SPY 785 User manual

Spy® model 785 / 790
portable pulse
h o l i day detector
o p e r at i n g
instructions
PIPELINE INSPECTION COMPANY
picltd.com

2pi cltd.compi cltd.com 3
we lcome
Thank you for purchasing the SPY®Model 785 / 790 Pulse Holiday
Detector.
Pipeline Inspection Company and our SPY®brand of Coating Inspection,
JeepMeter 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 785 / 790 meet the Electromagnetic Compatibility
Directive and the Low Voltage Directive. The product is 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 purposes.
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.
Ta b l e of contents
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Principles of Holiday Detector Operation . . . . . . . . . . . . . . 7
SPY®Model 785 / 790 Pulse Holiday Detector Overview . . . . . 8
Connecting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Controls and Voltage Adjustments . . . . . . . . . . . . . . . . . . . 13
Field Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Charging and Storage Instructions . . . . . . . . . . . . . . 16
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . 21
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 22
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrode Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Related Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Test Voltage Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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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 the 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.
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 or salt from an operator’s hands). If conductive water covers the
wand (the 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! DO NOT USE AROUND SENSITIVE
ELECTRONICS OR RADIO EQUIPMENT. When in standby the
SPY®Model 785 / 790 Pulse 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 785 / 790
Pulse 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
the 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 principles of h o l i day
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.
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 785 / 790 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 1-15 kV for the 785 and 5-35 kV for the 790.
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, 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
Attention: Calibration
1919 Antoine Drive
Houston, Texas 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 [email protected].

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spy® model 785 / 790 pulse
h o l i day
detector overview
The Model 785 Pulse Holiday Detector is a high voltage (1-15 kV)
detector designed to cover a wide range of coatings from thin films
to tapes to extruded or coal tar types of coatings (4 -150 Mils). Since
the operating characteristics of this detector are very broad it is
recommended that thin film epoxy coatings be inspected with the
model 780 or 785 holiday detector.
The Model 790 Pulse Holiday Detector is a high voltage (5-35 kV)
detector designed specifically for tapes, extruded or coal tar types of
coatings, and thicker somatic type coatings (50 -750 Mils).
The Model 785 / 790 Pulse Holiday Detectors 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.
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 12V Battery
13 Quick Release Battery Button
14 Horn
15 Model & Serial Number
10
11
12
4
13
14
78
9
5
15
6
3
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 the “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.
CAUTION! DO NOT TOUCH THE GROUND CABLE 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
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 rotate it at least a quarter clockwise turn until it locks in place.
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 and also a grounding rod with a
grounding cable attached to the pipe cut back to complete the circuit.
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
OPTIONAL: BRUSH ADAPTER KIT. The Model 785 / 790 Kit comes with
a brush adapter kit for use in connecting flat brush /neoprene electrodes, half
circle electrodes and full circle electrodes.
TO JEEP PIPE ON SKIDS OR WHEN HANGING FROM PIPE SLINGS USE A GROUND
ROD WITH A GROUNDING CABLE CLAMPED TO THE PIPE CUTBACK WHILE HOLIDAY
DETECTOR GROUND CABLE IS ALSO CONNECTED TO THE PIPE CUT BACK.
DIAGRAM 1
EXTEND GROUND CABLE TO PIPE
GROUNDING
ROD

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controls an d
vo ltag e
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
VOLTAG E SE T
MIDDLE
STEP 4. CONNECTING THE CLIP \ SHOULDER STRAP. First attach the
strap clip to 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 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 3: Shows the method of using a grounding collar when the pipe
is on wood skids but no substrate is available to clamp to; attach the grounding
collar around the coated pipe then attach the holiday detector ground cable to the
grounding pad lug to complete the circuit.
DIAGRAM 3
USE A GROUNDING PAD IN CONJUNCTION WITH THE HOLIDAY DETECTOR
GROUND CABLE ATTACHED TO THE GROUNDING PAD.
GROUNDING COLLAR
EARTH
DETECTOR
TAIL WIRE (GROUND)
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.
DISPLAY IN "VOLTAGE SET" ONLY
KILOVOLTS
SET
ONOFF
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
POWER ON LED
VOLTAGE
ADJUSTMENT
HOLE
VOLTAGE

14 pi cltd.compi cltd.com 15
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 the
voltage reading.
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.
field calibration
instructions
Prior to each use of the Model 785 / 790 Pulse 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.
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 type and thickness. Use equation 525 x sqrt (mils) from NACE
SP0490 for Fusion-Bonded Epoxy and equation 1250 x sqrt(mils) from
NACE SP0274 for thick coatings. Use the spring or brush electrode to
travel over the test defects. See voltage table on page 27.
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 the test is successful.

16 pi cltd.compi cltd.com 17
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 button) 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 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 an d
storage
instructions
CAUTION! MAKE SURE THE SWITCH IS IN THE OFF
POSITION PRIOR TO REMOVING THE BATTERY.
Battery
Caution! - High Voltage
Cuidado! - Voltaje Alto
It is recommended that the battery be charged for 4 hours after each
use. After heavy usage charge the battery for 6 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!
CHARGING THE BATTERY. Slide the charger onto
the battery as far as possible. A discharged battery
requires 4-6 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.
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 15). 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
(see page 10).
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 and NACE SP0274-2011 Section 3.
Also refer to the voltage table on page 27.
Check Detector Ground
Connection
With the detector OFF remove the ground
cable and fully reinsert it twisting 90 degrees
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.
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 need to be conducted
on the battery, see Battery Troubleshooting.
THE DETECTOR
VOLTAGE
NEEDS TO BE
VERIFIED
Use SPY JM or PJM 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 kV DC
and 40 kV Peak (crescent) on pulse. The SPY
PJM can measure up to 20 kV.

20 pi cltd.compi cltd.com 21
troubleshooting guide
PROBLEM POSSIBLE SOLUTION CORRECTION METHOD
THE BATTERY
DOESN’T
SEEM TO BE
WORKING
WELL
Check/Replace Battery Use a multimeter to measure the battery
voltage on the freshly charged battery. The
voltage should read 13.0 Volts or higher if
it just came off the charger. If it has been
sitting for several hours the voltage can be
as low as 12.3 Volts.
If the voltage is lower than 12.0 Volts then
the battery may have a problem and will
probably need to be replaced. Test with a
different charger if possible.
PIPELINE
ENGINEERS,
INSPECTOR
OR OWNER
REQUIRE A
SPECIFIC
VOLTAGE FOR
TESTING BUT
HOLIDAYS ARE
NOT BEING
DETECTED
Field Calibration If the testing documentation on the pipeline
requires a specific voltage then that setting
must be used. However environmental
conditions such as humidity and temperature
will affect the required voltage to spark across
a specific gap size (holiday). For the holiday
detector to create a spark or Jeep the voltage
must be high enough to overcome the gap. If
the voltage is set too low for the thickness,
humidity and temperature then a spark will
not occur. It is recommended to perform a
field calibration every day or periodically as
conditions change (see page 15).
THE PIPELINE
NEEDS TO BE
CHECKED BUT
PIPE IS WET /
IT IS RAINING
Dry Pipe Holiday detection cannot be done in the rain
as it will conduct back to ground and give
false holidays. Holiday detectors maybe be
used with light moisture on the pipe however
it is highly recommended that the pipe be dry
and clean before testing. Proper safety and
safety equipment should be used when
in wet conditions to prevent user from
being shocked.
If maintained the Model 785 / 790 Pulse Holiday Detector will offer you
a lifetime of dependable operation. Regular care and maintenance of the
unit is a requirement of good quality management practices.
WARNING! This detector does not contain any user-serviceable
parts; your warranty will be voided if the SPY®unit is opened by
anyone other than a SPY®Authorized Service Center or SPY®
manufacturing facility.
In the event the unit fails to operate properly please return your unit
to a SPY®Authorized Service Center or SPY®manufacturing facility
located at:
Pipeline Inspection Company
Attention: Repair
1919 Antoine Drive
Houston, Texas 77055
Please include: Company name, contact information and a short
description of the problem with the unit. For a complete list of Authorized
Service Centers please visit our website at picltd.com.
ELECTRODES AND ACCESSORIES
Springs and Brush electrodes and all attached accessories are prone
to wear and tear and will eventually need to be replaced. The timing of
replacement will depend on how they are maintained and the coatings
that they are used on.
maintenance and r epai r

22 pi cltd.compi cltd.com 23
Spy® model 785 / 790
technical
specifications
MODEL
Voltage Type
Voltage Range (kV)
Voltage Output Accuracy
Coating Range (Min-Max)
Pulse Repetition Rate
Operating Temperature
Internal Volt Meter
Display Type
Holiday Indicator Type
Power Type
Quick Release Battery*
Battery charge time
Unit Weight (w/ battery only)
Unit Dimensions (w/o battery)
Unit Dimensions (w/ battery)
Domestic/International
Standards Unit Complies With
*Battery life is dependent upon selected voltage and load applied. Typical battery life 8 hours.
785
Pulse
1-15 kV
±5%
4-150 mils
28 Hz
–40°F to 148°F
YES - User Adjustable
LCD
Audible/Visual
12V Rechargeable Battery
YES
Approximately 4-6 Hours
7.45 lb
21.5” x 5” x 5.5” (L x W x H)
21.5” x 5” x 8” (L x W x H)
CE, NACE SP0274-2011,
NACE SP0490-2007
790
Pulse
5-35 kV
±5%
50-750 mils
28 Hz
–40°F to 148°F
YES - User Adjustable
LCD
Audible/Visual
12V Rechargeable Battery
YES
Approximately 4-6 Hours
7.45 lb
21.5” x 5” x 5.5” (L x W x H)
21.5” x 5” x 8” (L x W x H
CE, NACE SP0274-2011
Pipeline Inspection Company, hereafter referred to as (SPY®) warrants that
SPY®Model 785 / 790 Series Holiday Detectors shall, under normal use
and service, be free from defects in material and workmanship. SPY®‘s
entire warranty obligation shall be limited to, at SPY®’s option, the repair
or replacement free of charge to the buyer of any defective equipment or
parts thereof which prove to be defective in material and workmanship under
normal use and service.
Claims for defective parts must be made in writing within twelve (12) months
after shipment of the equipment from the works of SPY®. Fast wearing and
consumable parts including, but not limited to, electrodes and ground cables,
are expressly excluded from the warranty. SPY®shall have the option to
require return of a claimed defective part to SPY®’s manufacturing facility in
the U.S.A., freight prepaid by buyer for examination to establish buyer’s claim.
Except with SPY®’s prior written approval, SPY®shall not be liable (a) for
the cost of repairs, alterations or replacements or any expense connected
therewith made or incurred by the buyer or its designers, or (b) for defects
resulting from alterations or repairs made by others than SPY®‚ or its approved
representatives.
SPY®shall not be liable for damages, including but not limited to direct, special,
indirect or consequential, resulting from the handling, or use, whether alone
or in combination with other products, or any SPY®equipment or third party
designed or manufactured equipment, including without limitation, any loss
or damage sustained or caused by the operation and use of the equipment
which is improperly operated or its successful operation is impaired by natural
elements after its delivery to the buyer.
The foregoing warranty is exclusive and in lieu of all other warranties
whether written, oral or implied (including without limitation, any warranty of
merchantability or fitness for purpose).
warranty

24 pi cltd.compi cltd.com 25
FLAT BRUSH
(BRASS, STEEL
OR NEOPRENE)
1”- 72” (25-1829 mm)
Electrode types
The Model 785 / 790 can be fitted with a wide variety of electrodes that
vary in form, size and material to fit a wide range of coating inspection
projects. If we don’t carry it we can custom build an electrode to fit your
project needs.
HALF-CIRCLE
BRUSH (BRASS,
STEEL OR
NEOPRENE)
1”- 60”(2 5-1524 mm)
FULL- CIRCLE
BRUSH (BRASS,
STEEL OR
NEOPRENE)
8”- 60” (203-1524 mm)
FULL- CIRCLE
STEEL SPRING
2”- 80” (50-2032 mm)
Please call our office at [phone] or email us at [e-mail]
for more product details or to place an order.
30’-100’ INTERNAL
PULL CABLE
INTERNAL
NEOPRENE
1”- 64” (2 5-1625 mm)
OR SPONGE
2”- 28” (50-711mm)
SPRING
ADAPTER FOR
ELCOMETER
SPRINGS
ITEM #13996
ELECTRODE
WANDS
(36” – 72”)
SPRING SUPPORT
PUSHER WAND
(FOR SPRINGS
OVER 60”)
GROUND CABLE
(50 FT – 600 FT)
SPRING
ADAPTER FOR
TINKER & RASOR
SPRINGS
ITEM #13995
ELECTRODE FLEX
WAND
(36” – 72”)
accessories
The Model 785 / 790 has a wide variety of accessories to assist you with
your coating inspection project.
Please call our office at [phone] or email us at [e-mail]
for more product details or to place an order.

26 pi cltd.compi cltd.com 27
related equipment Test vo ltag e Guide for 785 / 790
portable h o l i day detector
SPY®MODEL 780 PORTABLE DC
HOLIDAY DETECTOR
SPY®MODEL JM
(VOLTAGE ME TER)
SPY®MODEL PJM POCKET
JEEPMETER (VOLTAGE METER)
525* SQRT (MILS) MINIMUM TEST VOLTAGE FOR THIN FILM COATINGS
COATING THICKNESS MINIMUM TESTING VOLTAGE
KiloVolts
1.67
1.82
1.97
2.10
2.35
2.63
2.88
3.33
mil
10
12
14
16
20
25
30
40
mm
0.25
0.30
0.36
0.41
0.51
0.64
0.76
1.0
1250* SQRT (MILS) MINIMUM TEST VOLTAGE FOR THICK FILM COATINGS
COATING THICKNESS MINIMUM TESTING VOLTAGE
KiloVolts
5.6
6.9
9.7
11. 9
13.7
15.4
16.8
28.0
31.3
34.3
mil
20
30
60
90
120
150
180
500
625
750
mm
0.51
0.76
1.5
2.3
3.0
3.8
4.6
12.7
15.9
19.1

PIPELINE INSPECTION COMPANY
picltd.com