Astl15a 25a 40a Bae2sp Spat.010.5023.en

SPARK TESTER SYSTEM
AST L 15A / 25A / 40A

(Electrode unit)
BAE 2 SP (OPTION)
(Control and display unit)
Document
INSTRUCTION MANUAL
identification number >>> SPAT.010.5023.EN
Applicable for CP software version D23S1001 and higher
The translation of the original instruction manual

This document, its contents, and the technology described are strictly confidential. It is provided for as-
sistance to ZUMBACH customers only. It may not be copied, reproduced or passed on to third parties
without express, written permission from ZUMBACH Electronics.
Registration, or Update Date of this Manual 27.08.2021
Sparktester AST L 15A/25A/40A 12 ZUMBACH owned companies in Switzerland (H.Q.), Benelux, China, Czech Republic, France, Germany,
SPAT.010.5023.EN_20210827 India, Italy, Spain, Taiwan, United Kingdom and USA, plus agents and service in more than 40 countries.
About this manual
This manual provides information on installation, operation, maintenance and safety

precautions for AST L 15A / 25A / 40A spark testers.
Read chapters 2, 3 and 4 before starting the installation.
Chapter
1 Generalities to be considered on receiving the goods,

Addresses of the Zumbach group
2 General and specific safety precautions, which are not mentioned in

the following chapters
3 Technical description and specifications,

hardware and installation overview
4 Installation
5 Operating instructions
6 Maintenance
7 Repairing
Return for repairs, spare parts
8 Decommissioning / disposal
9 Service port
10 RS Interface
11 Ethernet
12 Profinet
13 List of parameters and results
14 Web visualisation
15 Index
2/114 12 ZUMBACH owned companies in Switzerland (H.Q.), Benelux, China, Czech Republic, France, Germany, Spark Tester AST L 15A/25A/40A
India, Italy, Spain, Taiwan, United Kingdom and USA, plus agents and service in more than 40 countries. 20210827_SPAT.010.5023.EN
Contents
1 INTRODUCTION 7
1.1 DEAR CUSTOMER�� 7
1.1.1 Risks and transportation�� 7
1.1.2 Inspection of goods upon arrival�� 7
1.1.3 Warranty�� 7
1.2 ADDRESSES – THE ZUMBACH GROUP�� 8
1.3 SYMBOLS�� 9
1.4 ZUMBACH PRODUCT OVERVIEW�� 10
1.5 EU DECLARATION OF CONFORMITY (Copy)�� 12
2 SAFETY 13
2.1 SAFETY�� 13
2.1.1 Safety measures in the unit�� 13
2.2 USE ACCORDING TO DESTINATION�� 14
2.3 PROHIBITED USE�� 14
2.4 RESIDUAL RISK�� 15
2.4.1 High voltage�� 15
2.4.2 Fire hazard due to deposits and water in the electrode unit �� 16
2.4.3 Ozone�� 16
2.4.4 EMC�� 17
3 TECHNICAL DESCRIPTION 18
3.1 SYSTEM OVERVIEW�� 18
3.2 SPARK TEST PRINCIPLE�� 18
3.2.1 Production line to manufacture cables and wires�� 18
3.3 COMPONENTS OF THE AST L 15A / 25A / 40A SPARK TESTER�� 19
3.3.1 Control and display unit BAE 2 SP�� 20
3.3.1.1 Dimensional drawing BAE 2 SP�� 21
3.3.2 Electrode unit�� 22
3.3.2.1 Dimensional drawing AST.xxA.50 and AST.xxA.90�� 24
3.3.2.2 Dimensional drawing AST.xxA.250�� 25
3.4 TECHNICAL DATA�� 26
3.5 REQUIREMENTS FOR UL CERTIFICATION OF WIRE AND CABLE
PRODUCTS �� 27
3.6 SPARK TEST STANDARDS APPLYING TO AST L 15A / 25A / 40A
SPARK TESTERS�� 27
3.7 ELECTRODE LENGTH AND TEST FREQUENCY�� 27
3.8 FAULT DETECTION�� 28
3.9 EXTRUDING AND REWIND MODE�� 30
3.10 ACTIVATION OF CONTROL POSITIONS�� 30
Spark Tester AST L 15A/25A/40A 12 ZUMBACH owned companies in Switzerland (H.Q.), Benelux, China, Czech Republic, France, Germany, 3/111
4 INSTALLATION 32
4.1 INSTRUCTION FOR LIFTING AND CARRYING�� 32
4.2 LOCATION OF THE SPARK TESTER�� 32
4.3 MOUNTING INSTRUCTIONS�� 33
4.4 CONNECTIONS TO THE SPARK TESTER�� 34
4.4.1 Connections to the electrode unit�� 34
4.4.2 Connection to mains�� 35
4.4.3 Mounting the control and display unit BAE 2 SP�� 35
4.5 CORRECT EARTHING OF THE SPARK TESTER�� 36
4.6 SETTINGS AND USER INTERFACES�� 38
4.6.1 Operating mode of the control and display unit BAE 2 SP�� 39
4.6.2 Configuration menu of the control and display unit BAE 2 SP�� 40
4.6.3 Emergency stop connector�� 42
4.6.4 Encoder�� 44
4.6.5 Setting up the Service Ethernet interface�� 46
4.6.6 Potential free analog / digital input / output�� 47
4.6.7 Setting up the user configuration for RS host interface�� 50
4.6.8 Setting up the Ethernet interface�� 51
4.6.9 Setting up the user configuration for Profibus DP interface�� 52
4.6.10 Setting up the Profinet interface�� 54
4.7 PROTECTION AGAINST OZONE �� 55
5 OPERATING INSTRUCTIONS 56
5.1 EARTHING OF THE PRODUCT TO BE TESTED�� 56
5.2 CLEANING OF THE ELECTRODE�� 56
5.3 TEST VOLTAGE�� 57
5.4 IF YOU RUN INTO PROBLEMS IN YOUR APPLICATION�� 57
5.5 USING THE SPARK TESTER WITH CONTROL AND DISPLAY
UNIT BAE 2 SP�� 58
5.5.1 Front panel of the control and display unit BAE 2 SP�� 58
5.5.2 Control spark testers with control and display
unit BAE 2 SP�� 61
5.5.3 Using the control and display unit BAE 2 SP as local
display�� 63
5.6 OPERATING SPARK TESTERS WITH POTENTIAL FREE I / O�� 63
5.7 OPERATING SPARK TESTERS WITH RS OR ETHERNET
HOST INTERFACE�� 64
5.8 OPERATING SPARK TESTERS WITH PROFIBUS DP OR
PROFINET HOST INTERFACE �� 65
6 MAINTENANCE 66
6.1 REGULAR MAINTENANCE�� 66
6.2 SAFETY CHECK OF THE SPARK TESTER�� 67
6.3 CALIBRATION OF SPARK TESTERS�� 67
6.4 SPARK TESTER CALIBRATOR�� 68
6.5 CALIBRATION FORM FOR SPARK TESTER�� 69
6.6 CALIBRATION WITH CONTROL AND DISPLAY UNIT BAE 2 SP�� 70
6.6.1 Calibration of the test voltage�� 70
6.6.2 Calibration of the analog input nominal�� 71
6.6.3 Calibration of the analog output actual�� 72
6.7 CALIBRATION VIA INTERFACE�� 74
6.7.1 Calibration of the test voltage�� 74
6.7.2 Calibration of the analog input nominal�� 75
6.7.3 Calibration of the analog output actual�� 75
7 REPAIRING 76
7.1 RETURN FOR REPAIRS�� 76
7.2 CONDITIONS APPLYING TO SPARE PARTS�� 76
7.3 TROUBLE-SHOOTING�� 77
7.4 LIST OF SPARE PARTS OF THE ELECTRODE UNIT
AST L 15A / 25A / 40A�� 78
7.4.1 Common spare parts for all AST L 15A / 25A / 40A
electrode units�� 78
7.4.2 Spare electrodes and component parts of electrodes�� 79
8 DECOMMISSIONING / DISPOSAL 82
8.1 DECOMMISSIONING�� 82
8.2 GENERAL DISPOSAL�� 82
9 SERVICE PORT 83
9.1 SETTING UP THE LAPTOP�� 83
9.2 SETTING UP THE TERMINAL PROGRAM�� 84
9.3 USING THE SERVICE PORT�� 85
10 RS INTERFACE 86
10.1 SERIAL LINK�� 86
10.2 COMMUNICATION SYNTAX�� 88
10.3 GENERAL DEFINITIONS�� 88
10.3.1 Data and parameter access�� 89
10.4 ZUMBACH ASCII PROTOCOL�� 90
10.4.1 Upload�� 90
10.5 ANSI X3.28-2.5-A4 STANDARD PROTOCOL�� 91
10.5.1 Upload�� 91
10.5.2 Download�� 92
11 ETHERNET 94
12 PROFINET 95
13 LIST OF PARAMETERS AND RESULTS 96

13.1 PARAMETERS GROUP A – SYSTEM�� 96
13.2 PARAMETERS GROUP B – LINE PARAMETERS�� 97
13.3 PARAMETERS GROUP C – PRODUCT PARAMETERS�� 98
13.4 PARAMETERS GROUP D – MEASUREMENTS�� 98
13.5 PARAMETERS GROUP E – ALARM MESSAGES AND DEVICE
STATUS�� 99
13.6 PARAMETERS GROUP F – CONTROL FUNCTIONS�� 99
13.7 PARAMETERS GROUP S – MEASUREMENT HEAD AND
CALIBRATION�� 100
13.8 DEFINED ONLY FOR ODAC PROTOCOL�� 101
13.9 PROFIBUS AND PROFINET SPECIFIC PARAMETERS�� 102
14 WEB VISUALISATION 103

14.1 LOCAL DISPLAY WITH A VISU-TOUCH�� 103
14.2 LOCAL DISPLAY OF A PAGE WITH A WEB BROWSER�� 103
14.3 USING AND DISPLAYING MENUS�� 104
14.3.1 Main page�� 105
14.3.2 Settings page�� 107
15 INDEX 109
1 INTRODUCTION
1.1 DEAR CUSTOMER

Thank you for giving us and our products your trust. Kindly read the operating
instructions carefully. This is a prerequisite to achieve faultless initial operation and
functioning of the unit. The safety precautions must be observed during all phases of
installation, operation, maintenance, repair and decommissioning.
▶ The commercial terms and conditions of the document "General terms and
conditions of sale" (ZUMB.540.0003.E) are binding.
1.1.1 Risks and transportation

The moment the equipment is shipped from our plant, Buyer assumes all risks
regarding it, in particular but not limited to the risk for damage, loss, theft, attachment
or confiscation.
1.1.2 Inspection of goods upon arrival

• Remove packing material carefully.
• Keep it for possible storing or return of the unit.
• Check the equipment for possible damage due to transportation.
• In case of damage, inform immediately both the forwarder and the carrier.
• Examine the equipment within a reasonable period of time and notify us
immediately in writing of any defects, or missing parts.
1.1.3 Warranty
As far as practically possible and in our opinion deemed necessary, each part of the
equipment is tested for its proper working condition prior to shipment.
The general warranty regulations can found in our "General sales and delivery terms"
(ZUMB.540.0003.E).
Certified Quality
In addition to conforming to ISO 9001:2015, Zumbach's quality standards
guarantee a highly precise, robust and reliable product. The goal of the
ZUMBACH group is to offer industry the most complete line of measuring
and monitoring instruments of the highest quality and technology. Worldwide
support by competent advisors and reliable service is provided by 11
ZUMBACH owned enterprises and by over 40 agencies, we are committed
to Total Customer Satisfaction. ISO 9001:2015
The ZUMBACH Group
1.2 ADDRESSES – THE ZUMBACH GROUP
Switzerland Zumbach Electronic AG France ZUMBACH Bureau France
(H.Q.) P.O. Box (vente) 6 rue de l'Avenir
CH-2552 Orpund FR-77760 La Chapelle La Reine
Phone +41 (0)32 356 04 00 Tél. +33 (0)1 64 24 46 31
Fax: +41 (0)32 356 04 30 Fax +33 (0)1 64 24 46 26
E-mail: sales@zumbach.ch E-mail: ventes@zumbach.com.fr
Benelux Zumbach Electronic AG Service ZUMELEC Sarl
P.O. Box après-vente: 6 rue de l'Avenir
CH-2552 Orpund FR-77760 La Chapelle La Reine
Tel. +32 (0)52 31 18 81 Tél. +33 (0)1 64 24 42 69
Fax +41 (0)32 356 04 30 Fax +33 (0)1 64 24 46 26
E-mail: sales@zumbach.be E-mail: service@zumbach.com.fr
China Zumbach Electronic (Shanghai) Co., Ltd. India Zumbach Electronic India Pvt. Ltd.
2F, Building 18 S No: 106/2/1, 2nd lane, "Daffodils" Society
No. 481 Guiping Road Row House No: 7, Near Karnataka Bank,
200233 Shanghai, P.R. China Behind D mart, Baner Mahalunge Road,
Tel. +86 (0)21 542 60 443 Baner, Pune - 411045
Fax +86 (0)21 542 61 151 Maharashtra
E-mail: sales@zumbach.com.cn Mobile +91 9890 100 813
E-mail: sales@zumbachindia.com
Czech Zumbach Czech Office
Republic Hutska 126 Italia Zumbach Electronic Srl
CZ-27201 Kladno Via Adua, 19
Tel. +420 608 474 664 IT-21045 Gazzada Schianno (VA)
Fax: +41 (0)32 356 04 30 Tel. +39 0332 870 102
E-mail: jvorlicek@zumbach.cz Fax +39 0332 464 605
E-mail: zumit@zumbach.it
Deutschland Zumbach Electronic GmbH
Kesselsgasse 2 Taiwan Zumbach Electronics Far East
DE-50259 Pulheim 4F., No. 262, Sec. 6
Tel. +49 (0)2238 8099-0 Ming-Chuan E. Road
Fax +49 (0)2238 8099-49 Taipei
E-mail: verkauf@zumbach.de Taiwan R.O.C.
Tel. +886 2 2630 5530
Büro in Gera: Fax +886 2 2630 5529
Robert-Leube-Weg 3 E-mail: info@zumbach.tw
DE-07548 Gera
Tel. +49 (0)365 8320265 UK Zumbach Electronics Ltd.
Fax +49 (0)365 8320268 Registered Office Address:
Mobil +49 (0)172 9318525 22 Cromwell Business Centre
E-mail: fwohlfeld@zumbach.de Howard Way, Newport Pagnell
Milton Keynes, MK16 9QS.
España Zumbach Electrónica S.L. Phone: +44 (0)870 774 3301
Avinguda de Cornellà, 144, 3o, 3a Fax: +44 (0)870 774 3302
ES-08950 Esplugues de Llobregat E-mail: sales@zumbach.co.uk
(Barcelona) Company Registered in England
Tel. +34 93 666 93 61 Company Registration Number: 1233358
E-mail: gestion@zumbach.es
USA Zumbach Electronics Corp.
140 Kisco Avenue
Mount Kisco, NY 10549-1407
Phone: +1 914 241 7080
Fax: +1 914 241 7096
E-mail: sales@zumbach.com
www.zumbach.com
20190429 blog.zumbach.com
1.3 SYMBOLS
This symbol warns the user of the presence of dangerous

voltage.
Disposal of old devices: This symbol indicates that this product

must not be disposed together with regular household waste.
Collect old devices separately and deliver them to the designated
collection point for recycling of electrical devices and electronic
accessories according to WEEE (waste electrical and electronic
equipment) directives.
WARNING Safety warning: A warning with the heading WARNING indicates

a danger which could possibly lead to injury or death. Only
continue the process if you have fully understood the note and
can adhere to it.
1.4
1.1 ZUMBACH PRODUCT OVERVIEW
ZUMBACH Measuring and Control Systems for On-line and Off-line Use in the Wire
and Cable Industry, Plastics and Rubber Industry, Steel and Metal Industry, for Medical
and Laboratory Applications and more.
ODAC® 1, 2 and 3 axis Laser

Diameter Scanners for
non-contact dimensional
measurement
MSD Diameter and Ovality

measuring heads for
non-contact dimensional
measurement with
"Linear Sensor
Technology"
ODEX® Non-contact Eccentricity,

Diameter and Ovality
Measuring System
USYS Multitasking Data

Acquisition and Control
Systems
RAYEX® X-Ray Measuring System

for CV lines (Continuous
Vulcanization)
CELLMASTER® Foam and Foam Skin

Measuring and Control
System
CAPAC® Capacitance Measuring

and Control Systems
UMAC® Ultrasonic Eccentricity
and Wall Thickness
Measuring and Control
Systems
KW Lump and Neckdown

Fault Detectors
PROFILEMASTER® In-Line Profile

Measurement using
"Light Section" Principle
and Machine Vision
SIMAC® Surface Quality

Inspection Systems
LSV Speed and Length

Measuring System
WST TEMPMASTER Conductor Preheaters
AST L
AST H 15A Spark Testers
DST 28A
CALIBRATOR SP Spark Tester Calibrator

for all Spark Tester
Models
1.5 EU DECLARATION OF CONFORMITY (Copy)
The following EU declaration of conformity is a content report of the original document
only, which is keep and available at the Zumbach Electronic AG. The document has
no serial number or signing.
EU DECLARATION OF CONFORMITY
The manufacturer:
Zumbach Electronic AG
Hauptstrasse 93
CH-2552 Orpund
herewith declares that
the spark testers AST L 15A/25A/40A series,

AST.15A.50.200UL-x, AST.15A.50.400UL-x, AST 15A.50.1000UL-x,
AST.15A.90.200UL-x, AST.15A.90.300UL-x, AST.25A.50.200UL-x,
AST 25A.50.400UL-x, AST 25A.50.1000UL-x, AST.25A.90.200UL-x,
AST.25A.90.300UL-x, AST.15A.250.200UL-x, AST.25A.250.200UL-x,
AST.40A.250.200UL-x with BAE 2 SP
are in conformity with the provisions of the following directives:
2014/35/EU Low voltage directive

2014/30/EU Directive relating to electromagnetic compatibility
2011/65/EU Directive on the restriction of the use of hazardous substances (RoHS)
2015/863/EU Delegated directive amending Annex II to Directive 2011/65/EU as regards
the list of restricted substances
and furthermore declares that the following harmonised standards and other standards (or parts/
clauses thereof) have been applied:
IEC 62230 Electric cables – Spark-test method
EN 61010-1 Safety requirement for electrical equipment for measurement,

control and laboratory use – Part 1: General requirements
IEC 61326-1 Electrical equipment for measurement, control and laboratory use –
EMC requirements – Part 1: General requirements
CISPR 11 Industrial, scientific and medical equipment – Radio – frequency disturbance

– limits and methods of measurement
CH-2552 Orpund, March 16, 2020
2 SAFETY
2.1 SAFETY
The spark tester AST L 15A / 25A / 40A fulfils the requirements of European directives
for low voltage and EMC.
This instruction manual provides safety precautions and information about

installation, operation and maintenance of spark testers. Instruct the operating
personnel on how to use the spark tester correctly and on how to avoid hazards.
Installation, maintenance, repair and decommission must be done by electrically
qualified personnel.
Observe the safety precautions given in the corresponding chapters, when
• Installing,
• Operating,
• Maintaining,
• Servicing and
• Placing out of operation.
WARNING
High voltage. Danger to life. Observe the safety instructions given in the instruction
manual and the general precautions for working with hazardous live voltages.
• Operation must be done by instructed operating personnel.
2.1.1 Safety measures in the unit

The Zumbach Electronic AG company sets the highest priority on personal safety when
designing its systems. The spark testers are equipped with the following safety features:
• The information sheet # SPAT.009.0006.E must be affixed at a clearly visible
place for the operating and maintenance personnel. The warnings must be
respected.
One information sheet # SPAT.009.0006.E is included in the delivery of each
spark tester; further information sheets are available on request.
• Safety switches interrupt the test voltage if the electrodes are opened.
Do not modify or disable components which serve to fulfil a safety function. All
safety components must be intact.
• The short-circuit current of the spark tester is limited to a maximum value of

10 mArms. This current limitation is an intrinsic characteristic of the voltage
source and the control circuit.
• Charge removal devices at the entry and exit of the electrodes. The charges
adhering to the cable are stripped off, thus reducing the danger of an electrostatic
charge buildup on the cable. These charge removal devices also protect from
electric shock when the cable is humid.
2.2 USE ACCORDING TO DESTINATION
The spark tester AST L 15A / 25A / 40A is exclusively intended for the applications listed
below. Zumbach Electronic AG disclaims liability for all other applications.
• The spark tester AST L 15A / 25A / 40A is intended for testing cable sheaths and
conductor insulation during extrusion, sheathing or rewinding.
The layer to be tested must be electrically insulating (nonconducting) and the
leakage currents must be sufficiently low.
Zumbach spark testers detect the small pinholes as well as bare patches in
cable sheaths and conductor insulation.
• The spark tester AST L 15A / 25A / 40A allows spark-testing with test voltages up
to 15 kV, 25 kV or 40 kV and there are electrode units available for diameters up to
50 mm, 90 mm or 250 mm.
• The spark tester electrode units are designed exclusively for operation with the
Zumbach control and display unit BAE 2 SP and user interfaces as described into
this instruction manual.
• The spark testers are only provided for operation in fixed installed facilities.
The installation must be carried out and tested by qualified personnel.
The instruction manual must be respected.
• The spark testers must exclusively be operated by healthy persons.
2.3 PROHIBITED USE

Any use of the spark tester not intended for its destination can be hazardous to the
operator or result in damage and voids all warranty claims.
Amongst others, the following use is explicitly prohibited:
• The spark testers are not intended for use in mobile installations or as handheld
device.
• The spark tester is not intended to be used out of the range of the specified
environmental conditions.
WARNING
Operating the electrode unit with disabled safety means and testing conductors
which are not earthed are strictly forbidden.
Spark testers are not intended for:

• Testing of conductive or semiconductive layers or conductive surfaces or other
materials with high leakage currents (electrical heating, undesired leakage
currents)
• Testing of insulating materials with conductive additives like carbon, carbon black,
graphite, conductive colorants or pigments if the additives result in high leakage
currents.
• Wet products or partially wet products
• Tests with very low test voltage < 3 kV (insufficient ionisation).
• Spark testers are unsuitable for detecting reduced insulation resistance.
Not authorized operating personnel:

• Persons with pacemaker, defibrillators or other similar devices.
• Persons with heart malfunctions that have reduced tolerance to electrical currents
passing through the body.
• Persons on medication which affects the response capability or the perception
• Persons under the influence of alcohol or unprescribed drugs
2.4 RESIDUAL RISK
2.4.1 High voltage

Spark tester systems do require a high electric voltage in order to operate and fulfil
their task. This can be hazardous to personnel in the form of an electric shock.
Please refer to chapter 4.5 for more information on the correct protective earthing of
spark testers.
There are several safety measures to be met by the user:
Always earth the conductor or shielding of the cable to be tested on both sides.
WARNING
Do not insert body parts or other objects into the openings for product inlet and
outlet (except products to be tested and earthing rods).
Do not touch the cable to be tested when the spark tester is switched on.
Touching the spark tester or the control unit BAE 2 SP can be hazardous to the user
if there is high voltage between the user and earth. The control and display unit
BAE 2 SP works with non-hazardous voltages close to earth. The insulation between
BAE 2 SP and the user is not intended to be used with high voltages.
When it is necessary to touch the cable for operational reasons, the following additional
security measures must be applied in order to protect the operators:
– The floor or floor covering in the area of the operating personnel must be made of
insulating material
– All tangible objects within the area of the workplace must be insulated, e.g.
control devices of rewinding or extrusion equipment
he corresponding isolations must be sufficiently sized for the nominal test voltage
T
of the spark tester.
Explanation:
• As a difference of potential between the conductors (floating potential) and
the earth always exists whenever the conductors are not earthed, an electric
discharge may occur if a person touches the conductor or the cable. The current
flowing through the human body can result in involuntary muscular contractions
or immobilization and therefore cause subsequent injuries. The physiological
effects depend on the health of the person, body part and surface area of
contact, duration of the electric shock etc. but usually no organic damage is to be
expected. (IEC TS 60479-1,-2).
In case of an electric shock, contact immediately an emergency doctor on call.
• If the conductor of the cable to be tested is not properly earthed, it cannot be

guaranteed that the insulation has been tested with the required test voltage.
I.e. proper earthing is also mandatory when cable testing must be done according
to a given standard.
• It is not sufficient to earth the conductor only on one side because there is risk of
electrical shock if:
– only the roll away coil side is earthed and the cable head leaves the roll away
coil
– the conductor is not continuous, e.g. broken.
2.4.2 Fire hazard due to deposits and water in the electrode unit
Deposits of dirt, talc, abrasion of products, etc. in the electrode unit and on the insulators
can cause creeping currents and thus induce a fire. Particularly critical are conductive
deposits and moisture.
Due to the spark-test method with high voltage, it is mandatory that the products
must be dry when entering into the electrode. A water film on the cable may results
in short-circuiting the test voltage and therefore impairing the proper operation of the
spark tester.
In addition, water can result in:

– damaged products: heating up of the insulation, melting of the insulation, risk of
fire, especially at standstill line or low line speeds
– risk of fire due to deposits of dirt, talc, abrasion of products inside the electrode
unit
Therefore, it is mandatory to use dryers, e. g. water scrapers, strong air blower,

compressed air dryers or a combination of it.
Make sure that the dryer is always working properly. In case of improper drying, stop
the test voltage of the spark tester immediately.
The electrode must regularly be inspected:

– In case of dirt inside the electrode unit, clean the inside of the electrode unit
and the insulators. Refer to chapter 6.1 regular preventive maintenance and
corrective maintenance.
– In case of creepage paths on the insulator (erosion, brown or black traces eroded
into the surface of the insulator) do not operate the spark tester anymore.
The defective insulators must be replaced.
If the voltage of the spark tester is much lower than the preset test voltage, the unit
must immediately be switched off and the area of the electrodes must be inspected
for contamination and damaged isolators. If the voltage is still below the preset value,
do not operate the spark tester anymore and return the spark tester for repair.
In case of fire, switch off immediately the spark tester and remove the mains plug.
Before extinguishing the fire, make sure that the spark tester is separated from the
mains.
2.4.3 Ozone
For reliable detection of small insulation faults, the air surrounding the cable must be
ionized. This unavoidably produces ozone. The quantity of ozone produced depends,
among other things, on the following factors:
• Type of material and surface quality of the insulation being tested.

• Value of the test voltage.
• Fault rate
The ozone concentration in the close workshop environment should not be allowed to
exceed 0.1 ppm (parts of ozone per one million parts of air by volume; IEC 62230), or
the value given in national industrial hygienic standard, whichever is lower.
The ozone concentration can be tested by taking a smell at the air: Ozone smells
sweet and in higher concentration like chlorine. The olfactory threshold for ozone is
0.01 ppm (0.02 mg / m3), i.e. 10 times lower than the tolerance.
When operating spark testers, precautions to ensure that the maximum permis-
sible values for ozone are not exceeded must be taken if the ozone concentration
is too high.
In case of ozone like odour, the following measures must be applied to minimize
exposure of personnel:
• Use the spark tester in spacious production halls.

• Ensure a good air circulation in areas where spark testers are used.
• Ozone extraction hose connected to the electrode unit.
Refer to chapter 4.7 for protection against ozone.
When persons are exposed to high ozone concentrations the symptoms can vary
from dryness in the mouth and throat, coughing, headache and chest restriction.
2.4.4 EMC
When a spark tester is operating, electromagnetic emission is generated due to the
test method (air ionized in the electrode, corona discharges and a long cable being
fed through).
By correctly earthing the spark testers and the product to be tested, it is possible
to reduce the interference to values not causing problems. The spark tester itself is
immune against such interference.
Please refer to chapter 4.5 "Correct Earthing of the spark tester" for further
information regarding correct EMC installation.
The spark tester complies the following standards or parts / clauses there of:
– IEC 61326-1 Electrical equipment for measurement, control

and laboratory use - EMC requirements
Part 1: General requirements
– CISPR 11 Industrial, scientific and medical equipment -

Radio-frequency disturbance characteristics -
Limits and methods of measurement
Spark testers are class A equipment and intended for use in an industrial en-
vironment. In other environments (domestic), there is may be a potential of
electromagnetic interference, e.g. radio or TV reception disturbed if too close
to the spark tester.
3 TECHNICAL DESCRIPTION
3.1 SYSTEM OVERVIEW

Core extrusion
Sheathing
Rewinding
3.2 SPARK TEST PRINCIPLE

The product to be tested travels through a high voltage test electrode. If there is a
defect in the insulation, a voltage flash-over takes place between the test electrode
and the internal conductor and the spark tester registers a fault.
The ionized air in the test electrode provides an optimal contact with the entire surface
of the product, and this allows to detect even very small faults with good reliability.
3.2.1 Production line to manufacture cables and wires

Spark testers are used
• at the end of extrusion lines,
• in sheathing lines or
• in rewinding facilities
for detecting bare patches and faults in the insulating jacket:
Spark tester
Pay-off reel Cable to Take up reel
be tested
Earthing of the
spark tester
Earthing of the conductor, Earthing of the conductor,
sheath or armour sheath or armour
The conductor, metallic sheathing or armoured shield must be earthed on both sides.
Also the spark tester itself must be earthed.
3.3 COMPONENTS OF THE AST L 15A / 25A / 40A SPARK TESTER
Control and display unit BAE 2 SP with stand

Order number BAE.040.01000
Electrode unit with integrated interface
Connecting cable to control and display unit BAE 2 SP
Length Order number

1m A10 220 4811
3m A10 220 4831
5m A10 220 4851
10 m A10 220 48101
20 m A10 220 48201
Mounting bracket for VISU-Touch

Order number N2.796.0
3.3.1 Control and display unit BAE 2 SP
The electrode units AST L 15A / 25A / 40A can be controlled via BAE 2 SP or service
port or one of several remote interfaces.
The BAE 2 SP has two operating modes, whereas one can be selected with an internal
changeover switch:
In control mode (C), the spark tester is controlled via BAE 2 SP, e.g.:
– Set the desired test voltage
– Switch on and off the test voltage
– Displays the actual test voltage, number of faults etc.
– Reset the fault counter
– Calibrate the spark tester
– Settings and configuration of the spark tester
If the BAE 2 SP is in control mode, the service port and the remote interface is
deactivated.
In display mode (D), the spark tester is controlled via service port or the remote
interface. The control via BAE 2 SP is deactivated (No test voltage on / off commands,
no reset the fault counter etc.). The BAE 2 SP serves for monitoring values only:
– Displays the test voltage, actual value and set point value
– Displays the number of faults, pin holes and bare patch
– Displays the actual length and the fault positions
In display mode, all controls and settings are to be done via service port or via the
host port built-in in the electrode unit.
305 12.01
Option 1 65.2 2.57
241 9.49
36.2 1.43
Pivotable
SPAT.010.5023.EN_20210827
Spark Tester AST L 15A/25A/40A
Schwenkbar
Pivotant
122.2 4.81
171.5 6.75
3.3.1.1 Dimensional drawing BAE 2 SP
Pivotable
Optional mountig angle
Schwenkbar
Montagewinkel optional
Pivotant
Angle on option
Option 2
25
M5 Screw 2x
M5 Schrauben 2x
0.9
8
M5 Visser 2x
25 0.98
M5 Screw 2x
M5 Schrauben 2x
M5 Visser 2x
India, Italy, Spain, Taiwan, United Kingdom and USA, plus agents and service in more than 40 countries.
12 ZUMBACH owned companies in Switzerland (H.Q.), Benelux, China, Czech Republic, France, Germany,
Projection
(1 : 2)
• Subject to modifications
21/111
• Dimensions in mm (inch)
3.3.2 Electrode unit
The AST L 15A / 25A / 40A electrode unit consists of the following:
• The high voltage test electrode in a earthed and closed housing to provide
protection against electrical shock
• Charge removal devices at inlet and outlet for removing static charges.
• Safety switch to switch off the test voltage when the electrode is open
• Signalization lamps:
– Yellow indicator lamp, lights up when the test voltage is switched on
– Red indicator lamp "Alarm", lights up during the set alarm prolongation after
each fault. If another fault is detected within this time, the time duration will be
prolonged again by the alarm prolongation..
• High voltage generator and associated control electronics
Charge removal Bead chain

Safety switch
devices Electrode
Signalization lamps
Machine feet
Ozone Electrode trough Earthing rod

extraction port
(in the rear)
The electrode unit is equipped with one out of the following remote interfaces:
Interface x: Suffix in y: Suffix in
the model the order
number number
RS interface; for USYS 200,
RS 2
USYS IPC 1e / 2e or Host
Profibus DP DP 3
Ethernet EN 4
Profinet PN 5
Ethernet IP EI 7
Electrode units AST L 15A / 25A / 40A:

Model Order number Max. Active Max. wire Max. wire
diameter length line speed line speed
of of according according
product electrode to IEC to UL
mm mm 62230 m/ 1581 m/min.
min.
AST.15A.50.200UL-x AST.261.05201y 50 200 240 66.6
AST.15A.50.400UL-x AST.261.05401y 50 400 480 133
AST 15A.50.1000UL-x AST.261.05991y 50 1000 1200 333
AST.15A.90.200UL-x AST.261.09201y 90 200 240 66.6
AST.15A.90.300UL-x AST.261.09301y 90 300 360 100
AST.25A.50.200UL-x AST.262.05201y 50 200 240 66.6
AST 25A.50.400UL-x AST.262.05401y 50 400 480 133
AST 25A.50.1000UL-x AST.262.05991y 50 1000 1200 333
AST.25A.90.200UL-x AST.262.09201y 90 200 240 66.6
AST.25A.90.300UL-x AST.262.09301y 90 300 360 100
AST.15A.250.200UL-x AST.261.25201y 250 200 240 66.6
AST.25A.250.200UL-x AST.262.25201y 250 200 240 66.6
AST.40A.250.200UL-x AST.263.25201y 250 200 240 66.6
3.3.2.1 Dimensional drawing AST.xxA.50 and AST.xxA.90
B - 20 400
A max.
3.15
11 0.43
65 2.56 15.16
Model Order number A B

max. ø
AST.15A.50.200UL AST.261.05201 50 600
AST.25A.50.200UL AST.262.05201 50 600
AST.15A.90.200UL AST.261.09201 90 800
AST.25A.90.200UL AST.262.09201 90 800
AST.15A.90.300UL AST.261.09301 90 800
AST.25A.90.300UL AST.262.09301 90 800
AST.15A.50.400UL AST.261.05401 50 800 Projection
AST.25A.50.400UL AST.262.05401 50 800

AST.15A.50.1000UL AST.261.05991 50 1400
AST.25A.50.1000UL AST.262.05991 50 1400 • Subject to modifications
3.3.2.2 Dimensional drawing AST.xxA.250
• Subject to modifications
Projection
650
Approximate weight: 260kg

250 max.
30.51
1006
645
13.5 0.53
100
16.02
3.4 TECHNICAL DATA
Mains
100 – 127 Vac, 200 – 240 Vac
Mains voltage
Automatic switch over between both ranges
Mains voltage operation* 90 – 146 Vac, 180 – 276 Vac typical
Mains frequency 47 – 63 Hz
Power consumption 20 – 150 W typical, load-dependent
Current consumption 2.1 A max.
2 fuses inside the appliance inlet,
Fuse
250 VAC / 5 x 20 mm 3.15 A slow blow
Output
Sinusoidal alternating voltage
AST.15A: 0.5 kV - 15 kVacrms
High voltage
AST.25A: 0.5 kV - 25 kVacrms
AST.40A: 0.5 kV - 1540kVacrms
Accuracy < +/- 4 %
Test frequency 50 - 120 Hz adjustable
Short circuit output current < 10 mArms
Electrode units
Zumbach AST L 15A / 25A / 40A electrode
units, refer to chapter 3.3.2
AST.xxA.50 / 90: approx. 110 kg (242.5 lbs)
Weight
AST.xxA.250: approx. 300 kg (661.4 lbs)
Control and display unit
For all electrode units BAE 2 SP, see chapter 3.3.1
Environmental conditions
Temperature + 5 ... + 50 °C
(+ 41 ... 122 °F)
No wetness, no direct exposure to sunlight.
Operating temperature, pollution
Only low non-conductive pollution, casually
temporary condensation (pollution degree 2)..
Designed for indoor use only.
Temperature when shipping / storing -20 ... 50 °C (4 ... 122 °F)
Humidity max. 95 % (not condensing)
* The test voltage is switched off as long as the mains voltage is outside the operating
range. The test voltage remains off after interruption and re-establishment of the mains
voltage.
The maximum test voltage of 15 kV, 25 kV or 40 kV is for use at up to 2000 m altitude.

For an altitude greater than 2000 m, the test voltage must be reduced to the values
shown below:
Maximum test voltage

Rated operating altitude
AST.15A AST.25A AST.40A
2001 up to 3000 m 13.1 kV 21.9 kV 35 kV
3001 up to 4000 m 11.6 kV 19.3 kV 31 kV
4001 up to 5000 m 10.1 kV 16.8 kV 27 kV
3.5 REQUIREMENTS FOR UL CERTIFICATION OF WIRE AND CABLE
PRODUCTS
For UL certification of wire and cable products, refer to the website of UL.
Concerning spark test, the following must be fulfilled:

1. The Spark tester must be in compliance with the requirements for spark tester
given in UL1581, refer to chapter 3.3.2 for electrode units with suffix UL.
2. Annual calibration of the spark tester and the calibrator
3. Keep the following documents at the disposal of the UL engineer:
– Calibration report of the spark tester; calibration done by Zumbach or the
customer
– Calibration report of the calibrator; calibration done by Zumbach
– Calibration certificate of the used high tension voltmeter; provided by Zumbach
3.6 SPARK TEST STANDARDS APPLYING TO AST L 15A / 25A / 40A

SPARK TESTERS
AST L 15A / 25A / 40A spark testers comply with the standard IEC 62230 (Electric
cables - Spark-test method).
In addition, the spark testers are in compliance with the requirements given in cable
standards, e.g. ISO 6722-1.
Electrode units with suffix UL can be used for insulation tests according to UL2556,
UL 1581, UL 444, UL44 and other cable standards.
3.7 ELECTRODE LENGTH AND TEST FREQUENCY

To achieve proper spark testing, every point of the insulated conductor should be in
contact with the electrode during a certain number of cycles or a certain duration. The
required values are specified in standards. Together with the given wire line speed,
this results in a required minimum electrode length.
The table below shows accordingly the maximum wire line speed in m / min for the
given standards.
Length of electrode 200 mm 300 mm 400 mm 1000 mm

Max. line speed according
240 360 480 1200
to IEC62230
Maximum line speed according
to UL2556, UL1581, ISO6722,
66.6 100 133.3 333.3
FED-STD-228 method 6211.1,
at test frequency 50 Hz
Some standards require a number of cycles and the test frequency is not limited to
the usual mains frequencies of 40 Hz to 62 Hz. Therefore, higher wire line speeds
can be applied for the same length of the electrode if the test frequency is increased.
Examples of such standards:

– UL1581: Reference standard for electrical wires, cables and flexible cords
– UL2556: Wire and cable test methods
Both standards require that the product should be in contact with the electrode during
9 cycles and there are no limitations for the test frequency.
The table below shows accordingly the maximum wire line speed in m / min for the
standards UL1581 and UL2556 at different test frequencies.
Length of electrode 200 mm 300 mm 400 mm 1000 mm

50 Hz 66.6 100 133.3 333.3
60 Hz 80 120 160 400
100 Hz 133.3 200 266.6 666.6
120 Hz 160 240 320 800
With AST L 15A / 25A / 40A spark testers, the test frequency can be adjusted from 50 Hz
to 120 Hz, the factory setting is 50 Hz.
The test frequency should be set as low as possible to reduce the capacitive loading
and the amount of ozone.
• If the wire line speed is lower than the values shown in the table above for
50 / 60 Hz, the spark test should be done at 50 Hz or 60 Hz.
• If the wire line speed is higher than the values shown in the table above for
50 / 60 Hz, the test frequency can be increased up to 120 Hz maximum for small
product diameters,
– at dielectric coefficient < 3 up to a product diameter of 28 mm
– at dielectric coefficient 3 to 6 up to a product diameter of 14 mm
At higher test frequencies, the output loading capability for capacitive loads is lower.
When testing cables with too high capacitance, the spark tester does not reach the
desired value of the test voltage and the maximum achievable test frequency is lower.
3.8 FAULT DETECTION

The fault detector detects a voltage breakdown of the insulation. If the voltage drop in
the electrode is larger than the setting value, a fault will be indicated.
Normative reference: UL1581 Reference Standard for Electrical Wires, Cables, and
Flexible Cords, section 910.10: A breakdown is defined as decrease of 25 % or more
from the test voltage applied between the electrode and the earth-grounded conductor.
The fault detector is in compliance with IEC62230: Test with an artificial fault device
according to IEC62230.
Adjustment of the sensitivity of the fault detector
The adjustment range for the sensitivity is 10 % to 40 % drop of the test voltage. A
voltage drop of 10 % of the test voltage corresponds to the highest sensitivity and
40 % drop corresponds to the lowest sensitivity, which is more immune against corona
discharges.
Very high test voltages or specific insulating materials may cause strong corona
discharges during spark test. These corona discharges can result in false triggering
of the fault detector. In the majority of cases, there are no specific customer settings
for the sensitivity needed.
The factory setting (highest sensitivity, 10 % voltage drop) is suitable for most of the
products.
If there are false fault indications caused by corona discharges or capacitive loading,
the sensitivity should be decreased.
After changing the sensitivity setting, the proper fault detection should be tested with
the same cable and an artificial fault device (e.g. Calibrator SP).
Pin hole and bare patch

Usually, two different types of faults can be present:
– Pin holes: Small defects in the insulation
– Bare patch: Large area of uninsulated wire, e.g. due to dropout of material during
extrusion
The two types of faults can often be identified based on the time duration of the fault.
The user can set the minimum duration of a bare patch event accordingly via control
and display unit BAE 2 SP or via interface, value range 0.1 ... 9.9 s.
One count per discrete fault is registered in the fault counter and indicated with the
control and display unit BAE 2 SP as "Total faults".
In addition, if the fault duration is shorter than the time duration of a bare patch event
a fault named "pin hole" is registered, else a "bare patch" is registered.
Via interface, the total number of faults and the number of bare patch events can be
readout.
Fault position
To localize the position of the faults, the length from the beginning of the product to
the fault position can be captured. Therefore, an incremental rotary encoder must be
connected to the spark tester, refer to chapter 4.6.4. The positions of the last faults
(up to 20 faults) can be registered and readout via BAE 2 SP or interface.
Fault resolution
The fault detector detects two consecutive faults with time interval 30ms.
Reset of the counter

A reset command via BAE 2 SP or interface resets the fault counter, pin hole counter,
bare patch counter and the fault position. All measured fault position values are cleared.
3.9 EXTRUDING AND REWIND MODE
One out of two modes can be selected by a changeover switch located on the rear
panel of the electrode unit:
• Extruding mode:
A fault is counted for each insulation fault.
The red indicator lamp "Alarm" on the electrode unit lights up during the fault and
the set alarm prolongation after each fault. If another fault is detected within this
time, the time duration will be prolonged again by the alarm prolongation.
The potential free output "Alarm" is activated accordingly.
After the fault travels out of the electrode, the spark tester resumes operation and
the test voltage recovers to the desired value.
• Rewind mode:
After detecting a fault, test voltage is switched off immediately and a fault is
counted (bare patch is not indicated in rewind mode).
The red indicator lamp "Alarm" on the electrode unit is switched on. The
potential free output "Alarm" is activated and the output "Test voltage enabled"
deactivated.
A test voltage off-on sequence reactivates the test voltage and deactivates the
red indicator lamp "Alarm". The potential free output "Alarm" is deactivated and
the output "Test voltage enabled" activated.
3.10 ACTIVATION OF CONTROL POSITIONS

The spark tester can be controlled by one out of the following control positions:
• Control and display unit BAE 2 SP
• Ethernet based service port
• Host port, depending on the version of the electrode unit, one out of the following
RS Interface, Profibus DP, Ethernet, Profinet or Ethernet IP
• Potential free I / O
Normative reference: Directive 2006 / 42 / EC of the European Parliament and of the

Council on machinery, annex 1, number 1.2.2: Where there is more than one control
position, the control system must be designed in such way that the use of one of them
preludes the use of the others [..].
Active control like switch the test voltage on / off or reset the fault counter can only be
done via the active control position.
The deactivated control positions serve for monitoring values only, e.g. deactivated
control positions indicate the test voltage, actual value and set point value or display
the number of faults, pin holes and bare patches.
To activate a desired control position, the following must be done:
Desired control Required settings

position
BAE 2 SP • Connect a BAE 2 SP to the electrode unit
• The internal switch in the BAE 2 SP must be in position
C = control (Factory setting)
Potential free • No BAE 2 SP connected to the electrode unit, or if a BAE 2 SP
inputs / outputs is connected, the internal switch must be in position D = display
• The switch in the rear of the electrode unit must be set to
position "Potential free I / O"
Host port • No BAE 2 SP connected to the electrode unit, or if a BAE 2 SP
(RS interface, is connected, the internal switch must be in position D = display
Profibus DP, • The switch in the rear of the electrode unit must be set to
Ethernet or position "Interface"
Profinet) • Select the host port as active control position via the host port
Service port • No BAE 2 SP connected to the electrode unit, or if a BAE 2 SP
is connected, the internal switch must be in position D = display
• The switch in the rear of the electrode unit must be set to
position "Interface"
• Select the service port as active control position via the
service port
The following arrow diagram can be used to identify which control position is the active
control position, whereas the other control positions are deactivated:
Active control position:

BAE 2 SP
internal switch BAE 2 SP
C = Control
Potential free I/O

Switch in the rear
BAE 2 SP of the electrode unit:
connected „Potential free I/O“
Host port
BAE 2 SP Control via (RS interface,
internal switch host port Profibus DP,
D = Display activated Ethernet, Profinet or
Ethernet IP)
Switch in the rear

BAE 2 SP
of the electrode unit
not connected
„Interface“
Control via Service port
service port Ethernet
activated
4 INSTALLATION
• Any work related to the installation should be carried out by electrically

qualified personnel only.
• The installation must be carried out in a way that ensures the safety of operators
without specific electrical know-how.
Do not open the electrode unit. No user adjustable parts inside.
WARNING
When working on the open system, be aware that certain parts of the circuitry
are hazardous life. Disconnect from mains before access.
Follow the indications in this chapter for the installation and initial operation of the
spark tester.
4.1 INSTRUCTION FOR LIFTING AND CARRYING

Carry the electrode unit carefully. If needed for lifting, lifting straps can be attached
to the electrode box.
4.2 LOCATION OF THE SPARK TESTER

• The product to be tested must always be dry when entering into the electrode. If
the product is wet, make sure that reliable dryers are installed before the spark
tester.
• If an installation for powdering with talc is used with the product to be tested, the
spark tester should be placed before it, to avoid deposits inside the electrode.
• The electrode unit is cooled by natural convection. Approx. 50 mm free space
around the case is needed for cooling. Do not obstruct the air flow.
Refer to chapter 2.4.2 for further informations.
4.3 MOUNTING INSTRUCTIONS
Attach the spark tester to the floor with 4 appropriate screws. Use the 11 mm mounting
holes in the mounting brackets of the mounting foot.
Mounting of the mounting foots:
• Lift the electrode unit and place the machine mount under the tapped through
hole of the frame.
• Insert the levelling bolt into the tapped through hole and turn it by hand until the
bolt hits bottom. Apply the grease supplied for added lubrication and protection
against corrosion of the levelling bolt.
• Add a nut and a washer between frame and machine mount before turning
the levelling bolt into the machine mount. Screw down the counter nut and the
machine mount as shown above to attach the levelling bolt to the upper part of
the machine mount.
• Balance the electrode unit by using a water level and turning the levelling bolts.
• Lock the levelling bolts by using the remaining nut and washer.
4.4 CONNECTIONS TO THE SPARK TESTER
4.4.1 Connections to the electrode unit
Green LED, blinking

Connecting cable between when working properly
electrode unit and control
and display unit BAE 2 SP
Changeover switch to select

the active control position:
Interface or potential free I / O
Host port
Service port
Changeover switch
Extrusion / Rewind
Positioning mark
BAE 2 SP connector
Connector for incremental

rotary encoder
Connector for potential free

inputs / outputs
Emergency stop input

Mains inlet with Protective earth screw
integrated fuses M6 located below the rear
panel (not shown on the
photograph. The earth
thread bolt is internally
connected to the protective
conductor of the mains cord
4.4.2 Connection to mains
Before connecting to mains, check that your mains voltage corresponds to the input
voltage range specified on the type label.
Use a mains cord that meets the requirements of IEC 60227 or IEC 60245, i.e. rated
voltage at least 300 Vac, three wires with cross section at least 1 mm2 and conductors
coloured brown, blue and green-and-yellow, operating temperature at least 70° C.
The brown conductor must be connected to the phase, the blue conductor to neutral
and the green-and-yellow conductor to protective earth. When the local applicable
regulations are different, then these local regulations must be applied.
The cord must be equipped with a C13 mains connector and the conductors must be
connected as indicated on the rear panel of the electrode unit.
To isolate the spark tester from the electricity supply, unplug the mains connector in
the rear of the electrode unit.
If it is impossible to access this connector, the customer must install a suitable device
for external disconnection.
4.4.3 Mounting the control and display unit BAE 2 SP

The BAE 2 SP can be mounted on the electrode unit centred or on left or on right side.
In addition, the BAE 2 SP can be mounted elsewhere close to the electrode unit with
two screws M5 spaced 25 mm.
The BAE 2 SP is pivot-mounted and can be pivoted in horizontal and vertical direction.
Connection to the Positioning
electrode unit mark
The connector on both sides is a quick connecting device. Align the positioning mark
of plug and socket, plug in and turn the locking jacket by about one half turn.
Connect the electrode unit to the control and display unit BAE 2 SP only with the cable
supplied by Zumbach Electronic AG.
4.5 CORRECT EARTHING OF THE SPARK TESTER
Follow the recommendations below for earthing the spark tester in order to avoid
interference caused by the current of the spark tester to earth.
The wire cross section for the earth connections depend on the current carrying capacity
of the installation on the users site. The minimum cross section is 1 mm2. When the
local applicable regulations are different, then these local regulations must be applied.
• Directly earth the cable to be tested to the M6 earth screw in the rear of the
electrode unit. This will prevent earth currents caused by spark tests in your
facilities.
• The electrode unit is earthed via the protective earth connection of the mains
cord. Connect an additional earth wire between the earthing of the building and
the M6 earth screw in the rear of the electrode unit.
• The cable between the electrode unit and the control and display unit BAE 2 SP
does not constitute an earth connection.
Bad: Good:
• Set up the earth connection between the cable to be tested and the spark
tester in such a way that the surface (designated by A and marked in gray in the
previous figure) limited by the current loop (current loop: test electrode – cable
– earth connection – test electrode) is as small as possible. This will reduce
electromagnetic interference (EMC) during operation.
• After installation, verify electrically the proper operation of the earthing.
The following earth connections are of particular importance:

- Make sure that the coil on the coil winder has a proper earth connection to the
protective earth of the building. If the bearing is isolated, a slip ring must be used
for earthing.
- Make sure that the earth connection remains intact when the coil is accelerating
and rotating at full speed (proper earth terminal or clip).
For further information concerning earthing, refer to chapter 2.4.1
4.6 SETTINGS AND USER INTERFACES
The following connectors and user interfaces are available on the rear panel:
BAE 2 SP
Control and display unit, refer to chapter 4.6.1
Emergency stop
Remote start / stop and emergency stop input, refer to chapter 4.6.3
Encoder
To localise the position of faults, refer to chapter 4.6.4
Changeover switch rewind / extrude

To select the desired operating mode, refer to chapter 3.9
Changeover switch Interface / Potential free I / O

To select the active control position, either interface or potential free I / O.
Refer to chapter 3.10
Service
The Ethernet based service port can be used for the web visualisation to configure
and calibrate the spark tester. Refer to chapters 4.6.5, 9 and 14
Potential free input / output

Refer to chapter 4.6.6
The electrode unit is equipped with one of the following interfaces, according to the
version of the electrode unit:
RS interface
Refer to chapters 4.6.7 and 10
Ethernet
For the Ethernet host port, refer to chapters 4.6.8 and 11
For the host protocol description refer to chapter 10
Profibus DP
Refer to chapter 4.6.9 and the Profibus DP software instruction manual ZUMB.011.0700.E
Profinet
Refer to chapter 4.6.10 and 12
Ethernet IP
Refer to the Ethernet IP Adapter instruction manual SPAT.010.0003.EN
4.6.1 Operating mode of the control and display unit BAE 2 SP
The BAE 2 SP can be used in one of the two following modes:
Mode Display Control

Internal Upward position "D" = Display Downward position "C" = Control
changeover Factory setting
switch
Function The BAE 2 SP is a display unit for The BAE 2 SP is the active control
monitoring values only. Control via position.
BAE 2 SP is deactivated. Control via interface (RS, Profibus
One out of the interfaces (service DP, potential free I / O, etc.) is
port, RS, Profibus DP or potential free deactivated.
I / O) is the active control position. The interface serves for monitoring
values and to send out alarm
messages only.
Application – Local display in remote – Manually operated lines like rewind
controlled lines lines
– Monitoring and supervision of – Calibration of spark testers
settings done via interface – Test operation for testing cables
without using the remote control of
the line
– Test and verification of spark testers
without using the remote control of
the line
– Manual configuration of the spark
tester, e.g. for electrode units with
potential free I / O
If the BAE 2 SP is not connected to the electrode unit, one out of the interfaces can
be selected to be the active control position.
The changeover switch for selecting the desired mode is located inside the BAE 2 SP:
Remove the small anthracite end caps of the two screws on the left side and unscrew
the side frame on the left (Torx T10) to access the changeover switch.
4.6.2 Configuration menu of the control and display unit BAE 2 SP
Refer to chapter 5.5.1 on how to use the BAE 2 SP.
– Push the "Config." key until the page 1 / 6 of the configuration menu appears
– Select the desired language by entering the corresponding digit and terminate
with the key "Enter"
– Adjust the brightness of the display
– Activate or deactivate the encoder
– Select the desired unit of length
– Incremental rotary encoder input: adjust the length of product between 2 pulses.
– Activate or deactivate the password protection for the menu "Nominal"
– Set the desired password for the menu "Nominal", 6 digits
Factory setting: No password protection, password 954728
– Activate or deactivate the password protection for the menu "Configuration"
– Set the desired password for the menu "Configuration"
– Activate or deactivate the password protection for the menu "Calibration"
– Set the desired password for the menu "Calibration"
– Set the IP address of the spark tester, factory setting 192.168.001.009
– Set the subnet mask, factory setting 255.255.255.000
– Set the gateway address, factory setting 192.168.001.001
4.6.3 Emergency stop connector
This remote input can be used for one of the following applications:
• Remote start / stop:
This potential free 24 Vdc input can be used to activate the test voltage (24 Vdc)
and to deactivate the test voltage (pin 2, 3 free from tension).
This input allows to activate and deactivate several equipment together in one
wire line.
•Emergency stop:
If one or several emergency stops are needed for a given installation, the
emergency stop devices can be connected to the connector "Emergency stop".
The emergency stop device must be equipped with a potential free normally
closed contact and the contact must sustain open after activation, until the
operator disengages the stop command.
WARNING
Electronic control via normal serial interfaces is not accepted by safety standards
to be the sole means of inhibition. Always use the emergency stop interface (or
open the electrode or remove the power cord) before touching the product to
be tested.
This input activates or deactivates the test voltage:

• To activate the test voltage, apply 24Vdc from external to pin 2, 3 or bridge
pin 1 to pin 2 and pin 3 to pin 4.
This represents normal operating mode, i. e the test voltage can be switched on
and off via the active control position.
• To deactivate the test voltage, make pin 2, 3 free of tension.
This represents the emergency stop mode, i.e. the test voltage cannot be
switched on via other means.
Apply 24 Vdc to pin 2, 3 to return to normal operating mode.
The circuit diagram below shows on how to use the emergency stop interface.
a) Emergency stop connector deactivated:

Factory setting, the spark tester can be used without connecting an emergency
stop device and without remote start / stop function.
b) Usage with emergency stop device:

The emergency stop device must be equipped with a potential free normally
closed contact, which is connected to pin 1, 2.
The default bridge between pin 3 and pin 4 is still connected.
The 24 Vdc coil of the relay is powered from the internal 24 V supply available
on pin 1, 4.
This supply is connected to protective earth, and therefore a potential free switch
is mandatory.
c) Remote start / stop:

Remove the default bridges to allow for a potential free input.
Apply 24 Vdc to pin 2, 3 to activate the test voltage or keep it free of tension
to deactivate the test voltage.
The external 24Vdc supply should deliver at least 30 mA, the coil is non polarized.
4.6.4 Encoder
To localize the position of the faults, the length from the beginning of the product to
the fault position can be captured. Therefore, an incremental rotary encoder must be
connected to the encoder input.
The encoder must provide the following two quadrature signals, phase A and phase B:
Viewed from the end of the shaft, if the shaft is rotated clockwise (CW), phase A
normally leads phase B in this rotation direction and the counter increments. If the
shaft is rotated counterclockwise (CCW), phase B leads phase A and the counter
decrements. X1 encoding is used: one pulse results in one increment or decrement
of the counter.
The output circuit of the encoder should be either a complementary output a) or open
collector output b).
For each pulse, the length counter increments or decrements. The following settings
are to be done for the spark tester:
• Select the desired unit of length: metric or imperial
• Switch the length detector on or off
• Enter the length between two pulses of the encoder
The settings can be done via serial interface or control and display unit BAE 2 SP
(menu "Config.", page 2 / 6).
The length between two pulses depends on the number of pulses per revolution and
the diameter of the measuring wheel:
len = (p * diam) / n
where as:
len: length between two pulses, in meter or inch
p: 3.14
diam: diameter of the measuring wheel
n: number of pulses per revolution
Specification of the potential free encoder input:

• Supply for the encoder: 24Vdc +/- 10 %, 30 mA max
• Two phase quadrature encoder input (phase A, B) for incremental rotary
encoders with complementary output or open collector output:
– Input current 10 mA min.
– Maximum response frequency: 50 kHz, i.e. a rotary encoder with less than 100
pulses per revolution should be used.
– The maximum number of pulses should be less than 500'000'000 pulses for
the largest product length used.
The potential of the encoder signals should be close to earth due to the electrostatic
discharge protection circuits (maximum transient overvoltage 1 kV) .
4.6.5 Setting up the Service Ethernet interface
The service interface can be used for the web visualisation to configure and calibrate
the spark tester.
This interface corresponds the Ethernet standard ISO / IEC 8802-3:
• Ethernet 10 / 100 Base T

• Protocol TCP / IP
• Connector RJ45 (8P8C)
• Port No. 2020
• IP address of the spark tester: 192.168.1.9 (factory setting)
• Subnet mask: 255.255.255.0 (factory setting)
yellow LED : activity (data traffic)

Reset button
green LED : link (connection)
Reset button:
Resets the service interface to the factory settings.
Procedure: press the button for 5 sec. with a pointed object: for example, carefully press
the button using an opened out paper clip inserted through the hole on the connector
plate. The unit automatically restarts after releasing the button. The link LED goes off
briefly when the unit is connected to the Ethernet.
For further information, refer to the chapter 9.
4.6.6 Potential free analog / digital input / output
The electrode units are equipped with the following interface connector on the rear
panel:
• Potential free signalling outputs Pin 1…14

• Potential free analog signals Pin 15…17
• Potential free control inputs Pin 18…21
Electrode unit
1 ALARM_CO
2 ALARM_NO
3 ALARM_NC
4 BARE_CO
5 BARE_NO
6 BARE_NC
7 ST_ENABLED_CO
8 ST_ENABLED_NO
9 ST_ENABLED_NC
10 TV_ENABLED_CO
11 TV_ENABLED_NO
12 TV_ENABLED_NC
13 FAULT+
14 FAULT-
15 ACTUAL
16 GND2
17 NOMINAL
18 TV_ON+
19 TV_ON-
20 RESET+
21 RESET-
All interfaces are electrically separated from the electronics and from each other.
The potential of the interface signals must be close to earth.
Maximum permissible transient overvoltage toward earth 1 kV due to electrostatic

discharge protection circuits.
Assignment of the connector "Potential free I / O"
Pin Function Assignment Maximum load

1 Common Alarm output 33 Vac, 70 Vdc, 6 A
2 Normally open contact Alarm output 33 Vac, 70 Vdc, 6 A
3 Normally closed contact Alarm output 33 Vac, 70 Vdc, 6 A
4 Common Bare patch output 33 Vac, 70 Vdc, 6 A
5 Normally open contact Bare patch output 33 Vac, 70 Vdc, 6 A
6 Normally closed contact Bare patch output 33 Vac, 70 Vdc, 6 A
7 Common Spark tester enabled output 33 Vac, 70 Vdc, 6 A
8 Normally open contact Spark tester enabled output 33 Vac, 70 Vdc, 6 A
9 Normally closed contact Spark tester enabled output 33 Vac, 70 Vdc, 6 A
10 Common Test voltage enabled output 33 Vac, 70 Vdc, 6 A
11 Normally open contact Test voltage enabled output 33 Vac, 70 Vdc, 6 A
12 Normally closed contact Test voltage enabled output 33 Vac, 70 Vdc, 6 A
13 Phototransistor collector +Fault momentary output 70 Vdc 10-20 mAdc
14 Phototransistor emitter -Fault momentary output 70 Vdc 10-20 mAdc
Analog output signal 0 ... 10 V directly propor-
15 Actual 0 .. +10 V 10 kΩ
tional to the test voltage 0 .. 15/25/40 kV
16 GND2 Ground return path for pins 15 and 17 –
Nominal value input 0 ... 10 V for the desired
Input impedance
17 Nominal 0 .. +10 V test voltage. 10 V corresponds
200kΩ
to the maximum test voltage 15/25/40 kV
18 Relais coil TV Test voltage on + (or vice versa) input 24 Vdc 6600 Ω
19 Relais coil TV Test voltage on - (or vice versa) input 24 Vdc 6600 Ω
20 Relais coil Reset Counter reset + (or vice versa) input 24 Vdc 6600 Ω
21 Relais coil Reset Counter reset - (or vice versa) input 24 Vdc 6600 Ω
The relay coils are non polarized and there is no freewheeling diode needed.
Additional information to some of the signals:
Alarm output
• Extruding mode:
If a fault is detected, the normally closed contact (pin 1, 3) opens during the
fault and during the set alarm prolongation after the fault, and the normally open
contact (pin 1, 2) is closed accordingly. If another fault is detected within this time,
the time duration will be prolonged to the alarm duration after the last fault.
• Rewind mode:
If a fault is detected, the normally closed contact (pin 1, 3) opens and the
normally open contact (pin 1, 2) is closed.
A test voltage off-on sequence reactivated the test voltage and resets the alarm
output to default state.
Bare patch output

• Extruding mode:
If a fault is detected and after the duration of the bare patch event has elapsed,
the normally closed contact (pin 4, 6) opens during 0.7 s and the normally open
contact (pin 4, 5) is closed during 0.7 s.
• Rewind mode:
The bare patch output is not activated in rewind mode.
Spark tester enabled output
If the spark tester is powered by mains and there are no internal faults, the normally
closed contact (pin 7, 9) is open and the normally open contact (pin 7, 8) is closed.
Test voltage enabled output

If the test voltage is set on, the normally closed contact (pin 10, 12) is open and the
normally open contact (pin 10, 11) is closed.
Fault momentary output

During a fault, the transistor at this output (pin 13, 14) is switched on.
Test voltage on input

The test voltage is on when 24Vdc from external are applied to pin 18, 19. and the
changeover switch "Service / Potential free I / O" is in position "Potential free I / O".The
test voltage is off when pin 18, 19 are free of tension. In rewind mode, the test voltage
is switched off after detecting a fault. To switch the test voltage on again, apply an
off-on sequence to the test voltage on input.
Counter reset input

Apply a 24Vdc pulse on (pin 20, 21) to reset all of the following:
– fault counter
– pin hole counter
– bare patch counter
– actual length (if the length detector is on)
– fault positions of up to twenty of the last detected faults
(if the length detector is on)
4.6.7 Setting up the user configuration for RS host interface
The factory settings of the RS interface are the following:
Host
Description Value
parameter
7 -> Automatic output mode for USYS
a945 Output mode
(see grouped message d182)
a970 Baud rate 9 -> 57600 baud
a971 Bits per character 1 -> 7 bits
a972 Number of stop bits 0 -> 1 Stop bit
a973 Parity 0 -> Even
a983 Transmission mode 1 -> RS422, full duplex, RTS on zero
a986 Protocol selection 1 -> Host protocol
Pin assignment on the RS 9p Sub-D male connector
Pin 1 Pin 5
Pin 6
Pin 9
Pin. Signal Description

1 T+ Transmit RS-422 data
T+ / R+ Transmit / receive RS-485 data
2 RxD Receive RS-232 data
3 TxD Transmit RS-232 data
4 R+ Receive RS-422 data
5 GND GND (electrically isolated)
6 T- Transmit RS-422 data
T- / R- Transmit / receive RS-485 data
7 NC Not connected
8 NC Not connected
9 R- Receive RS-422 data
Termination impedance: The factory setting is not connected.

When the spark tester is located at the end of the transmission line (ANSI X3.28
network), the termination resistors should be connected (switch ON / OFF beside the
connector).
For the RS interface, the Error and Status LED are not used.
For further information and other settings possibilities, refer to the chapter 13.
4.6.8 Setting up the Ethernet interface
The measured values and parameters are, using a selectable Zumbach protocol
(ODAC or host protocol), integrated and transmitted in standardized packages of the
TCP / IP Protocol. This allows data transfer via existing networks such as company
internal networks.
Ethernet RJ45 socket
The LEDs COM 0 + 1 are not used and are therefore always switched off.
Both Ethernet interfaces are internally connected via a switch and allow a through
looping of the connection to simplify wiring.
The spark testers are set as factory setting with IP address: 192.168.001.009, subnet
mask: 255.255.255.0 and Gateway address: 192.168.001.001 when delivered. These
addresses can be set and read via the service interface with the following ODAC / host
parameter IP: IL / a940 - subnet : IM / a941 – Gateway : IO / a942.
The TCP / IP port is permanently set to 2020 and cannot be changed.
Before connecting the Interface to the Ethernet network, it is necessary to adjust the
Ethernet parameters IP Address, Subnet Mask and Gateway Address with the service
interface (A940, A941, A942 see chapter 13):
1. Select the service port as active

control position: S006 to 1
2. Modification of IP Address: A940[SP]xxx.xxx.xxx.xxx[CR]
3. Spark tester restarts
4. Modification of Subnet Mask: A941[SP]xxx.xxx.xxx.xxx[CR]
6. Modification of Gateway Address: A942[SP]xxx.xxx.xxx.xxx[CR]
The input of the parameters (A940, A941, A942) is not followed by an automatic
acknowledgement from the spark tester (because automatic software restart). A delay
of 3 – 5 seconds must be respected before treating the next parameter. The measuring
spark tester returns an [NAK] if wrong parameter has been given.
4.6.9 Setting up the user configuration for Profibus DP interface
Profibus DP slave address setting

There are two hexadecimal coded switches to set the Profibus DP slave address on
the rear panel of the electrode unit.
The Profibus address can be set from address 1 to address 126. If the switches are set
to address 126, the Profibus address is read from the flash memory of the processor
card. If the switches have an address between 1 and 125, the software takes the
switch settings as Profibus address.
Further it is also possible to set the Profibus address through the service port. For the
last address setting method, the two switches must be set to address 126.
The default factory setting for the Profibus address switches and in the flash memory
126.
Profibus slave-address upper digit (hexadecimal code x16)

Profibus slave-address lower digit (hexadecimal code x1)
Example: Set slave address with the switches to address 58

58 in decimal = 3A in hexadecimal
Turn switch x16 to position 3 and switch x1 to position A.
The two switches are hexadecimal coded!

Default address: 126 = (7Ehex)
After a change of the Profibus DP slave address, the spark tester has to be restarted.
Unplug the mains plug and replug it after a short time of waiting. The new address is
only valid after new startup.
Termination resistor
If your slave is the last device on the Profibus network, you have to switch on
the termination resistor with the switch on the external 9 pin Sub-D connector.
This is absolutely necessary to insure a correct impedance adaptation of the network.
If your slave is not at the latest position, then disconnect this resistor with moving the
switch to position off.
For further information, refer to the Profibus DP norm DIN 19245-1.
Pin assignment on the Profibus DP 9p Sub-D female connector
Pin 5 Pin 1
Pin 9
LED ERR LED STA Pin 6
For the Profibus interface, the ON / OFF function is not active.
Pin Signal Description

1 Shield Shield, Protective Ground
2 NC Not Connected
3 Line-B (RxD / TxD-P) Receive / Transmit-Data-P
4 CNTR-P Control-P
5 DGND Data Ground (GND1)
6 VP Voltage–Plus (+5V)
7 NC Not Connected
8 Line-A (RxD / TxD-N) Receive / Transmit-Data-N
9 CNTR-N Control-N (GND1)
LED signification
This interface complies with the Profibus DP standards IEC 61158 / IEC 61784
For further information, refer to the software manual Profibus DP

ZUMB.050.5009.EN.
4.6.10 Setting up the Profinet interface
This version has been developed especially for the integration in a real-time Ethernet
according to the Profinet IO standard. The PLC interface or the system computer
(Profinet controller, supervisor) communicates with the spark tester (Profinet device).
Ethernet RJ45 socket
Both Ethernet interfaces are internally connected via a switch and allow a through
looping of the connection to simplify wiring.
The spark testers are set as factory setting with IP address: 192.168.001.009, subnet
mask: 255.255.255.0 and Gateway address: 192.168.001.001 when delivered. When
initially starting the unit the PLC development environment assigns a Profinet unit
name. The Ethernet address (00-02-A2-XX-XX-XX) is imprinted to distinguish the unit.
The Profinet controller assigns the IP addresses automatically to the units (as set in
the PLC project) when starting.
For further information, refer to the manual SPAT.010.0002.EN.
4.7 PROTECTION AGAINST OZONE
Refer to chapter 2.4.3 for further information about ozone.
If the concentration of ozone in the workplace is much higher than the odour threshold at
which ozone can be smelled, the following means of protection must be applied:
1. Connect an air duct with 80 mm inner diameter to the ozone extraction port of the
electrode unit and evacuate the air from the inside of the electrode unit.
2. Use one of the following methods for the extracted air:
– Exhaust the extracted air outside the building
– Use an activated carbon filter or ozone absorber to remove the ozone
– Use a thermal ozone converter to decay the ozone
Materials resistant to ozone

There are a lot of ozone-resistant materials available from a lot of suppliers for industrial
ventilation, like exhaust ducts, flexible pipes, clamps, activated carbon filter, ventilators.
Ozone has no effect on the following materials:

– Butyl
– Cross-linked polyethylene (PEX)
– EPR
– Ethylene-Propylene
– HDPE
– Polycarbonate
– Polyurethane
– PVC
– Silicone
– Stainless steel
Normally, the ozone concentration is so low, that also less ozone- resistant materials
can be used like:
– ABS plastic
– Acrylic
– Aluminium
– Copper, brass, bronce
– LDPE
– Polyacrylate
Exhaust the extracted air outside the building

The preferred solution is to connect the exhaust duct from the sparker to the already
existing air exhaust system used for other air contaminants from extruders etc.
Usage of an activated carbon filter or ozone absorber

Ozone filters can be used to reduce the ozone concentration to a level suitable for
discharge inside the building. Ozone filters or absorbers absorb the ozone in materials
like activated carbon. I.e. the effectiveness of the filter must be supervised and the
filter must be replaced in case of wear out.
Thermal ozone converter

Ozone decomposes into oxygen with a half-life of 3 days at 20° C. At higher temperature,
the half-live is much shorter, e.g. 1.5 seconds at 250° C. Thermal ozone converter
heat the air up to convert the ozone to oxygen. Not recommended due to high costs
and high energy consumption.
5 OPERATING INSTRUCTIONS
• Familiarize yourself with all aspects of the operation. Pay particular attention
to safety instructions.
• Instruct the operating personnel on how to use spark tester and to avoid
hazards when operating spark testers.
Always earth the conductor or shielding of the cable to be tested on both sides.
Refer to chapter 5.1 for further information.
Follow the directions for cleaning the electrode given in chapter 5.2
For common aspects about operation refer to chapter 5.3 and 5.4.
For control via control and display unit BAE 2 SP, refer to chapter 5.5.
According to the remote interface built-in in the electrode unit, the information is given
in the following chapters:
– RS interface: Chapter 5.6
– Profibus DP:
Chapter 5.7 and the Profibus DP software instruction manual ZUMB.011.0700.E
– Ethernet: Chapter 5.8
– Profinet: Chapter 5.9
– Potential free inputs / outputs: Chapter 5.10
5.1 EARTHING OF THE PRODUCT TO BE TESTED

For safety reasons and for proper spark testing we prescribe: Always earth the
conductor or shielding of the cable to be tested on both sides.
All standards on spark testers specify earthing at least one cable head.
Some standards, such as UL and NEMA, also requires earthing of both cable heads
for thin conductors (AWG 14 ... 10) if the conductor is not checked for continuity.
For further information about earthing, refer to chapter 2.4.1 and 4.5
5.2 CLEANING OF THE ELECTRODE

Inspect regularly the inside of the electrode unit, the electrode and the insulators.
In case of dirt or creepage paths on the insulator (erosion, brown or black traces
eroded into the surface of the insulator), switch the spark tester off and remove the
power cord from the electrode unit.
Clean the inside of the electrode unit. Defective insulators and acryl glass windows
must be replaced.
Missing or insufficient cleaning can result in fire hazard. Refer to chapter 2.4.2. and
6.1 for further information.
5.3 TEST VOLTAGE
The value of the test voltage depends on the thickness of the outer insulation and the
standard used. The following standards, among others, contain concrete specifications
on the value of the test voltage.
• IEC 62230
• ISO 6722-1
• UL44, UL 444
Insulation thickness mm Insulation thickness inch Test voltage [kV]

0 … 0.25 0 … .01 3
> 0.25 … 0.5 > .01 … .02 5
> 0.5 … 1.0 > .02 … .04 7
> 1.0 … 1.5 > .04 … .06 10
> 1.5 … 2.0 > .06 … .08 13
> 2.0 … 2.5 > .08 … 0.1 16
> 2.5 ... 3.0 > 0.1 ... 0.12 19
> 3.0 ... 3.5 > 0.12 ... 0.14 22
> 3.5 ... 4.0 > 0.14 ... 0.16 25
> 4.0 ... 5.0 > 0.16 ... 0.2 32
> 5.0 ... 6.0 > 0.2 ... 0.24 38
The minimum field-strength should be 5 kVac / mm inside the insulation of the

product to be tested. Otherwise, faults cannot be reliably detected.
5.4 IF YOU RUN INTO PROBLEMS IN YOUR APPLICATION

• Cables with very high capacitance:
When testing cables with a very high capacitance, it may happen that the high
voltage generator is unable to provide the charging current needed. Then the
desired value of the test voltage cannot be reached.
• Leakage currents:
Depending on the electrical conductivity of the product to be tested, a leakage
current will flow from the high voltage electrode to the earthed conductor and
the bead chains for charge removal. At too high leakage currents, the current is
limited by reducing the output voltage. Therefore the desired value of the test
voltage cannot be reached.
• Insufficient test voltage:

If the test voltage remains clearly below the set-point value without product to be
tested in the electrode, do not use the electrode unit anymore and take it out of
service. Return the electrode unit for repair.
5.5 USING THE SPARK TESTER WITH CONTROL AND DISPLAY UNIT BAE 2 SP
5.5.1 Front panel of the control and display unit BAE 2 SP

Red signalisation Yellow signalisation lamp Green signalization lamp
lamp "Alarm" "Test voltage" "Ready"
Push button "Test voltage"

for switching the test voltage
on and off
Push button "Config." for

menu configuration
Push button "Actual"

for menu actual
Push button "Calib"

for menu calibration
Push button"Nominal"
for menu nominal
Push button "Fault reset" for Graphic display Numeric keypad

resetting the fault counter
The control and display unit BAE 2 SP consists of the following:

– Numeric keypad
– Function keys
– Signalization lamps
– Graphic display
Numeric keypad
To enter numeric values in various input fields.
Key Function
0 .. 9 Numerals to enter values in input fields.
+/- Toggles the sign of certain inputs
Select Reserved for future use
Shifts the cursor to the next input field.
Esc Canceling an entry and resetting the current input field

to the previous value.
Enter Confirm a current entry.
The entered value is checked and limited to the permissible
minimum or maximum value.
The input field closes and the cursor jumps to the next input field.
Function keys
for selecting menus, scroll pages and activating or deactivating functions:
Key Function
Test Toggles the high voltage on and off each time the key is pressed.
voltage In rewind mode, the test voltage is switched off after a fault.
Press the test voltage key twice to reactivate the test voltage.
Config. Opens the menu configuration or shows the next page of the menu
configuration. This menu is intended for the service personnel to
configure the spark tester.
Press this key repeatedly to display successive pages of the menu
configuration.
Actual Opens the menu actual or shows the next page of the menu actual.
This menu displays actual values, like the test voltage, faults and and
setpoints. Press this key repeatedly to display successive pages of
the menu actual.
Calib. Opens the menu calibration or shows the next page of the menu
calibration. This menu is intended for the service personnel to adjust
the the spark tester if needed during calibration. Press this key
repeatedly to display successive pages of the menu calibration.
Nominal Opens the menu nominal or shows the next page of the menu
nominal. This menu is for entering setpoints. Press this key
repeatedly to display successive pages of the menu nominal.
Fault Resets the fault counter, pin hole counter, bare patch counter and
reset the actual length. All measured fault position values are cleared.
Signalization lamps
Lamp Function
Red LED The red indicator lamp "Alarm" lights up during the fault and during 0.7 s
"Alarm" after each fault. If another fault is detected within this time, the time
duration will be prolonged to 0.7 seconds after the last fault.
In rewind mode, the red indicator lamp "Alarm" remains on until the test
voltage is reactivated.
The function of the red LED is the same as the red indicator lamp on
the electrode unit.
Yellow LED The yellow lamp is on when the test voltage is switched on. The function
"Test of the yellow LED is the same as the yellow indicator lamp on the
voltage" electrode unit.
Green LED The green lamp is on when the cover is closed and the emergency stop
"Ready" input is activated.
Graphic display
The graphic display is subdivided in the following areas:
Actual page
of the menu
Header of the page,

indicating the active Symbol indicates
menue that there are
succeeding pages
Indicator
panel
Information
line
If a menu has more than one page, the symbol ">>>" and the number of the actual
page are indicated in the upper right corner. Press the corresponding menu key again
to display the next page of the menu.
The information line displays error messages and normal operating state messages.
The information line is displayed in the same way on all pages.
Information line text Meaning

The control and display unit BAE 2 SP is not the active
control position, and therefore the desired function is
deactivated. The BAE 2 SP is in display mode.
INACTIVE KEY
To activate the BAE 2 SP as active control position, the
internal switch in the BAE 2 SP must be set in position
C = control
The temperature inside the electrode unit is too high.
Do not operate the spark tester at ambient temperatures
OVERTEMP
higher than 50° C or at direct exposure to sunlight or
other heat sources.
The test voltage is outside the tolerance band as entered
in the menu nominal. E. g. during short circuits, caused
OUT OF TOLERANCE
by too high leakage currents or too narrow tolerance
entered.
The applied mains voltage is outside the operating
range, refer to chapter 3.4 technical data.
MAINS OUT OF TOL- The test voltage is switched off as long as the mains
ERANCE voltage is outside the operating range.
The test voltage remains off after interruption and
re-establishment of the mains voltage.
5.5.2 Control spark testers with control and display unit BAE 2 SP
For control with BAE 2 SP, the BAE 2 SP must be the active control position, and
therefore, the internal changeover switch inside the BAE 2 SP must be set in position
C = control. For further information, refer to chapters 3.10 and 4.6.1.
• Introduce the product to be tested into the electrode, then close the electrode
• Earth the metal conductor of the cable to be tested on both cable heads
(see also chapters 2.4.1 and 5.1) .
• The spark tester must be connected to mains via the mains cord
• The green signalization lamp on the BAE 2 SP should light up (electrode closed
and test voltage activated via emergency stop input )
• Reset the fault counter if needed by pushing the button "Fault reset"
• Set the desired test voltage and test frequency:
– Select the page 1 / 2 of the menu nominal by pushing the button "Nominal"
– Enter the desired test voltage by using the numeric keypad and confirm with
the key "Enter"
– Enter the voltage tolerance (normally 5 -20 % of the test voltage) accordingly
• If needed, set the parameters of the fault detector:
– Select the page 2 / 2 of the menu nominal by pushing the button "Nominal"
– Enter the sensitivity of the fault detector by using the numeric keypad and
confirm with the key "Enter". The highest sensitivity (10 % voltage drop) is
suitable for most of the products.
– Enter the minimum duration of the bare patch event accordingly
• Switch on the test voltage by pushing the button "Test voltage"
• The yellow signalization lamps "Test voltage on" on the electrode unit and on the
BAE 2 SP lights up.
• If an insulation fault occurs, the fault counter is incremented and the red alarm
signalization lamps on the electrode unit and on the BAE 2 SP lights up.
When working in rewind mode (switch in the rear of the electrode unit in position
rewind), the test voltage is automatically switched off when an insulation fault
occurs and the red signalization lamps "Alarm" remain on.
To reactivate the test voltage and deactivate the red indicator lamps, push the button
"Test voltage" twice.
• To display the current test voltage and the number of faults, select the page 1 / 3
of the menu actual by pushing the button "Actual":
One count per discrete fault is registered in the fault counter and indicated as "Total
faults". In addition, if the fault duration is shorter than the time duration of a bare patch
event a fault named "pin hole" is registered, else a "bare patch" is registered.
• If the length detector is configured, select the page 2 / 3 of the menu actual by
pushing the button "Actual" to display the position of the faults:
• To display the current test parameters, select the page 3 / 3 of the menu actual by
pushing the button "Actual":
The current length position is shown only when the length detector is configured.
• Switch off the test voltage after the test or at standstill line by pushing the button
"Test voltage". If the test voltage is switched off, the yellow signalization lamps
"Test voltage" on the electrode unit and on the BAE 2 SP are in off-state.
• Disconnect the spark tester from mains if not used for some time.
5.5.3 Using the control and display unit BAE 2 SP as local display
The spark tester is operated via the built-in remote interface.
For use as display, the internal changeover switch in the BAE 2 SP must be set to D
= display.
In display mode, the BAE 2 SP is not the active control position, and therefore, the
following controls are deactivated:
– inactive keys: "Test voltage", "Fault reset"
– inactive settings in menu: Nominal, configuration and calibration
Inactive functions are indicated in the information line "INACTIVE KEY".
In display mode, current values and settings can be monitored by selecting the menus
actual and nominal. For further information about the displayed values, refer to chapter
5.5.2.
5.6 OPERATING SPARK TESTERS WITH POTENTIAL FREE I / O

For operating a spark tester via potential free inputs / outputs, the control and display
unit BAE 2 SP must be in display mode (internal changeover switch inside the BAE 2 SP
must be set in position D = display) or no BAE 2 SP connected to the spark tester.
The potential free inputs / outputs must be the active control position: Set the
changeover switch in the rear of the electrode unit in position "Potential free I / O".
For further information, refer to chapter 3.10 and 4.6.1.
Refer to chapter 4.6.6 for information about the potential free inputs / outputs.
(see also chapter 2.4.1 and 5.1) .
• The spark tester must be connected to mains via the mains cord. If there are no
internal faults, the spark tester enabled output (pin 7, 8 and 9) is activated.
• Set the desired test voltage:
Apply a control voltage in the range of 0 … 10 V and proportional to the desired
test voltage to pin 17 Nominal and pin 16 GND2 .
The maximum value of 10 V corresponds to the maximum test voltage of 15 kV,
25 kV or 40 kV.
• Reset the fault counter if needed by applying a 24 V pulse to pin 20, 21.
• Switch on the test voltage by applying 24 Vdc to the test voltage on input
(pin 18, 19).
The yellow signalization lamps on the electrode unit and on the control and
display unit BAE 2 SP light up if the test voltage is switched on.
• The output signal on Actual pin 15 and pin 16 GND2 is proportional to the actual
test voltage. 10 V corresponds to the maximum voltage 15 kV, 25 kV or 40 kV.
• If an insulation fault occurs, the red alarm signalization lamps on the electrode
unit and on the BAE 2 SP light up during at least 0.7 s. The fault is signalled
via the output alarm (pin 1, 2 and 3). In addition in extrude mode, if the fault
lasts longer than the duration of the bare patch event, the bare patch output is
activated (pin 4, 5 and 7).
To reactivate the test voltage and deactivate the red indicator lamps, make the
test voltage on input (pin 18, 19) free of tension and apply again 24 Vdc to switch
the test voltage on.
• Switch off the test voltage after the test or at standstill line by make the test
voltage on input (pin 18, 19) free of tension. If the test voltage is switched off, the
yellow signalization lamps "Test voltage on" on the electrode unit and on the BAE
2 SP are in off-state.
5.7 OPERATING SPARK TESTERS WITH RS OR ETHERNET HOST

INTERFACE
For operating a spark tester via RS or Ethernet host interface, the control and display
unit BAE 2 SP must be in display mode (internal changeover switch inside the BAE
2 SP must be set in position D = display) or no BAE 2 SP connected to the spark
tester. The changeover switch "Interface//Potential free I/O" must be set in position
"Interface". For further information, refer to chapter 3.10 and 4.6.1.
Refer to chapter 10 for RS or Ethernet interface communication protocols.
• Introduce the cable to be tested into the electrode, then close the electrode
(see also chapter 2.4.1 and 5.1)
• The spark tester must be connected to mains via the mains cord
• Set the RS or Ethernet interface as active control position:
Select control position command S006 1 (download sequence -> capital letter)
• Set the desired test voltage, e.g. 5 kV
Output voltage setpoint command in kV: C780 5.0
• Set the tolerance band for the test voltage, e.g. 10 % of the test voltage, 500 V:
Voltage tolerance command in kV: C786 0.5
(Alarm message e720 303 if the actual voltage is outside the tolerance band)
• Reset the fault counter if needed: Reset command F020 1
• Switch on the test voltage: Test voltage on / off command F710 1 → on
• Read the current test voltage:
Measured output voltage command d042 (upload sequence -> lower case letter)
The response from the spark tester is the measured test voltage in kV, e.g. d042
5.02
unit and on the BAE 2 SP light up during at least 0.7 s and the fault counter is
increased. In addition in extrude mode, if the fault lasts longer than the duration
of the bare patch event, the bare patch counter is incremented.
To detect if a fault happened, read the fault counter:
– Spark tester fault counter command d070
– Spark tester bare patch counter command d072
To reactivate the test voltage and deactivate the red indicator lamps, make a test
voltage off command F710 0 and a test voltage on command F710 1
• Switch off the test voltage after the test or at standstill line:
Test voltage on / off command F710 0 → off
• Before touching the product, deactivate the test voltage via connector
"Emergency stop" or open the electrode
5.8 OPERATING SPARK TESTERS WITH PROFIBUS DP OR PROFINET

HOST INTERFACE
For operating a spark tester via Profibus DP or Profinet host interface, the control and
display unit BAE 2 SP must be in display mode (internal changeover switch inside the
BAE 2 SP must be set in position D = display) or no BAE 2 SP connected to the spark
tester. The changeover switch "Interface//Potential free I/O" must be set in position
"Interface". For further information, refer to chapter 3.10 and 4.6.1.
For further informations about the Profibus DP interface communication protocol, refer
to the software instruction manual ZUMB.011.0700.EN chapter 10.
For informations about the Profinet interface, refer to the software instruction manual
SPAT.010.0002.EN.
(see also chapter 2.4.1 and 5.1) .
• The spark tester must be connected to mains via the mains cord.
• Set the Profibus DP or Profinet interface as active control position:
Select control position command 443 1
• Set the desired test voltage, e.g. 5 kV
Output voltage setpoint command in volts: 42 5000
• Set the tolerance band for the test voltage, e.g. 10 % of the test voltage, 500 V:
Voltage tolerance command in volts: 43 500
• Reset the fault counter if needed: Reset command 72 1
• Switch on the test voltage: Test voltage on / off command 77 1 → on
• Read the current test voltage:
Measured output voltage command 79
The response from the spark tester is the measured test voltage in volts,
e.g. 79 5020
unit and on the BAE 2 SP light up during at least 0.7 s and the fault counter is
increased. In addition in extrude mode, if the fault lasts longer than the duration
of the bare patch event, the bare patch counter is incremented.
To detect if a fault happened, read the fault counter:
– Spark tester fault counter command 322
– Spark tester bare patch counter command 323
When working in rewind mode (switch in the rear of the electrode unit in
position rewind), the test voltage is automatically switched off when an
insulation fault occurs and the red signalization lamps "Alarm" remain on.
To reactivate the test voltage and deactivate the red indicator lamps, make a
test voltage off command 77 0 and a test voltage on command 77 1
• Switch off the test voltage after the test or at standstill line:
Test voltage on / off command 77 0 → off
• Before touching the product, deactivate the test voltage via connector
"Emergency stop" or open the electrode
6 MAINTENANCE
• Maintenance work on spark testers should be carried out by electrically

qualified personnel only.
• Instruct your maintenance and repair personnel on how to avoid h a z a r d s
when handling spark testers.
• Disconnect the spark tester from mains by removing the mains cord before
beginning maintenance work.
Do not open the electrode unit. No user serviceable parts inside.
WARNING
When working on the open system, be aware that certain parts of the circuitry
are hazardous life. Disconnect from mains before access.
6.1 REGULAR MAINTENANCE
Check the following points:
Cleaning
Isopropyl alcohol for cleaning purposes should only be used in well-ventilated

areas or with the window open. Highly flammable liquid and vapor, may form
explosive mixtures with air. Keep away from heat, sparks, open flames and hot
surfaces. No smoking.
• Clean the chain or brush electrodes of the spark tester with a cloth and isopropyl
alcohol or methylated spirits. Eliminate deposits on the chains or brushes. Use a
metallic brush to remove the dirt that adheres too tenaciously to the electrode.
• Clean regularly the inside of the electrode unit and the insulators. Check if there
are creepage paths on the insulator (erosion, brown or black traces eroded into
the surface of the insulator). Defective insulators must be replaced. Refer to
chapter 2.4.2 "Fire hazard due to deposits in the electrode unit".
Defective parts:
Regularly inspect the spark tester and replace defective parts, e. g. damage cables,
viewing glass, insulators, defective signalization lamps, charge removal devices etc.
Use only original spare parts. The spare parts are listed in chapter 7.3.
Calibration:
It is recommended that the calibration is carried out once a year. Refer to chapter 6.3.
Safety check:
The safety check as described in chapter 6.2 must be done at least once a year and
every time when in doubt on the proper operation of the spark tester.
6.2 SAFETY CHECK OF THE SPARK TESTER
This check must be performed at least once a year and every time when in doubt on
the proper operation of the spark tester:
• Close the electrode

• The spark tester must be connected to mains via the mains cord.
• Switch on the test voltage.
• Set the test voltage to the maximum value 15 kV, 25 kV or 40 kV.
• The yellow lamps on the electrode unit and the control an display unit BAE 2 SP
should light up.
• Open the electrode. The test voltage display must go back to 0 kV
• Switch the test voltage off.
• Measure the short circuit current, as shown in chapter 6.3. At maximum voltage
the short-circuit current must be less than 10 mA.
If this test does not proceed correctly, do not use the electrode unit anymore and take
it out of service. Return the electrode unit for repair.
In addition, check all protective earth conductors of the spark tester system, as
described in chapter 4.5.
6.3 CALIBRATION OF SPARK TESTERS

The verification of the performance of the spark tester should be carried out at least
once a year.
The verification according to IEC62230 can be done with the calibrator SP from
Zumbach Electronic AG, refer to chapter 6.4 and the instruction manual of the Calibrator
SP.
According to IEC62230, the following two parameters should be calibrated:
1) Voltage monitoring equipment:

The displayed test voltage shall have an accuracy of +/-5 % of the indicated
value.
2) Sensitivity of the fault detector:

The calibration is done with an artificial fault device according to IEC62230.
The artificial fault device is connected between electrode and earth.
The test voltage shall be set to 3 kVrms (or 5 kVdc for dc systems).
Then the artificial fault device produces 20 sparks. The fault indicator shall
register neither more nor less than one count per spark.
Then the test voltage shall be increased to the maximum voltage and the test
shall be repeated.
Report all measured values in the calibration report form shown in chapter 6.5.
In the majority of cases, it is sufficient to make a calibration report of the measured

values and no new adjustments need to be done.
New adjustment should only be done in the rare events where test voltage values are
out of the required tolerance of 5 %. The adjustment procedure is easy: Measure the
voltages at two operating points, enter the value and enter the command to accomplish
the calibration.
A calibration can only be done:
– Via control and display unit BAE 2 SP: Chapter 6.6
– Via service port, RS or Ethernet interface: Chapter 6.7
The following parameters can be measured but not calibrated.
• Short circuit current:

To limit the effect of electric shock to personnel, according to IEC62230, the short
circuit is limited to less than 10 mArms.
Within Zumbach spark testers, this limit is guaranteed by the design of the spark
tester.
• Test frequency:
AST L xxA: The test frequency corresponds to the adjusted value and is in the
range of 50 Hz to 120 Hz.
AST H 15A: The test frequency depends on the load capacitance and is in the
range of 2 ... 4 kHz
6.4 SPARK TESTER CALIBRATOR

The Zumbach Electronic AG company provides the Calibrator SP 40A for checking
and calibrating all spark testers according to IEC 62230.
With the Calibrator SP 40A, the following measurements can be performed:
• Test Voltage:
RMS value, positive or negative peak value, average value
• Sensitivity of the fault detector:
The Calibrator SP is equipped with an artificial fault device
according to IEC 62230
• Test frequency
• Short circuit current:
RMS value, average value
Contact the Zumbach sales organisation for more information.
6.5 CALIBRATION FORM FOR SPARK TESTER
The following form can be used for the calibration and the verification of spark testers
according to the standard IEC 62230 and the prescriptions in this manual.
calibration report
Calibration done by Calibration number
Address Calibration date
Calibration location
Manufacturer Zumbach As received (in / out of tol.)
Spark tester model As returned (in / out of tol.)
Order number Asset number
Serial number Accessories
The results reported herein apply only to the calibration of the item described above and no
limitations of use apply to the calibrated unit.
Test voltage [kV]

Nominal As found Result As left Result Min 1) Max 1)
3.00 2.88 3.03
10.00 9.6 10.4
15.00 14.4 15.6
1
) According to the specification for this spark tester the admissible error is: ± 4 %
Sensitivity (Measured faults after 20 sparks)

Test voltage As found Result As left Result Min / Max 2)
[kV]
3 20 / 20
20 / 20
2
) According to IEC62230 the test shall be done with an artificial fault device specified in annex B and the
spark tester shall register neither more nor less than 20 faults for 20 sparks.
Short circuit current

Test voltage [kV] Measured short circuit current Result Max 4)
10 mA
4
) According to IEC62230 the short circuit current must be limited to less than 10 mArms
Used standard
ID number Model Calibration date Due date Traceability
number
Certified by technician: Inspected by auditor:

6.6 CALIBRATION WITH CONTROL AND DISPLAY UNIT BAE 2 SP
Refer to chapter 6.3 to 6.5 on how to do the calibration. The adjustments described
in this chapter should only be done in the rare events where test voltage values are
out of the required tolerance of 5 %.
The control and display unit BAE 2 SP must be connected to the electrode unit and
the internal changeover switch must be in position C = control, refer to chapter 4.4.1.
6.6.1 Calibration of the test voltage

1. Connect the high voltage probe of the Calibrator SP or an other adequate high
voltage probe to the electrode.
For further information, refer to the instruction manual of the Calibrator SP.
2. Select the page 1 / 2 of the menu nominal and set the test voltage to 3 kV
3. Switch the test voltage on
4. Measure the test voltage with the calibrator SP.
5. Select the page 1 / 6 of the menu calibration and enter the measured test voltage
value.
6. Select the page 1 / 2 of the menu nominal and set the test voltage to 13 kV, 23 kV
or 36 kV (25 kV max with the Calibrator SP) according to the maximum voltage of
the spark tester.
8. Select the page 2 / 6 of the menu calibration and enter the measured test voltage
value.
9. To finish the calibration and save the values, enter "1".
After pushing the button "Enter" the result of the calibration is displayed on the
input field for short duration:
– "OK" the calibration is passed
– "ERROR" the calibration failed due to too large deviation.
Verify if the procedure has been done correctly and calibrate again.
10. Verify the calibration: Set the test voltage to the two operating points used
above and measure the test voltage with the calibrator SP.
11. Switch the test voltage off.
6.6.2 Calibration of the analog input nominal

This signal is only available on electrode units with potential free inputs / outputs.
1. Apply a control voltage of 2Vdc to the input nominal pin 17 and GND2 pin 16 of
the connector "Potential free I / O" in the rear of the electrode unit.
Measure this control voltage with a digital voltmeter.
2. Select the page 3 / 6 of the menu calibration and enter the measured control
voltage value.
3. Apply a control voltage of 9 Vdc to the input nominal pin 17 and GND2 pin 16.
4. Select the page 4 / 6 of the menu calibration and enter the measured control
voltage value.
6. Verify the calibration: Set the control voltage to the two operating points used
Therefore, the control and display unit BAE 2 SP must be disconnected to
activate the potential free inputs / outputs as active control position.
6.6.3 Calibration of the analog output actual

1. Select the page 1 / 2 of the menu nominal and set the test voltage to 3 kV.
2. Switch the test voltage on.
3. Use a digital voltmeter to measure the voltage on actual pin 15 and GND2 pin 16
of the connector "Potential free I / O" in the rear of the electrode unit.
4. Select the page 5 / 6 of the menu calibration and enter the measured voltage
value.
5. Select the page 1 / 2 of the menu nominal and set the test voltage to 13 kV 23 kV
or 36 kV (25 kV max with the Calibrator SP) according to the maximum voltage of
the spark tester.
6. Use a digital voltmeter to measure the voltage on actual pin 15 and GND2 pin 16
of the connector "Potential free I / O"
7. Select the page 6 / 6 of the menu calibration and enter the measured voltage
value.
above and measure the voltage on actual pin 15 and GND2 pin 16 of the
connector "Potential free I / O" with a digital voltmeter
6.7 CALIBRATION VIA INTERFACE
Refer to chapter 6.3 to 6.5 on how to do the calibration.
The adjustments described in this chapter should only be done in the rare events
where test voltage values are out of the required tolerance of 5 %.
To perform the adjustments, the interface must be the active control position, i.e.
– No control and display unit BAE 2 SP connected, or if connected, the internal
changeover switch of the BAE 2 SP must be in position D = display.
– The changeover switch in the rear of the electrode unit must be in position
"Interface"
– Activate the interface as active control position by transmitting the command
S006 1 via the interface.
6.7.1 Calibration of the test voltage

1. Connect the high voltage probe of the Calibrator SP or an other adequate high
voltage probe to the electrode.
For further information, refer to the instruction manual of the Calibrator SP.
2. Set the test voltage to 3 kV: Output voltage setpoint command C780 3.0
3. Switch the test voltage on: Test voltage on command F710 1
5. Enter the measured test voltage value:
Calibration of the measured test voltage step 1 command S010 xx.xx
whereas xx.xx is the measured test voltage in kV
6. Set the test voltage to 13 kV 23 kV or 36 kV (25 kV max with the Calibrator SP)
according to the maximum voltage of the spark tester: E.g. for 13 kV, the output
voltage setpoint command is
C780 13.0
8. Enter the measured test voltage value:
Calibration of the measured test voltage step 2 command S012 xx.xx
whereas xx.xx is the measured test voltage in kV
9. To finish the calibration and save the values, enter the following command:
Calibration of the measured test voltage step 3 command S014 1
10. Read the result of the calibration: Enter the command e718
Result:
– e718 0: The calibration is passed
– e718 1: Calibration error, the calibration failed due to too large deviation.
12. Switch the test voltage off: Test voltage off command F710 0.
6.7.2 Calibration of the analog input nominal
1. Apply a control voltage of 2Vdc to the input nominal pin 17 and GND2 pin 16 of
the connector "Potential free I / O" in the rear of the electrode unit.
2. Enter the measured control voltage:
Calibration of the analog input voltage step 1 command S020 xx.xx
whereas xx.xx is the measured control voltage in volts.
3. Apply a control voltage of 9Vdc to the input nominal pin 17 and GND2 pin 16.
4. Enter the measured control voltage:
Calibration of the analog input voltage step 2 command S022 xx.xx
Calibration of the analog input voltage step 3 command S024 1
Result:
7. Verify the calibration: Set the control voltage to the two operating points used
6.7.3 Calibration of the analog output actual

1. Set the test voltage to 3 kV: Output voltage setpoint command C780 4.0
2. Switch the test voltage on: Test voltage on command F710 1
3. Use a digital voltmeter to measure the voltage on actual pin 15 and GND2
pin 16 of the connector "Potential free I / O" in the rear of the electrode unit.
4. Enter the measured voltage value:
Calibration of the analog output voltage step 1 command S030 xx.xx
5. Set the test voltage to 13 kV, 23 kV or 36 kV (25 kV max with the Calibrator SP)
according to the maximum voltage of the spark tester.
6. Use a digital voltmeter to measure the voltage on actual pin 15 and GND2
pin 16 of the connector "Potential free I / O"
7. Enter the measured voltage value:
Calibration of the analog output voltage step 2 command S032 xx.xx
Calibration of the analog output voltage step 3 command S034 1.
Result:
above and measure the voltage on actual pin 15 and GND2 pin 16 of the
connector "Potential free I / O with a digital voltmeter
11. Switch the test voltage off. Test voltage off command F710 0.
7 REPAIRING
Repairs must be carried out only by qualified electricians.
Instruct the repair personnel on the proper repair and the prevention of risks in
the repair of the electrode unit.
WARNING
Dangerous voltages inside. Be sure to disconnect the device from the power
supply before working inside the device: Pull the power plug! It is the respon-
sibility of qualified electricians to recognise the resulting dangers and to take
appropriate safety measures.
Do not open the electrode unit. No user serviceable parts inside.
Chapter 7.3 contains a list of spare parts that can be replaced by the user.
7.1 RETURN FOR REPAIRS

• Enclose an exact description of the failure, including the operational mode in
which the failure or breakdown first occurred.
• Indicate clearly the person that should be contacted in your firm and telephone
number.
• For transportation, please use the original packing material (as far it is still
available). Should this no longer be available, please make sure that the package
protects the equipment adequately.
• Assuming it is necessary and possible, send the entire equipment back (with
cables, peripheral devices etc.).
▶ Our service and sales subsidiaries can of course also contacted by phone,
fax or email. The addresses are listed in chapter 1.2.
7.2 CONDITIONS APPLYING TO SPARE PARTS

Only use original spare parts from Zumbach. To use products from another source
could harm safety, reliability and performance.
Chapter 7.3 contains a list of standard spare parts. Additional spare parts are available
on request.
To replace the mains cord, use a cord that meets the requirements of IEC 60227
or IEC 60245, i.e. rated voltage at least 300 Vac, three wires with cross section at
least 1 mm2 and conductors coloured brown, blue and green-and-yellow, operating
temperature at least 70 °C.
7.3 TROUBLE-SHOOTING
In case of malfunction check the following points before contacting servicing:
Malfunction Cause
1 Electrode unit not powered • Mains cord not connected to mains
• Mains interrupted
• Fuses in the mains inlet blown
• Check if the green LED in the rear of the electrode unit
is blinking. If the LED is continuous on or off, return the
spark tester for repair.
2 • The green signalization • Check if the cover of the electrode unit is properly
lamp "Ready" on BAE 2 closed
SP is off • Test voltage not activated via emergency stop input
• Error message 300 via
interface "Spark tester not
ready"
3 Potential free output • Spark tester not powered
"spark tester enabled" not • Internal fault, e. g.:
activated The temperature inside the electrode unit is too high.
Do not operate the spark tester at ambient temperatures
higher than 50 °C or at direct exposure to sunlight or
other heat sources.
4 No high voltage on the • Electrode unit in rewind mode and test voltage
electrode switched off after detection of a fault
• Check if the cover of the electrode unit is properly
closed
• Test voltage not switched on
• Test voltage not activated via emergency stop input
• Electrode short-circuited
• Remove the product from the electrode. Inspect the
electrode and clean if dirty. Switch the test voltage off
and on when the electrode is empty.
• High voltage source defective. Return the spark tester
for repair.
5 Not possible to switch the Check if the internal changeover switch in the BAE 2 SP
test voltage on via push is in position C = Control.
button "Test voltage" on
BAE 2 SP
6 Not possible to switch the If a BAE 2 SP is connected, check if the internal
test voltage on via remote changeover switch in the BAE 2 SP is in position
interface D = Display.
7 No detection of faults or • Verify if both cable heads are earthed properly
faults detected where there • Verify if the test voltage applied corresponds to the
is no defect in the cable values given in chapter 5.3
• Use another value of the sensibility of the fault detector,
refer to chapter 3.9
8 The test voltage remains • Too high leakage currents: Product to be tested is
clearly below the setpoint conductive or wet.
value • Remove the product from the electrode. inspect the
electrode and clean if dirty. Switch the test voltage off
and on when the electrode is empty.
• High voltage source defective. Return the spark tester
for repair.
7.4 LIST OF SPARE PARTS OF THE ELECTRODE UNIT Electrode unit
AST L 15A / 25A / 40A AST L 15A/25A/40A
Photocopy this page, enter the desired quantities, and mail it or fax it to one of the
Zumbach addresses in chapter 1.2 of this instruction manual.
When ordering spare parts, please make sure to always note the order number and
serial number from the technical label.
Order Serial
Nr.: Nr.:
Company ..............................................................
Name ..............................................................
Title ..............................................................
Adress ..............................................................
Phone ..............................................................
Fax ..............................................................
E-mail ..............................................................
Website www......................................................
7.4.1 Common spare parts for all AST L 15A / 25A / 40A electrode units
Number/ Order
Illust. Order number Description
unit qty
Mains plug
A10 200 0032 1
250 V / 10 Amp 70°, black for cable
A11 520 6114 Yellow lamp cap Rafi 1
A11 520 0113 Red lamp cap Rafi 1
Fuse slow blow

A12 101 3122 2
250V, 3.15A, 5 x 20 mm
AST.262.103.0 Acryl glass window 1
A08 413 2040 4 pole pluggable terminal block 2
A08 415 0040 housing for 4 pole terminal block 2
A08 413 0210 21 pole pluggable terminal block 1
A08415 0211 housing for 21 pole terminal block 1
• Technical specifications are subject to change without notice
7.4.2 Spare electrodes and component parts of electrodes
For servicing electrodes, it is possible to replace component parts only. Bead chains
are delivered as single piece and need to be cut in pieces of the required length.
AST.15A.50.200UL-x and AST.25A.50.200UL-x

Order number AST.261.05201y and AST.262.05201y
Order number Description Number/ Order

Unit quantity
B.AST.257.1410 Charge removal device assembled 2
AST.257.152.1 Top insulator 2
B.AST.262.3511 Chain unit assembled 50.200 1
AST.262.351.0 Electrode plate 50.200 1
A31 300 1048 Bead chain DM 3 / 16" 39.5 m
AST.257.156.0 Rubber pressure plate 90.200 1
AST.262.302.0 Cable trough 50.200 1
AST.262.110.0 Bottom insulator 2
AST.262.113.0 HV bushing insulator 1


Unit quantity
A31 300 1048 Bead chain DM 3 / 16" 76.6 m
AST.262.357.0 Rubber pressure plate 1
50.400 / 90.300

Unit quantity
A31 300 1048 Bead chain DM 3 / 16" 191.5 m
AST.262.307.0 Cable trough 50.1000 1


Unit quantity
A31 300 1048 Bead chain DM 3 / 16" 34.6 m
B.AST.262.3021 Pulley assembled 2

Unit quantity
A31 300 1048 Bead chain DM 3 / 16" 51 m
AST.262.357.0 Rubber pressure plate 1
50.400 / 90.300
B.AST.262.3021 Pulley assembled 2
AST.15A.250.200UL-x, AST.25.250.200UL and AST.40A.250.200UL-x

Order number AST.261.25201y, AST.262.25201y and AST.263.25201y

Unit quantity
A31 300 1048 Bead chain DM 3 / 16" 39.5 m
AST.262.302.0 Cable trough 250.200 1
8 DECOMMISSIONING / DISPOSAL
Decommissioning must be carried out only by qualified electricians.
WARNING
Dangerous voltages inside. Be sure to disconnect the device from the power
supply before working inside the device: Pull the power plug! It is the respon-
sibility of qualified electricians to recognise the resulting dangers and to take
appropriate safety measures.
8.1 DECOMMISSIONING
The sparker can be removed from the line and disposed of without taking any additional
measures.
8.2 GENERAL DISPOSAL

The sparker is an electrical and electronic equipment without dangerous substances.
The disposal must be done in accordance with the directives on waste electrical and
electronic equipment (WEEE), i.e.:
– Separate collection of electrical and electronic equipment
– Return of the material according to national directives for recycling according to
national directives
▶ For disposal or recycling information please contact your local authorities.
9 SERVICE PORT
The Ethernet based service port can be used for the web visualisation to configure
and calibrate the spark tester.
If the spark tester is equipped with a control and display unit BAE 2 SP, the configurations
and calibration can be done with the BAE 2 SP.
To make settings via Ethernet based service port, the following equipment is needed:
– Laptop, PC or similar with Ethernet interface and terminal program that supports
TCP / IP
– Ethernet cable
9.1 SETTING UP THE LAPTOP

1. Connect the spark tester to mains via the mains cord.
2. After power up, connect an Ethernet cable to the laptop and the jack "Service" on
the rear panel of the spark tester.
3. Set the LAN connection to a fixed IP address given, e.g. 192.168.001.005.

The factory setting of the spark tester is IP address 192.168.001.009.
I.e. the IP address of the laptop must be within the same subnet mask but not
identical as the IP address of the spark tester.
Example on how to do the setting on a windows 7 laptop:

– Select Start / Control panel / Network and sharing center
– Local area connection / Properties
– Double click on item Internet protocol version 4 (TCP / IPv4)
– Make the following settings:
9.2 SETTING UP THE TERMINAL PROGRAM
By way of example, Tera Term is used as terminal program. Tera Term is the terminal
emulator for Microsoft Windows and supports TCP / IP connections.
This program is free software and can be downloaded from the following URL:
http://ttssh2.sourceforge.jp/
4. Start Tera Term and make the following settings:

– Enter the IP address of the spark tester in the input box "Host".
The factory setting is 192.168.001.009
– Set the TCP port to 2020
– Activate the check box "History"
– Select "other" of the selection "Service"
– Proceed with "OK"

– Select the menu Setup / Terminal...
– Set the input box "Transmit" to "CR + LF"
– Activate the check box "Local echo"
– Proceed with "OK" and Tera Term is ready for communication
9.3 USING THE SERVICE PORT
5. Tera Term is now ready for entering commands and reading transmitted values.
Refer to the host protocol codes given in chapter 13.
An upper case (capital) letter is used for a download sequence, a lower case
letter is used for an upload sequence.
To perform active commands, the service port must be the active control position, i.e.
– No control and display unit BAE 2 SP connected, or if connected, the internal
changeover switch of the BAE 2 SP must be in position D = display.
– The changeover switch in the rear of the electrode unit must be in position
"Interface"
– Activate the service port as active control position by transmitting the command
S006 1 via service port.
This is a download command from terminal to the spark tester (write) and therefore
a capital letter must be used.
Use the enter key to terminate the commands.
Refer to chapter 6.7 on how to do the calibration via service port.

An example on how to switch the test voltage on and off is given below:
– Set the test voltage to 5 kV: C780 5.0
– Set the voltage tolerance to 500V: C786 0.5
– Switch the test voltage on: F710 1
– Read the measured output voltage: d042
This is for initiating an upload sequence from spark tester to the terminal program
(read) and therefore, a lower case letter is used.
After termination of this command, d042 4.95 is uploaded from the spark tester
to the terminal program to display the measured test voltage of 4.95 kV.
– Switch the test voltage off: F710 0
6. After using the service port, the LAN connection of the laptop must again be set
to obtain the IP address automatically. Make the reverse settings as described in
chapter 9.1.
10 RS INTERFACE
10.1 SERIAL LINK

The serial cable connection must be installed in conformance with the following
schematic or by means of a standard Zumbach cable (serial number RS.4220.4xxxx).
RS-485 Connection
Sparker RS interface Host Computer
T+/R+ 1 T+/R+
T-/R- 6 T-/R-
R+ 4 R+
R- 9 R-
GND 5 GND
RS-422 Connection
T+ 1 T+
T- 6 T-
R+ 4 R+
R- 9 R-
GND 5 GND
RS-232 Connection
TxD 3 TxD
RxD 2 RxD
GND 5 GND
Electrical interface
The RS interface lines are electrically isolated from any circuit. The signal ground and
cable shield must be connected at the both extremities.
Termination impedance: The factory setting is not connected.
When the spark tester is located at the end of the transmission line (ANSI X3.28
network), the termination resistors should be connected (switch ON / OFF beside the
connector).
Watchdog
For safety reason, a watchdog can be activated to supervise the presence of the
remote link by means of a time out in the range of 1 to 99 seconds, see up / download
code s008. The test voltage is switched off if the spark tester is waiting for a message
during more than the time given and when the watchdog is active.
Factory setting: Watchdog deactivated.
ASCII protocol
This communication protocol is a simple ASCII protocol. It is the standard Zumbach
ASCII protocol implemented in almost all Zumbach electronics units. The protocol is
well suited for point to point connections. Some of the advantages of this protocol are:
A simple terminal or terminal program may be used (no block check character must
be calculated). It can be used by service personnel to trouble shoot or inspect the
system without special software.
It's very easy to implement on a Host computer. Debugging of the communication link
is easy. Automatic output of measuring data without request from Master is possible.
Multidrop protocol
The implemented protocol corresponds to the ANSI standard ANSI X 3.28 rev. 1976,
subcategories 2.5 and A4. It is a simple and safe Fieldbus Master-Slave protocol.
Some of the advantages of this protocol are:

The safety of the messages is guaranteed due to a Block Check Character. This Block
Check Character is calculated easily and fast with just a few XOR operations. Up to
99 Slave devices may be connected via a single RS 422 or EIA 485 bus. Any future
expansion of the installation with other Zumbach devices like ODEX® 10, USYS, CI-
CS / 485, CI-XJ / RS is not a problem.
The protocol is easy to implement on the Host, compared with more complex Fieldbus
standards. The protocol runs on cheap Host hardware, there is no heavy load for the
Host processor nor the need for large buffers in the data memory.
The messages are the same as those of the Zumbach ASCII protocol, just a frame
with the network address and the Block Check Character is added.
The following pages contain a description of these two protocols, beginning with some
general definitions, followed by the easier to understand Zumbach ASCII protocol.
These specifications concern the layers 2 and 7 of the ISO-OSI model for data
communications.
10.2 COMMUNICATION SYNTAX
For the purposes of the following explanations the names of single non printable ASCII
characters are indicated by placing the name of the character between "["and "]". The
following non printable characters are used in the descriptions:
Character Function Decimal Hex

[ACK] Acknowledge 6 06
[LF] Line Feed 10 0A
[CR] Carriage return 13 0D
[X-ON] Software Handshake 17 11
[X-OFF] Software Handshake 19 13
[NAK] Negative Acknowledge 21 15
[SP] Space 32 20
[EOT] End of Transmission 4 04
[ENQ] End of Inquire 5 05
[STX] Start of Text 2 02
[ETX] End of Text 3 03
Representations of a group of ASCII characters, such as an address or a command,

are placed between "<" and ">".
10.3 GENERAL DEFINITIONS

Download -> Data transmitted from the Master to the Slave.
Upload -> Data transmitted from the Slave to the Master.
Master -> Host Computer.
Slave -> Zumbach device.
Command Format
A command tells the Slave to either supply data to, or accept data from the Host
computer.
A command is identified in the following explanations by <CMD>.
Group
Transmitted parameters and data are divided into groups. Each group is
designated with a letter.
Letter
An upper case (capital) letter is used for a download sequence.
lower case letter is used for an upload sequence.
Number
Each member of a group is designated with a three digit number. The numbers range
from 000 to 999. Leading zeros are mandatory.
Data Format
The data may be a value, a string, a selection or nothing at all. Data is identified in
the following explanations as <DATA>.
Value
A value consists only of numbers, sign prefixes, and a decimal point.
String
A string is a series of characters. Any printable ASCII character is allowed.
The maximum length of a downloaded string depends on the definition.
Selection
A selection from a list can be made by sending a number that corresponds to the
placement of the desired selection in the list. The first selection is 0.
Multiple (Selection)
A multiple selection is used when more than one selection may be selected at one time.
Example
e720 Hardware Self test Alarm Multiple R
0 = No alarm
300 = Spark tester not ready
303 = Spark tester voltage out of tolerance
Function
Does not have a value (although any value must be downloaded to conform with the
protocol). Triggers an action.
10.3.1 Data and parameter access

Some data or parameters may only be read from the Slave, some may only be written
to the Slave, and some may be read and written.
The Access to the data and parameters is noted in the parameter list as:
R -> Read only

W -> Write only
RW -> Read and Write
10.4 ZUMBACH ASCII PROTOCOL
Refer to chapter 13 for the list of parameters and results.
10.4.1 Upload
Masters request
<CMD> Four character sequence, C1, C2, C3, C4, representing the parameter
code.
For example, the Slave software version number is requested with the
<CMD> of 'a'‚9' ‚9' ‚0' (lower case letter!).
[CR] ASCII carriage return terminates the request.
[LF] ASCII Line Feed. (Optional) Ignored by the Slave.
Example - Request for measured value: g155[CR][LF]
Response from Slave
<CMD> Echo of the four character sequence representing the parameter code.
[SP] ASCII space character.
<DATA> A variable number of characters (D1, D2, D3, ... Dn), representing the
value requested.
[CR] ASCII carriage return. Indicates the end of the data.
[LF] ASCII Line Feed. (Note: The output of this character may be disabled in
some devices, to reduce the telegram length. Refer to manual)
Example-Slave response to request for measured value:

g155[SP]2.65103[CR][LF]
→→
→
→→→→
Master Slave
No Reply
[NAK]
Wrong <CMD> or
No Message
→ → → <CMD> [SP] <DATA> [CR] [LF]
<CMD> [CR] [LF] (optional)
10.5 ANSI X3.28-2.5-A4 STANDARD PROTOCOL
10.5.1 Upload
Master Slave Master
[EOT] <ADD> <CMD> [ENQ] No Reply [EOT]
[NAK]
[EOT]
(Wrong <CMD> or no Message)
[STX] <CMD> [SP] <DATA> [ETX] <BCC> [ACK]
Masters request
[EOT] ASCII control character. Resets the communication link passing control
back to the control station (Master). Alerts all devices on the link to
examine the next four characters to see if they correspond with their
group / unit address identifier.
<ADDR> Four character sequence representing the address of the instrument.
The address is broken down into a most significant digit (MSD) and a
least significant digit (LSD). Each digit is repeated for security.
The format of the address, is MSD MSD LSD LSD. For example,
the "<ADDR>" for device number 10 is '1' '1' '0' '0'.
code. For example, the Slave software version number is requested with
the <CMD> of 'a' '9' '9' '0' (lower case letter!).
[ENQ] ASCII control character. Indicates the end of an inquire message.
Response from Slave
[EOT] ASCII control character. If the <CMD> is not recognized or if the Slave
has no value to send, the Slave will send an [EOT] to return control to the
control station (your PCB).
or
[STX] ASCII control character indicating the Start of Text.
<CMD> Echo of the four character sequence representing the parameter code.
value requested.
[ETX] ASCII control character. Indicates the end of the message.
[BCC] Block Check Character. Generated by taking the Exclusive OR of the
values of the ASCII characters following and excluding [STX] up to and
including [ETX].
i.e.: [BCC] = C1 XOR C2 XOR C3 XOR C4 XOR SP XOR D1 XOR D2
XOR D3 XOR D4...XOR Dn XOR ETX.
10.5.2 Download
Response from Master

[EOT] ASCII control character. Returns control to the Master station.
This may be in response to a valid response from the Slave or to a
"Time Out" if no reply was received.
or
[NAK] ASCII control character. Used to indicate an unsuccessful receipt of a
message. This will cause the Slave to repeat the transmission.
or
[ACK] ASCII control character. Used to indicate a successful receipt of a
message.
This will cause the Slave to repeat the transmission (with updated value).
Master Slave Master
[ETO] <ADD> [STX] <CDM> [SP] <DATA> [EXT] <BCC> No reply [EOT]
[ACK]
[NAK]
Masters Message
back to the control station (your PCB). Alerts all devices on the link to
examine the next four characters to see if they correspond with their
group / unit address identifier.
<ADDR> Four character sequence representing the address of the instrument.
The address is broken down into a most significant digit (MSD) and
a least significant digit (LSD). Each digit is repeated for security.
The format of the address, is MSD MSD LSD LSD.
For example, the "<ADDR>" for device number 10 is '1' '1' '0' '0'.
[STX] ASCII control character indicating the Start of Text.
code. For example, the diameter averaging time is downloaded with the
<CMD> of 'B' '0' '3' '0' (upper case letter!).
value downloaded.
ETX] ASCII control character. Indicates the end of the message.
[BCC] Block Check Character. Generated by taking the Exclusive OR of the
values of the ASCII characters following and excluding [STX] up to and
including [ETX].
Response from Slave
[ACK] ASCII control character. Used to indicate a successful receipt of a
message.
or
[NAK] ASCII control character. Used to indicate an unsuccessful receipt of a
message. This may cause the Master to repeat the transmission.
Response from Master

back to the control station (itself).
or
The Master repeats the transmission (e.g. after a [NAK]).
or
The Master sends another message to the same device (same address).
11 ETHERNET
For further information about:

– the settings of this interface, refer to chapter 4.6.8
– the host protocol, refer to chapter 10
– the spark tester specific parameters, refer to the table in chapter 13, in particular
the columns ODAC or Host
12 PROFINET
For further information, refer also to the manual SPAT.010.0002.EN.
13 LIST OF PARAMETERS AND RESULTS
The following tables list all parameters for the Host protocol, ODAC protocol, Profibus
and Profinet protocol.
13.1 PARAMETERS GROUP A – SYSTEM
Profibus
ODAC Host Description Range of values
Profinet
Output interval for service and host
0 -> 0.04 s
ports (or update rate for Profibus).
- CA a138 0.04 - 99.99 s
Factory setting 0.1 s.
xx.xx s
Fieldbus: Factory setting 0.04 s
IP address of the service Ethernet
- SL a930 interface xxx.xxx.xxx.xxx
This command will restart the system
Subnet mask of the service Ethernet
- SM a931 interface xxx.xxx.xxx.xxx
Gateway address of the service
- SO a932 Ethernet interface xxx.xxx.xxx.xxx
IP address of the Ethernet host
- IL a940 interface xxx.xxx.xxx.xxx
Subnet mask of the Ethernet host
- IM a941 interface xxx.xxx.xxx.xxx
Gateway address of the Ethernet host
- IO a942 interface xxx.xxx.xxx.xxx
2 -> Standard
masterslave
(all parameters
on request only)
- - a945 Host port output mode:
7 -> Automatic output
mode for USYS
(see grouped
message d182)
3 -> 1200 baud
4 -> 2400 baud
5 -> 4800 baud
6 -> 9600 baud
- AM a970 Host port: Baud rate
7 -> 19200 baud
8 -> 38400 baud
9 -> 57600 baud
10 -> 115200 baud
1 -> 7 bits
- AP a971 Host port: Bits per character
2 -> 8 bits
0 -> 1 Stop bit
- AO a972 Host port: Number of stop bits
1 -> 2 Stop bit
Profibus
Profinet
0 -> Even
- AN a973 Host port: Parity 1 -> Odd
2 -> No parity check
Read Profibus address switches.
Returns the actual setting of the
- SC a978 0 - 126
Profibus address switches
(only for version with Profibus)
Write Profibus address.
- SD a979 Select Profibus address 1 - 125
(only for version with Profibus)
0 -> RS-485, half
duplex, with RTS
1 -> RS-422,
full duplex,
- SB a983 Host port: Transmission mode
RTS on zero
2 -> RS-232,
full duplex,
RTS on zero
0 -> ODAC protocol
- SP a986 Host port: Protocol selection
1 -> Host protocol
0 -> no length counter
Operating mode of length counter
485 SQ a987 1 -> length counter
Factory setting: No length counter
in use
CP software name and corresponding
- - a989
GSD file version
- ZA a990 CP software name
- ZB a991 CP software date
CP printed circuit board assembly
- ZC a992
version
Initialisation
- AZ a995 0 = nil 0/1
1 = for version with host protocol
- ZI a996 Actual CPU charge in % 0 - 100
- ZP a998 Software version power part xxxx
- ZQ a999 Hardware version power part xxxx
13.2 PARAMETERS GROUP B – LINE PARAMETERS
Profibus
Profinet
Alarm prolongation:
0.003 - 9.9
Range 0.003 - 9.9s, Factory setting:
46 BT b100 Fieldbus:
0.7s
3 - 9900
Fieldbus: Alarm prolongation in ms
Calibration for the length counter: x.xxxxx m /
- SR b310 Distance between two pulses. x.xxxxx inch
Factory setting: 1.00000
Measuring unit for the length detection 0 -> metric m
493 SY b400
Factory setting: metric 1 -> imperial feet
13.3 PARAMETERS GROUP C – PRODUCT PARAMETERS
The parameters of group C cannot be modified if a control and display unit BAE 2
SP is connected and in mode C = Control or if the changeover switch is in position
"Potential free I/O". In this case, these parameters are read only.
Profibus
Profinet
Output voltage setpoint in kV:
xx.xx kV
DST 10: 1 to 10 kV, factory setting 5 kV
DST 28A: 1 to 28 kV, factory setting 5 kV
AST H 15A: 0.5 to 15 kV, factory setting 4 kV
42 BP c780
AST L 15A: 0.5 to 15 kV, factory setting 3 kV
Fieldbus:
xxxxx V
Fieldbus: Output voltage setpoint in volts
Test frequency (AST L xxA only):
78 CZ c782 xxx
Range 50 - 120 Hz, factory setting 50 Hz
Voltage tolerance in kV: xx.xx kV
43 BQ c786 Range 0 - 40 kV, factory setting 2 kV Fieldbus:
Fieldbus: Voltage tolerance in volts xxxxx V
Fault detector sensitivity in percent voltage
44 BR c788 drop of the output voltage setpoint. 10 - 40
Factory setting 10 % (highest sensitivity)
Minimum duration of bare patch event in 0.1 - 9.9
seconds.
45 BS c790 Range 0.1 s to 9.9 s, factory setting 1 s
Fieldbus: Minimum duration of bare patch Fieldbus:
event in milliseconds 100 - 9900
13.4 PARAMETERS GROUP D – MEASUREMENTS
Profibus
Profinet
xxxxx.x m / xxxxxx ft
actual length in m or ft
96 DR d000
Fieldbus: Actual length in cm or ft
Fieldbus: xxxxxxx cm
Measured output voltage in kV xx.xx kV
79 DA d042 Fieldbus: Mesured output
voltage in volts Fieldbus: xxxxx V
322 MJ d070 Spark tester total fault counter 0 - 9999 faults
323 MK d072 Spark tester bare patch counter 0 - 9999 bare patch events
Format: d182[SP][v1][SP][v2]
[SP][v3][SP][v4][CR][LF]
Automatic output for each fault v1: e720
- - d182
(see mode selection a945) v2: d042
v3: d070
v4: d072
Length counter value of the last xxxxx.x m or xxxxx ft
fault in m or ft.
102 DX d184 Value 0 for no fault
Fieldbus: Length counter value of
the last fault in cm Fieldbus: xxxxxxx cm or ft
Profibus
Profinet
Length counter value of the 20 times xxxxx.x m or
last 20 faults in m or ft. xxxxx ft
- DY d185 Fixed data format with 20
numbers, empty if no fault
Fieldbus: 0 Fieldbus: 0
13.5 PARAMETERS GROUP E – ALARM MESSAGES AND DEVICE STATUS
Profibus
Profinet
Calibration error 0 = no error
- EA e718
1 = calibration error
0 -> TV off / no alarm
300 -> TV off / spark tester not ready
301 -> TV off / overtemperature
Error and status 302 -> TV off / spark tester alarm
messages. 303 -> TV off / test voltage out of tolerance
The status 304 -> TV off / overload (AST L xxA only)
on / off of the 305 -> TV off / Mains out of operating range
test voltage is (AST L xxA only)
80 EB e720
combined in
this message by 1000 -> TV on / no alarm
adding 1000 if 1301 -> TV on / overtemperature
the test voltage 1302 -> TV on / spark tester alarm
is on 1303 -> TV on / test voltage out of tolerance
1304 -> TV on / overload (AST L xxA only)
1305 -> TV on / Mains out of operating range
(AST L xxA only)
13.6 PARAMETERS GROUP F – CONTROL FUNCTIONS

The parameters of group F cannot be modified if a control and display unit BAE 2
SP is connected and in mode C = Control or if the changeover switch is in position
"Potential free I/O". In this case, these parameters are read only.
Profibus
Profinet
Reset fault counter
0 -> counter running
72 1) CT f020 See also at Profibus device
1 -> counter reset to zero
specific parameters
Test voltage on / off
0 -> turn test voltage off
77 1) CY f710 See also at Profibus device
1 -> turn test voltage on
specific parameters
1)
These two parameters are included into the device command and control word
(see parameter1000).
13.7 PARAMETERS GROUP S – MEASUREMENT HEAD AND CALIBRATION
The parameters s000, s002 and s004 cannot be modified by the user. These
parameters are read only.
Profibus
Profinet
0 -> AST 15 (RI)
1 -> AST 25 (RI)
2 -> AST 40 (RI)
3 -> AST 15 HF
4 -> DST 10
5 -> DST 25
6 -> IST SP20
Electrode type: 7 -> DST SP20
665 ZO s000
This parameter is read only. 8 -> SP10 simul (SP20)
9 -> AST 15 HF (SP20)
10 -> DST 28A
11 -> AST H 15A
12 -> AST L 15A
13 -> AST L 25A
14 -> AST L 40A
15 -> DST 10
0 -> none
Indicates the active control 1 -> BAE 2 SP
444 RB s002 position. This parameter is 2 -> Host port
read only. 3 -> Service port
4 -> Potential free I/O
0 -> BAE not connected
Status of the control and display 1 -> BAE connected and
- RC s004 unit BAE 2 SP active control position
This parameter is read only. 2 -> BAE connected and
in display mode
Select the active control position:
This parameter can only be used
0 -> another interface is the
if the changeover switch is in posi-
active control position
443 RA s006 tion "Interface" and if no control
1 -> this interface is the
and display unit BAE 2 SP is con-
active control position
nected or the BAE 2 SP is in mode
display only.
Host communication watchdog 0 -> watchdog is off
- RD s008 Factory setting: Watchdog off 1 - 99 -> watchdog is on
with time in xx seconds
Calibration of the measured test
voltage, step 1: xx.xx kV
Enter the external measured
- RF s010
voltage 1 in kV
Fieldbus: External measured volt- Fieldbus: xxxxx V
age 1 in volts
Profibus Range of
ODAC Host Description
Profinet values
xx.xx kV
Calibration of the measured test voltage, step 2:
Enter the external measured
- RG s012
voltage 2 in kV
Fieldbus:
Fieldbus: External measured voltage 2 in volts
xxxxx V
Calibration of the measured test voltage, step 3: 1 ->
- RH s014
Accomplish calibration and store values accomplish
Calibration of the analog input voltage, step 1: xx.xx V
Enter the external measured voltage 1 in volts
- RI s020
Fieldbus: Enter the external measured voltage 1 Fieldbus:
in millivolts xxxxx mV
Calibration of the analog input voltage, step 2: xx.xx V
- RJ s022
Calibration of the analog input voltage, step 3: 1 ->
- RK s024
Calibration of the analog output voltage
xx.xx V
step 1:
- RL s030 Enter the external measured voltage 1 in volts
Fieldbus:
Fieldbus: Enter the external measured voltage 1
xxxxx mV
in millivolts
Calibration of the analog output voltage, step 2: xx.xx V
- RM s032
Calibration of the analog output voltage, step 3: 1 ->
- RN s034
13.8 DEFINED ONLY FOR ODAC PROTOCOL
ODAC Description Range of values

AA System code 150858
ZX Disabling the system code -
Service port (EN) output 0 -> no automatic output. Upload of selected
CI mode: CK values with commands DS (factory setting)
1 -> at the end of the output interval CA
Host port (RS2) output 0 -> no automatic output. Upload of selected
CJ mode: CL values with commands DT (factory setting)
1 -> at the end of the output interval CA
Service port (EN) output
CK Up to 5 values from groups D, E and M
selection:
Host port (RS2) output
CL Up to 5 values from groups D, E and M
selection:
CM Output of the configuration
DS Query of measuring results Values according to selection CK
DT Query of measuring results Values according to selection CL
13.9 PROFIBUS AND PROFINET SPECIFIC PARAMETERS
Module Format Description

1W+ 2DW Change parameters and get status
Handshake needed (REQ, ACK)
Parameter
0 W0 Parameter number, bit 15 REQ (writeable)
channel
DW1 Parameter value (writeable)
DW2 Status, bit 31 ACK (readable)
32 bit Grouped control parameters
1000
Command-/ Bit 6 Fault counter running (0) or stop / reset (1)
(72)
Control word Bit 7 Test voltage off (0) on (1)
(77)
Other Reserved
14 WEB VISUALISATION
WEB VISUALISATION WITH A VISU-TOUCH OR

WITH A WEB BROWSER
The VISU-Touch or a web browser give the possibility of:
– Set the desired test voltage.
– View the current test voltage, the number of faults, adjustments etc.
– Switch on and off the test voltage.
– Reset the fault counter to zero.
– Calibrate and configure the spark tester.
The VISU-Touch, a laptop, PC or similar with an internet browser is connected to the

Ethernet service port. The control and visualisation via the Ethernet service port is not
accepted by safety standards to be the sole means of inhibition (see chapter 4.6.3).
14.1 LOCAL DISPLAY WITH A VISU-TOUCH

The VISU-Touch is a rugged and compact 7" touch screen with a mounting bracket.
This universal touch screen is powered from the spark tester with PoE (Power over
Ethernet). After power on, the web visualisation appears on the display after around
30 seconds.
Article-No.: VISU.001.01XXX
Ethernet network cable, Sales No.: A15 608 8XXX

Ethernet network cable cat. 6 S / FTP with RJ45 connectors.
The positions XXX in the article number correspond to the cable length in metres
multiplied by a factor of 10. For example, a 2.5 meter long cable will have an article
number A15 608 8025 or XXX = 2.5 x 10 = 25.
14.2 LOCAL DISPLAY OF A PAGE WITH A WEB BROWSER

To display the specific values of the spark tester on a web page, connect the Ethernet
service port of the spark tester to the Ethernet port of a laptop, PC or similar. Open
an Internet browser such as Internet Explorer, Firefox or Chrome and enter in the
address bar http://192.168.1.9:8080/ or the last address assigned to the service port
if it has been modified.
14.3 USING AND DISPLAYING MENUS
The layout of the pages is the same when using a VISU-Touch or when opening a
page in a web browser.
Meanings of icons and function keys
Access key to the main page
Access key to the settings page
Green light, spark tester is ready
Grey light, spark tester is not ready
Yellow light, the test voltage is switched on.

Key to switch off the test voltage
Grey light, the test voltage is switched off.
Key for switching on the test voltage
Key for resetting the fault counter
Confirmation key
Discard the value and close the dialogue window
Full-screen mode for this part of the display
Quit full-screen mode
Delete the entire value
Delete backwards
Enter/return
Display the values as a line diagram
Display the value as a number
14.3.1 Main page
The main page displays the test voltage value, the total number of faults, the number
of pinholes and the bare platches. The field with the test voltage value is coloured red
when the voltage is zero and yellow when the high voltage is switched on.
Navigation in windows
By pressing the high voltage button, By pressing the fault button,

a submenu appears in a submenu appears
which it is possible to define the value of in which it is possible to adjust the
the test voltage and the tolerance. sensitivity of the fault detector and
define the minimum duration of a
bare part.
By pressing the pinholes button, By pressing the bare patches button,

a submenu appears a sub-menu appears
in which it is possible to adjust the in which it is possible to adjust the
sensitivity of the detector of defects. sensitivity of the fault detector and
define the minimum duration of a
bare part.
14.3.2 Settings page
To access the settings page, press the setting button on the main page:
The page consists of the following menus:

– Display that allows you to define the number and characteristics displayed on the
main page.
– Configuration that allows you to define the active control position.
Access to the menu is protected by password 954728.
– Information about the spark tester will be displayed, such as electrode type or
software version.
– Calibration, to calibrate the spark tester. Access to the menu is protected by
password 954728.
– Fault positions displays a list with the position of each fault. For the list to be
created, the spark tester must be equipped with an encoder.
– Length sensor that allows you to activate or deactivate an encoder to measure
the fault position. Access to the menu is protected by password 954728.
– Access right that allows you to activate the protection of certain menus with
a password and to change the password. Access to the menu is protected by
password 954728.
– Terminal enabling communication with the spark tester via the Ethernet service
port. Only the ODAC protocol is supported. Access to the menu is protected by
password 954728.
15 INDEX
A
Activation of control positions..........................................................................................................................30
Addresses – The ZUMBACH Group..................................................................................................................8
ANSI X3.28-2.5-A4 standard protocol.............................................................................................................91
C
Calibration form for spark tester......................................................................................................................69
Calibration of spark testers..............................................................................................................................67
Calibration of the analog input nominal.....................................................................................................71 ,75
Calibration of the analog output actual......................................................................................................72, 75
Calibration of the test voltage....................................................................................................................70, 74
Calibration via Interface...................................................................................................................................74
Calibration with control and display unit BAE 2 SP......................................................................................... 70
Cleaning of the electrode................................................................................................................................56
Common spare parts for all AST L 15A / 25A / 40A electrode units................................................................... 78
Communication syntax....................................................................................................................................88
Components of the AST L 15A / 25A / 40A spark tester.................................................................................... 19
Conditions applying to spare parts..................................................................................................................76
Configuration menu of the control and display unit BAE 2 SP........................................................................ 40
Connections to the electrode unit....................................................................................................................34
Connections to the spark tester.......................................................................................................................34
Connection to mains........................................................................................................................................35
Control and display unit BAE 2 SP..................................................................................................................20
Control spark testers with control and display unit BAE 2 SP......................................................................... 61
Correct earthing of the spark tester.................................................................................................................36
D
Data and parameter access............................................................................................................................89
Dear customer...................................................................................................................................................7
Decommissioning............................................................................................................................................82
Decommissioning / Disposal............................................................................................................................82
Defined only for ODAC protocol....................................................................................................................101
Dimensional drawing AST.xxA.50 and AST.xxA.90......................................................................................... 24
Dimensional drawing AST.xxA.250..................................................................................................................25
Dimensional drawing BAE 2 SP......................................................................................................................21
Download........................................................................................................................................................92
E
Earthing of the product to be tested................................................................................................................56
Electrode length and test frequency................................................................................................................27
Electrode unit..................................................................................................................................................22
EMC.................................................................................................................................................................17
Emergency stop connector..............................................................................................................................42
Encoder...........................................................................................................................................................44
Ethernet...........................................................................................................................................................94
EU Declaration of conformity (Copy)...............................................................................................................12
Extruding and rewind mode.............................................................................................................................30
F
Fault detection.................................................................................................................................................28
Fire hazard due to deposits and water in the electrode unit ........................................................................... 16
Front panel of the control and display unit BAE 2 SP...................................................................................... 58
G
General definitions..........................................................................................................................................88
General disposal.............................................................................................................................................82
H
High voltage....................................................................................................................................................15
I
If you run into problems in your application..................................................................................................... 57
index..............................................................................................................................................................109
Inspection of goods upon arrival.......................................................................................................................7
Installation.......................................................................................................................................................32
Instruction for lifting and carrying....................................................................................................................32
Introduction........................................................................................................................................................7
L
List of parameters and results.........................................................................................................................96
List of spare parts of the electrode unitAST L 15A / 25A / 40A.......................................................................... 78
Local display of a page with a web browser.................................................................................................. 103
Local display with a VISU-Touch...................................................................................................................103
Location of the spark tester.............................................................................................................................32
M
Main page......................................................................................................................................................105
maintenance....................................................................................................................................................66
Mounting instructions......................................................................................................................................33
Mounting the control and display unit BAE 2 SP............................................................................................. 35
O
Operating instructions.....................................................................................................................................56
Operating mode of the control and display unit BAE 2 SP.............................................................................. 39
Operating spark testers with potential free I / O............................................................................................... 63
Operating spark testers with Profibus DP or profinet host interface ............................................................... 65
Operating spark testers with RS or Ethernet host interface............................................................................ 64
Ozone..............................................................................................................................................................16
P
Parameters Group A – System........................................................................................................................96
Parameters Group B – Line parameters.........................................................................................................97
Parameters Group C – Product parameters.................................................................................................... 98
Parameters Group D – Measurements...........................................................................................................98
Parameters Group E – Alarm messages and device status............................................................................ 99
Parameters Group F – Control functions......................................................................................................... 99
Parameters Group S – Measurement head and calibration.......................................................................... 100
Potential free analog / digital input / output....................................................................................................... 47
Production line to manufacture cables and wires............................................................................................ 18
Profibus and Profinet specific parameters..................................................................................................... 102
Profinet............................................................................................................................................................95
Prohibited use.................................................................................................................................................14
Protection against ozone ................................................................................................................................55
R
Regular maintenance......................................................................................................................................66
Repairing.........................................................................................................................................................76
Requirements for UL Certification of wire and cable products ....................................................................... 27
Residual risk....................................................................................................................................................15
Return for repairs............................................................................................................................................76
Risks and transportation....................................................................................................................................7
RS interface.....................................................................................................................................................86
S
Safety..............................................................................................................................................................13
Safety check of the spark tester......................................................................................................................67
Safety measures in the unit.............................................................................................................................13
Serial link.........................................................................................................................................................86
Service port.....................................................................................................................................................83
Settings and user interfaces............................................................................................................................38
Settings page................................................................................................................................................107
Setting up the Ethernet interface.....................................................................................................................51
Setting up the laptop.......................................................................................................................................83
Setting up the Profinet interface......................................................................................................................54
Setting up the Service Ethernet interface........................................................................................................ 46
Setting up the terminal program......................................................................................................................84
Setting up the user configuration for Profibus DP interface............................................................................. 52
Setting up the user configuration for RS host interface................................................................................... 50
Spare electrodes and component parts of electrodes..................................................................................... 79
Spark tester calibrator.....................................................................................................................................68
Spark test principle..........................................................................................................................................18
Spark test standards applying to AST L 15A / 25A / 40A spark testers............................................................. 27
Symbols.............................................................................................................................................................9
System overview.............................................................................................................................................18
T
Technical data.................................................................................................................................................26
Technical description.......................................................................................................................................18
Test voltage.....................................................................................................................................................57
Trouble-shooting..............................................................................................................................................77
U
Upload.......................................................................................................................................................90, 91
Use according to destination...........................................................................................................................14
Using and displaying menus.........................................................................................................................104
Using the control and display unit BAE 2 SP as local display......................................................................... 63
Using the service port......................................................................................................................................85
Using the spark tester with control and display unit BAE 2 SP....................................................................... 58
W
Warranty............................................................................................................................................................7
Web Visualisation..........................................................................................................................................103
Z
ZUMBACH ASCII protocol...............................................................................................................................90
ZUMBACH Product overview..........................................................................................................................10

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SPARK TESTER SYSTEM

AST L 15A / 25A / 40A

Applicable for CP software version D23S1001 and higher

The translation of the original instruction manual

Registration, or Update Date of this Manual 27.08.2021

This manual provides information on installation, operation, maintenance and safety

Read chapters 2, 3 and 4 before starting the installation.

1 Generalities to be considered on receiving the goods,

2 General and specific safety precautions, which are not mentioned in

3 Technical description and specifications,

13 List of parameters and results

13 LIST OF PARAMETERS AND RESULTS 96

14 WEB VISUALISATION 103

1.1 DEAR CUSTOMER

1.1.1 Risks and transportation

1.1.2 Inspection of goods upon arrival

This symbol warns the user of the presence of dangerous

Disposal of old devices: This symbol indicates that this product

WARNING Safety warning: A warning with the heading WARNING indicates

ODAC® 1, 2 and 3 axis Laser

MSD Diameter and Ovality

ODEX® Non-contact Eccentricity,

USYS Multitasking Data

RAYEX® X-Ray Measuring System

CELLMASTER® Foam and Foam Skin

CAPAC® Capacitance Measuring

KW Lump and Neckdown

PROFILEMASTER® In-Line Profile

SIMAC® Surface Quality

LSV Speed and Length

WST TEMPMASTER Conductor Preheaters

CALIBRATOR SP Spark Tester Calibrator

herewith declares that

the spark testers AST L 15A/25A/40A series,

are in conformity with the provisions of the following directives:

2014/35/EU Low voltage directive

IEC 62230 Electric cables – Spark-test method

EN 61010-1 Safety requirement for electrical equipment for measurement,

CISPR 11 Industrial, scientific and medical equipment – Radio – frequency disturbance

CH-2552 Orpund, March 16, 2020

This instruction manual provides safety precautions and information about

Observe the safety precautions given in the corresponding chapters, when

• Operation must be done by instructed operating personnel.

2.1.1 Safety measures in the unit

• The short-circuit current of the spark tester is limited to a maximum value of

2.3 PROHIBITED USE

Spark testers are not intended for:

Not authorized operating personnel:

2.4.1 High voltage

There are several safety measures to be met by the user:

In case of an electric shock, contact immediately an emergency doctor on call.

• If the conductor of the cable to be tested is not properly earthed, it cannot be

In addition, water can result in:

Therefore, it is mandatory to use dryers, e. g. water scrapers, strong air blower,

The electrode must regularly be inspected:

• Type of material and surface quality of the insulation being tested.

• Use the spark tester in spacious production halls.

– IEC 61326-1 Electrical equipment for measurement, control

– CISPR 11 Industrial, scientific and medical equipment -

3.1 SYSTEM OVERVIEW

3.2 SPARK TEST PRINCIPLE

3.2.1 Production line to manufacture cables and wires

Control and display unit BAE 2 SP with stand

13 LIST OF PARAMETERS AND RESULTS 96

14 WEB VISUALISATION 103