfully
detected defects (holidays) in the coating and verified the detector operation.
4. If your test does not successfully detect the test defect then increase the
voltage by 10% and test again. If test fails again continue increasing by 10%
until test is successful.
METHOD 2: USING THE BARE METAL END OF THE TEST SURFACE.
1. Roll the spring or brush electrode toward the bare metal end of the pipe. When
the electrode is sufficiently close to the bare metal, a spark will jump from the
electrode to the pipe, the running tone will change to a loud signal horn will
sound and the light on the detector display will go out to designate a holiday.
Of course it is not a real holiday but it demonstrates what happens when the
electrode encounters a holiday and verifies correct detector operation.
2. If your test does not successfully detect the test defects then first verify the
voltage setting is accurate for the surface coating.

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Quick Release
Battery Button
The SPY®battery is a completely sealed, rechargeable 12 volt unit. It can
be used in any position and under most conditions. Batteries are shipped
fully charged however prior to use we recommend you place them on
the charger to verify charge level is full.
BATTERY REMOVAL. Press the release (orange part) on the base
plate (black part) and push the battery away from the rear handle. Newer
batteries can be a bit resistant when trying to remove the battery because
of the newness of the battery and the tight fit on the slide path; if so give
a gentle tap with your palm on the battery in the direction of removal.
battery charging and
storage
instructions
CAUTION! Make sure the switch is in the OFF position prior to
removing the battery.
Battery
Caution! - High Voltage
Cuidado! - Voltaje Alto

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CHARGING THE BATTERY. Slide the charger onto
the battery as far as possible. A discharged battery
requires 8-20 hours to fully charge.
There is no danger of overcharging the battery. After
the battery is fully charged, the charger will maintain a
trickle charge to keep the battery at peak charge.
It is recommended that the battery be charged for 8
hours after each use. After heavy usage charge the battery for 20 hours.
Do not disconnect the charge power cord while the battery is attached.
BATTERY STORAGE. The battery should be fully charged BEFORE
storing. Storage at temperatures below 75˚F is recommended. After
six months of storage or storage in extremely high temperatures, the
battery should be recharged to maintain peak efficiency and maximize
its life span.
IMPORTANT! Contacts on the battery, charger and the detector must
be kept clean and bright to assure good connection!
WARNING! Do not use any other type of charger. This charger
is specifically designed for this battery.
BATTERY DISPOSAL. The battery pack is a sealed non-
replaceable lead acid battery, when the battery pack is no
longer good it must be recycled.
Battery
Charger

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TROUBLESHOOTING GUIDE CONTINUED ON THE NEXT PAGE...
troubleshooting guide
PROBLEM POSSIBLE SOLUTION CORRECTION METHOD
HOLIDAY
DETECTOR
WILL NOT
DETECT
HOLIDAYS
Field Calibration Perform a field calibration to compensate
for environmental factors (see page 16). Use
NACE equation to set min voltage. Travel over
known holiday. Turn up voltage and repeat
until holiday is detected. (Note: Max voltage
is determined by the coating manufacture,
typical values for new coating range from 400
to 1000 Volts/mil).
Detection Testing Touch electrode/wand directly to bare ground
cable to test that the unit is functioning
properly. A spark will appear and the horn
will sound if switch is in the “ON” position.
If it does not detect then ensure ground cable
and electrode wand are correctly inserted
using steps 4 and 5 above.
If unit still fails to detect a direct short repair
may be needed, Call Pipeline Inspection
Company for support.
Minimum Voltage
Setting
Follow NACE standard SP0490-2007:
Section 3.
Check Detector Ground
Connection
With the detector OFF remove the ground
cable and fully reinsert it twisting 90 degree
until locked. Ensure the opposite end is clean
and well connected to the pipe or earth
ground.
Check Electrode/Wand
Connection
With the detector OFF remove the wand and
fully reinsert until it locks into place. Ensure
wand and electrode connection points are clean.

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troubleshooting guide
PROBLEM POSSIBLE SOLUTION CORRECTION METHOD
HOLIDAY
DETECTOR
WILL NOT
DETECT
HOLIDAYS
Check Ground
Connections
If pipe is connected to an earth grounding rod
and the ground cable from the holiday detector
is dragging the ground make sure all connections
are clean (free of debris) and secure.
If ground cable from the holiday detector
is directly connected to the pipe cutback
(substrate) make sure all connections are
clean (free of debris) and secure.
If the ground cable from the holiday detector
and the earth grounding rod are both connected
to a grounding collar make sure all connections
are clean (free of debris) and secure.
Adjust Travel Speed Travel speed is important on Pulse units
and must not be too fast or holidays could
be missed. Follow NACE standard SP0274-
2011 section 6.3: Make or find a holiday and
attempt to detect at various speeds until
reliable detection is obtained.
HOLIDAY
DETECTOR
TURNS OFF
WHILE IN-USE
Charge/Replace Battery The detector will automatically power down
if the battery voltage drops below the
required level. Ensure that the battery has
been fully charged before use.
Use a second battery that is charged and see
if the detector still turns off.
Test Battery Additional testing may be needed conducted on
the battery, see Battery Troubleshooting below.
THE DETECTOR
VOLTAGE
NEEDS TO BE
VERIFIED
Use SPY JM or DCPJM Do not use a regular multimeter as they will
get damaged and are not rated for over 1,000
Volts. The SPY JM is rated for 7,000 Volts DC
and 40,000 Volts Peak (crescent) on pulse. The
SPY DCPJM can measure up to 5,000 Volts DC.