p o rtab l e p u ls e holiday detector o p e r at i n g i n st r u ct i o n s
p i c lt d.com PIPELINE INSPECTION COMPANY
spy® model 785 / 790 pulse holiday 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.
8 p i c lt d.com 2 3 6 5
15 7 8
1 9 6
10 4
13 12 14 11 1 Spring or Brush Electrode 8 Control Knob (3 positions: 2 Electrode Accessory Off / Voltage Set / On) Connection Point 9 Voltage Set Access Hole 3 Electrode Wand 10 Comfort Grip 4 Wand Release 11 Ground Cable Connection Point 5 Easy Carry Top Handle 12 12V Battery 6 Shoulder Strap Connection 13 Quick Release Battery Button 7 Built In Digital LCD JeepMeter 14 Horn (Voltage meter) 15 Model & Serial Number p i c lt d.com 9 connecting accessories CAUTION! DO NOT TOUCH. Make sure the switch is in the OFF position prior to connecting any accessory.
Clip Installation Shoulder Strap 4 Control Knob 1 2 3 1 Electrode Wand Caution! - High Voltage Cuidado! - Voltaje Alto
3 5 Battery
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. 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.
10 p i c lt d.com 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.
GROUNDING ROD DIAGRAM 1
EXTEND GROUND CABLE TO PIPE
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.
CAUTION! DO NOT TOUCH THE GROUND CABLE WHILE THE
DETECTOR IS OPERATING. 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. DIAGRAM 2
DETECTOR GROUND ROD GROUND CABLE
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
CUSTOM LENGTH GROUND CABLES AVAILABLE FROM SPY®
p i c lt d.com 11 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.
GROUNDING COLLAR DIAGRAM 3
EARTH DETECTOR TAIL WIRE (GROUND) USE A GROUNDING PAD IN CONJUNCTION WITH THE HOLIDAY DETECTOR GROUND CABLE ATTACHED TO THE GROUNDING PAD.
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.
12 p i c lt d.com 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 OFF VOLTAGE SET POWER ON LEFT MIDDLE RIGHT
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. VOLTAGE ADJUSTMENT HOLE POWER ON LED DISPLAY IN "VOLTAGE SET" ONLY OFF
DON'T TOUCH ELECTRODE WITH UNIT ON
VOLTAGE
KILOVOLTS
CHARGE BATTERY AFTER EACH USE
SET
KEEP ELECTRODES FREE OF TAR
DO NOT CUT OR KINK GROUND CABLE PIPE SHOULD BE GROUNDED TO EARCH ON
p i c lt d.com 13 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.
14 p i c lt d.com battery charging and storage instructions 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. CAUTION! MAKE SURE THE SWITCH IS IN THE OFF POSITION PRIOR TO REMOVING THE BATTERY.
Caution! - High Voltage
Cuidado! - Voltaje Alto
Quick Release Battery Button Battery
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.
16 p i c lt d.com WARNING! DO NOT USE ANY OTHER TYPE OF CHARGER. This charger is specifically designed for this battery. Charger 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 Battery trickle charge to keep the battery at peak charge.
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! 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.
p i c lt d.com 17 maintenance and repair 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.
p i c lt d.com 21 warranty 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).
