Spark 2000 Ul: Instruction Manual

Instruction Manual
SPARK 2000 UL
Version 5.2 - June 18, 2015
English Version - Copy of Original (German)

CONTENT
TABLE OF CONTENTS
1. CONTACT ................................................................................. 5
2. INSTRUCTION MANUAL REFERENCES .......................................... 6

2.1 USED SIGNAL WORDS AND SYMBOLS ............................................................. 7
2.2 STRUCTURE AND CONTENT OF THE MAIN CHAPTERS ...................................... 8
3. SAFETY ADVICES ........................................................................ 9

3.1 OZONE PRODUCTION .................................................................................. 9
3.2 CAPACTITVE CURRENT ................................................................................. 10
3.3 DECLARATION OF CONFORMITY ................................................................. 11
3.4 INTENDED USE ............................................................................................ 12
3.4.1 REQUEST FOR PERSONNEL ............................................................................................ 12
3.4.2 SAFETY RELEVANT ENVIRONMENT CONDITIONS ........................................................... 12
3.4.3 FORESEEABLE MISUSE .................................................................................................... 13
3.4.4 BEHAVIOR IN CASE OF EMERGENCY ............................................................................. 13
3.4.5 CONSIDERATION OF THE INSTRUCTION MANUAL ........................................................ 14
3.4.6 SAFETY LABELING AT DEVICE ......................................................................................... 14
3.4.7 RESIDUAL RISK AND PRECAUTIONS ................................................................................ 14
4. DEVICE DESCRIPTION ...............................................................15

4.1 TECHNICAL DATA ........................................................................................ 16
4.2 INTERFACES OVERVIEW ................................................................................ 17
4.3 SCOPE OF DELIVERY .................................................................................... 18
5. INSTALLATION ..........................................................................19
5.1 DEVICE ASSEMBLY ....................................................................................... 21
5.2 WIRING ...................................................................................................... 22
5.2.1 GROUNDING ................................................................................................................ 23
5.2.2 VOLTAGE SUPPLY .......................................................................................................... 24
5.2.3 SIGNAL LINES ................................................................................................................ 25
5.3 OZONE EXHAUST DEVICE ............................................................................ 25
5.4 'OPTION | MOUNTING REMOTE 2000 .......................................................... 26
6. INITIATION ...............................................................................27
6.1 DEVICE CONNECTIONS............................................................................... 27
6.2 OPERATION MODE CONFIGURATION .......................................................... 28
6.2.1 MAIN PCB ...................................................................................................................... 29
6.2.1.A PCB WITH PROFIBUS DP .............................................................................................. 30
6.2.2 BAUD RATE .................................................................................................................... 31
INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

ENGLISH VERSION - COPY OF ORIGINAL (GERMAN) SPARK 2000 UL 2
CONTENT
6.2.2.A S2 AT POSITION 1 ....................................................................................................... 31

6.2.2.B S2 AT POSITION 2 ....................................................................................................... 31
6.3 ANALOGUE INPUT/OUTPUT ......................................................................... 32
6.4 RELAY CONTACTS / EXTERNAL CONTACT HV ON/OFF ................................... 32
6.5 CONNECTION ECOCONTROL DISPLAY DEVICE ............................................. 33
6.5.1 PROCEEDING ................................................................................................................ 33
6.6 CONNECTION CABLES TO SIKORA DISPLAY DEVICES ..................................... 36
6.6.1 CONNECTION TO ECOCONTROL 6000 / 1000 ........................................................... 36
6.6.2 CONNECTION TO ECOCONTROL 2000 ....................................................................... 36
6.6.3 CONNECTION TO ECOCONTROL 600 ......................................................................... 37
6.6.4 CONNECTION TO REMOTE 2000 / DISPLAY 2000 ......................................................... 37
6.7 CONFIGURATION VIA DIAGNOSTIC SOFTWARE ............................................ 38
6.7.1 RS232 CONNECTION CABLE FOR SETUP/DIAGNOSTIC ................................................. 39
6.8 SC400 (ASCII) TELEGRAM ............................................................................. 40
6.8.1 TELEGRAM STRUCTURE .................................................................................................. 41
6.8.2 VALUE SETTINGS ............................................................................................................ 42
6.8.3 CHECKSUM BYTE BCC ................................................................................................... 42
6.8.4 TIME OUT ...................................................................................................................... 42
6.8.5 RECEIVING TELEGRAM SLAVE (MEASURING DEVICE) ....................................................... 43
6.8.6 SENDING TELEGRAM SLAVE (MEASURING DEVICE) ......................................................... 43
6.9 'OPTION | PROFIBUS DP .............................................................................. 44
6.9.1 INTERFACE .................................................................................................................... 44
6.9.2 TELEGRAM STRUCTURE .................................................................................................. 45
6.9.3 DATA MODULE .............................................................................................................. 46
6.9.3.A IN DATA (FROM DEVICE) ............................................................................................. 46
6.9.3.B OUT DATA (TO DEVICE) .............................................................................................. 46
7. OPERATION .............................................................................47
7.1 EXTERNAL SAFETY SWITCH HV ON/OFF ......................................................... 47
7.2 COVER ....................................................................................................... 48
7.3 LED INDICATOR LAMP .................................................................................. 48
7.4 SWITCH DEVICE ON/OFF ............................................................................. 49
7.4.1 SWITCH DEVICE ON ...................................................................................................... 49
7.4.2 SWITCH DEVICE OFF ..................................................................................................... 49
7.5 OPERATING MODES .................................................................................... 50
7.5.1 TEST OPERATION ........................................................................................................... 50
7.5.2 INLINE OPERATION ....................................................................................................... 51
7.6 CONTROL MODES ...................................................................................... 52
7.6.1 DIGITAL CONTROL MODE ............................................................................................. 53
7.6.2 ANALOGUE CONTROL MODE ....................................................................................... 54
8. MAINTENANCE .........................................................................55

CONTENT
8.1 DEVICE CHECK WITH EXTERNAL TESTING DEVICES ......................................... 56
9. APPENDIX .................................................................................57
9.1 TECHNICAL DRAWINGS ............................................................................... 57
9.1.1 SPARK 2030 UL .............................................................................................................. 58
9.1.2 SPARK 2030 UL WITH STAND ......................................................................................... 59
9.2 CABLE AND CONFIGURATION PLAN ............................................................. 60
9.3 SIEMENS RS485 REPEATER (PROFIBUS CONNECTION) .................................... 61
9.4 REVISION OVERVIEW.................................................................................... 62
10. GLOSSARY ...............................................................................63
11. INDEX ......................................................................................64

CONTACT
1. CONTACT
SIKORA AG
Bruchweide 2
28307 Bremen
-Germany-
 Phone : +49 (0) 421 / 48 900 - 0
 Fax : +49 (0) 421 / 48 900 - 90
 Email : sales@sikora.net
 Internet : www.sikora.net
An actual overview for all sales and service offices can be found on our website under Sales &
Service. Contact your country specific office for service advices. Most countries offer locally SIKORA
service engineers. If you could not found an own sales and service office for your country or have no
direct contact person, refer to our service central office in Germany.
 Phone : +49 (0) 421 / 48 900 - 50
 Email : service@sikora.net
In case of error or problems using your SIKORA device, we recommend reading the corresponding
chapters of this instruction manual first. If this provides insufficient, contact your responsible service
for assistance.
Make sure you have the corresponding device number when talking to your SIKORA contact
person. This will assure a quick processing of your request!

INSTRUCTION MANUAL REFERENCES
2. INSTRUCTION MANUAL REFERENCES

This instruction manual is a copy of the german original version. All rights are reserved!
Neither the document nor parts of it may be reproduced in any form or processed, duplicated or
broadcasted by using electronic systems without the prior permission of the SIKORA AG.
All corresponding documents / appendices have been produced with the appropriate care. The
instruction manual content based on the ISO/IEC 82079-1 also as the directive 2006/42/EC of the
European Parliament and of the Council of 17 May 2006 on machinery and amending directive
95/16/EC (recast) – annex I – chapter 1.7.4.1 general principles for the drafting of instructions. The
use of this guideline reference to content requirements of an instruction manual for all SIKORA
devices only and is not automatically binding to fulfill this directive. To comprehend the fulfilled
directives during production of the accordant SIKORA device, consult the corresponding declaration
of conformity.
The SIKORA AG meets the demands of instruction responsibility about installation, operation,
maintenance, possible safety risks and foreseeable misuse with the appropriate care. Possible wrong
information respect to the documentation will not be impossible and exist without own knowledge.
If you find such wrong information contact your respective contact person to correct / actualize this
state of knowledge.
There is no responsibility at all for direct, indirect, random or other damages as well as subsequent
damages, resulting from incorrect or abusive use of this document and the associated products. The
same applies for a correct or incorrect use of the product with the assistance of this document by
persons that are not destined resp. trained for this product.
The SIKORA AG is not liable for damages or problems resulting from the use of options which are no
original SIKORA products.
Information in this instruction manual is subject to change without notice

and does not represent a commitment on the part of SIKORA AG.

2.1 USED SIGNAL WORDS AND SYMBOLS

The advices / safety indications used at this documentation are harmonized labels and comply with
the standards ANSI Z535 and ISO 3864-2.
HINT Special remark to corresponding text passage.
The listed information here makes the use with the corresponding device or the corresponding event easier.
REFERENCE Cross reference to another chapter or external documentation.
For further information, read the chapter / documentation named at this reference.
NOTICE Device specific andvice

about operating procedures, events or material.
Regard this advice for intended use of the SIKORA device and its components. Disregard can lead to incorrect use
up to physical device damage.
CAUTION Safety indication or warning advice

with corresponding about operating procedures, events or material.
pictograph
Obey the shown information absolutely.
Non-compliance can lead to device damages or to slight, moderate injuries!
The compliance has to be provided by the customer. The SIKORA AG is not liable for non-compliance / disregard.
WARNING Safety indication or warning advice

with corresponding about dangerous operating procedures, events or material.
pictograph
Non-compliance can lead to device damages or to heavily injuries up to death!

2.2 STRUCTURE AND CONTENT OF THE MAIN CHAPTERS

This instruction manual is divided into different main chapters, sorted to its usage. The subdivision
and directive of the chapters refer to the standard composition and use of the measuring device with
all important safety and application criteria.
Main chapter Content

Safety advices Listing of all relevant safety regulations, precautions and/or certificates to
use the measuring device. Furthermore references for the intended use.
Device description General overview of the measuring device, existing measuring principles,
technical data and available interfaces. At the end of the chapter is a
listing of the included and optional scope of delivery.
Installation This chapter describes all general instructions to mount the measuring
device. It consists of the device assembling and wiring also as optional
components if available, to install them to/into the measuring device.
Initiation This chapter describes all functions and instructions for the configuration
and initiation of the measuring device. It includes besides general
information of the measuring device the different customer interfaces and
possible data telegrams for communication with the measuring device.
Operation This chapter describes all instructions and proceedings for the general
operation of the measuring device.
Maintenance An overview of all instructions and operations for maintenance, care and
servicing the measuring device.

SAFETY ADVICES
3. SAFETY ADVICES
3.1 OZONE PRODUCTION
CAUTION POTENTIAL OZONE PRODUCTION!

Because of potential ozone production you have to regard a good air
ventilation while operate the device!
Regard the toxicity of ozone. Make precautions to prevent persons from contact with ozone on a
minimum. The concentration of ozone at production environment should not exceed 10x10-6 %
(means 10 parts ozone on one hundred million air volume parts) or the value of the actual direction
on hazardous materials, if it is lower.

SAFETY ADVICES
3.2 CAPACTITVE CURRENT

During spark testing, the conductor of the tested wire is loaded via the bead chain high voltage
electrode with a capacitive current. Special design of the internal circuitry assures a high capacitive
load current capability for cable testing purposes and at the same time a defined limited maximum
resistive current of approx. 10 mA, which would flow if the high voltage electrode is touched
inadvertently by a person. According to all regulations known this value is absolutely not dangerous.
CAUTION Careful grounding!

However, for safety reasons and for perfect device performance it is
most important to bond the conductor of the cable under test as well
as the device housing properly to system ground (PE). For further
details refer to regulations UL1581 and BS5099.
Make sure that in order to avoid high capacitive contact current the test voltage is switched off when
your production line stands still. Else, due to the high test voltage in con¬junction with corona
effects, the insulation of the wire under test is locally heated up and may be damaged over time.
HINT An operate protection / safety hood guarantees, using

the insulation test is only available, while the hood is
closed!

SAFETY ADVICES
3.3 DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
We confirm that the product
SPARK TESTER
SPARK 2000 UL
is in conformity with the EC directives 2006/95/E.E.C. and 2004/108/E.E.C.
This declaration is valid for all products which are produced in accordance with the technical
documentation which is part of this declaration.
For verification of conformity with regard to safety requirements and electromagnetic compatibility
the following harmonized standards are applied:
 EN 61010-1 Safety requirements for electrical equipment for measurement,
control and laboratory use.
Part 1: General requirements.
 EN 61000-6-2 Electromagnetic compatibility (EMC)

Part 6-2: Generic standards - Immunity for industrial environments.
 EN 61000-6-4 Electromagnetic compatibility (EMC) Part 6-4:

Generic standards: Emission standard for industrial environments
This declaration is given under the sole responsibility of:

SIKORA AG, BRUCHWEIDE 2, 28307 BREMEN, GERMANY
SIKORA AG
Bruchweide 2
28307 Bremen/Germany
Phone: +49 421 48900 0
sales@sikora.net
www.sikora.net Fulfills requirements according to
DIN EN ISO 9001:2008
The following declaration of conformity is a content report of the original document only, which is part of the product delivery / available at the SIKORA AG
(depending on order). It has no serial number, date or signing.

SAFETY ADVICES
3.4 INTENDED USE

The high voltage testing device is used as stand-alone measuring system to detect cable defects
occurring in the wire insulation during production. Therefore, depending on it usage, it is integrated
to the production line at chosen place behind the cooling trough.
3.4.1 REQUEST FOR PERSONNEL

In general the same workplace conditions apply as for the production line.
A basic instruction for the personnel will be realized during the initial operation, according to the
locally necessity.
NOTICE Regard that service activities or device configuration are to be carried

out by qualified personnel only!
3.4.2 SAFETY RELEVANT ENVIRONMENT CONDITIONS

Inside the housing there are several components carrying mains voltage. To prevent any accidents
you must disconnect the device from mains before you open the housing!
Regard for good air ventilation at device environment (see Ozone production (page 9)).

SAFETY ADVICES
3.4.3 FORESEEABLE MISUSE

The following practice is not permitted for the measuring device and its components:
 The use of the device or its components as hand tool or striking tool.
 The use of the device as throwing object.
 The use of the device frame as seating or footprint.
Further foreseeable misuses for the measuring device and its components are not known on side of
the SIKORA AG.
If possible foreseeable misuses appear, the SIKORA AG has to be informed immediately so they can
be documented to guarantee the intended use of the measuring device ant its components. The
SIKORA AG will assume no liability for not known foreseeable misuses.
3.4.4 BEHAVIOR IN CASE OF EMERGENCY

In case of emergency de-energize the device
to prevent from further damage or hazard sources.
Proceed according to the instructions of your destined specialists (safety delegate or other
specialist).

SAFETY ADVICES
3.4.5 CONSIDERATION OF THE INSTRUCTION MANUAL

The safety instructions and guidelines of this documentation have to be obeyed!
If noted precautions of this documentation are disregarded, an intended use can not be guaranteed.
The SIKORA AG will assume no liability for generated damages through incorrect device use or
disregard of noted safety advices. Same for misuse operation or at the moment unknown
foreseeable misuses which are not noted in this documentation.
In the case of foreseeable misuse which is not noted in this documentation so far or not sufficient
description of operating processes / safety advices, contact the respective contact person (sales or
service), so we can add your information to future documentation updates.
3.4.6 SAFETY LABELING AT DEVICE

Regard the accordant safety labeling at device and its components.
If the safety labeling is disregarded, an intended use can not be guaranteed. SIKORA AG will assume
no liability for generated damage through incorrect use or disregard of labeled safety advices.
3.4.7 RESIDUAL RISK AND PRECAUTIONS

All known residual risks are accordant to possibility and destined precaution listed in the
corresponding chapter of this documentation. Proceed as shown in the safety advices and
precautions of this documentation, to guarantee an intended use of the device.
Unknown and therefore not documented residual risks are not excluded.
The SIKORA AG endeavors to complete the explanations for residual risk and precaution. In the case
of a missing documentation, contact the respective contact person.

DEVICE DESCRIPTION
4. DEVICE DESCRIPTION
The SPARK 2000 UL is a precision high voltage testing device for detecting and signalizing cable
defects occurring in the wire insulation during production. It is especially suited for conductors with
small dimensions, communication cables, coaxial cables, automotive cables, LAN-cables and data
cables. The device detects, signalizes and records pin holes and bare conductor areas within the
insulation layer of wires and cables. Optionally, the SPARK 2000 UL can be equipped with the
REMOTE 2000 as display and operation unit.
The device housing contains the bead chain high voltage

electrode, the device electronics and the high voltage
transformer.
Insulation testing is done using a direct current voltage which is

continuously monitored and regulated. This voltage can be set
within a range of 0.75 to 15 kV via one of the various device SPARK 2000 UL with
Option REMOTE 2000
interfaces or the REMOTE 2000.
The SPARK 2000 UL is equipped with several interfaces. All relevant operating data can be
transferred vial these interfaces to resp. from an external control computer or the REMOTE 2000
unit.
For safety reasons the SPARK 2000 UL is equipped with a safety switch off input and a LED HV
warning lamp. The maximum contact current of the high voltage electrode is reliably limited to an
absolutely harmless value. Additionally, the high voltage electrode is protected with a hinged
transparent cover from inadvertently being touched.

DEVICE DESCRIPTION
4.1 TECHNICAL DATA
Voltage supply 115 / 230 V AC ±10%, 50/60 Hz, 300 VA

Temperature range +5 ... +50 °C | +41 ... +122°F
Air humidity max. 95% (without condensation)
Dimensions
Height [mm] 188
[inch] 7.40
Width [mm] 305
[inch] 12.0
Depth [mm] 357 + 55.5 (Handle)
[inch] 14.1 + 2.19 (Handle)
Weight (approx.) 9.7 kg
Measuring range 0.5 to 30 mm | 0.02 to 1.2 inch

Electrode length 100 mm | 3.9 inch
2000 m/min | 6512 ft/min at 3.0 kHz
Line speed
1333 m/min | 4373 ft/min at 2.0 kHz
Line height 900 to 1100 mm | 35.4 to 43.3 inch
Power factor > 0.5
Test frequency 3.0 kHz (optional 2.0 kHz)
Range 0.75 to 15 kV
Resolution continuous adjustable
Maximum active
approx. 10 mA
current
Max. capacitive current approx. 20 mA
Sealing IP 54
Max. altitude above SL < 2000 m | 6562 ft
EMC according to EN50081-2, EN50082-2
EN 61010-1
DIN VDE 0800 / IEC 479-1, -2
Safety
Active current limit 10 mA
Input for external safety cut-off
Alarm Dry contact, switch duration approx. 1 sec

DEVICE DESCRIPTION
4.2 INTERFACES OVERVIEW
Serial interface RS232
-reserved-
D-Sub connections module frame

Serial interface RS485 Display device,
Externer PC
Profibus DP (Option)
Profibus system
SPARK 2000
Analog output
External display
Overview IF1
external connections
Analog input
External potentiometer or
Connections Main PCB
voltage source
IF1
Relay contacts
External signaler
IF2
Input HV-OFF
safety switch
External contact / switch
IF2

DEVICE DESCRIPTION
4.3 SCOPE OF DELIVERY
HINT Check the parts after unpacking carefully for damage and completeness
of the components.
If you miss components at delivery or they are damaged, contact the

service of SIKORA AG or your responsible office.
Standard parts of delivery:
 Device unit with integral HV electrode

 Connection socket for power cable, referring to IEC 320
 1 Device CD with instruction manual and relevant documentations also as DIAGNOSTIC software
Optional components (depending on order):
 Product 90-5001 Profibus DP

Product 90-5003
 Product 90-5083 Ethernet interface to connect to a PC / a SIKORA display device /

controller device (only in combination with REMOTE 2000)
 Product 90-5080 Universal field bus module (Profibus, Profinet IO, CANopen, DeviceNet,
EtherNet/IP)
 Product90-1101 Small bead-chain electrode with 2.5 mm | 0.1 inch diameter (instead
standard 5 mm | 0.2 inch)
 Product 99-0001 Special electrode for measurement at flat products
 Product 90-3001 2 KHz frequency
 Product 90-1202 Mounting brackets for REMOTE 2000 / DISPLAY 2000
 Product 90-0201 Protocol printer (needs REMOTE 2000)
 Product 90-0141 Device stand for electrode
 Product 07-2004 Display device REMOTE 2000 with connection cable
 Product 07-2005 Display device DISPLAY 2000 with connection cable

INSTALLATION
5. INSTALLATION
HINT An operate protection / safety hood guarantees, using

the insulation test is only available, while the hood is
closed!
CAUTION Components with mains voltage!

Inside the device housing are several components carrying mains
voltage. To prevent any accidents you must disconnect the device from
mains before you open the housing!
The measuring device can be installed in an extrusion line at any point after the cooling trough. This
can be done by using the SIKORA INLINE 2000 device stand or by fixing the device on a suitable
mounting base construction.

INSTALLATION
NOTICE Leakage current!

Look ahead to assure the suitable operation of the SPARK device by
limiting the leakage current to a minimum, e.g. by removing the surface
moisture of the product before entering the flow voltage test electrode
to prevent from error messages.
Especially when placing the device directly after the cooling trough, you have to make sure that the
object is dry. Water on the cable insulation may lead to so-called ghost faults being detected and test
voltage breakdown. Also, water may cause corrosion of the bead chain electrode. This is why we
recommend installing a blower to keep the object to be tested sufficiently dry.
Furthermore, make sure that the tested wire or cable does not oscillate within the bead chain
electrode, as otherwise ghost faults might be detected. Proper damping equipment should be used.

INSTALLATION
5.1 DEVICE ASSEMBLY
CAUTION De-energize device!

Always remove the voltage supply (pull plug) first, before mounting or
adjusting the measuring device!
The horizontal alignment of the device must be matched to the test object.
The vertical position should be adjusted so, that the wire to be tested slightly touches the U-shaped
trough of the high voltage electrode.
OK
NOT
OK

INSTALLATION
5.2 WIRING
All SIKORA measuring and display devices are

conceived (produced) for the TN network (TN-S,
TN-C, TN-C-S). Regard this for the grounding and
voltage supply of the device.
Example TN network
NOTICE If no TN network exists at the place of installation

(TT network or IT network), it has to be provided by the
customer by interconnecting a transformer!
Execute the wiring in the corresponding order of the following sub chapters. It guarantees an
appropriate wiring procedure.

INSTALLATION
5.2.1 GROUNDING
For perfect and reliable device performance the spark tester housing must be bonded properly to the
system ground. This must be done because of safety, EMI and for reliability of fault detection.
To obtain proper grounding the M6 grounding stud on the device side has to be low-impedance
connected to the system ground, by using either a ground bonding wire or strap with a size of at
least 10 mm² (AWG7). Concerning safety standards, the mains PE terminal of the mains plug has to
be connected to system ground anyway; however this wire link does not represent a sufficient
low-impedance connection to system ground.
NOTICE Regard the necessary grounding of the test object as demanded by

most of the applicable spark testing standards!

INSTALLATION
5.2.2 VOLTAGE SUPPLY
Pin 1
L = 115 / 230 V AC ±10%, 50/60 Hz, 300 VA
Pin 2
PE
Pin 3
N ≈ 0 V AC
When designing the device, special care has been taken to suppress any electromagnetic
interference and to obtain interference immunity. It fulfils EMI requirements according to EN50081-2
and EN50082-2.
Nevertheless, we recommend to use a separate mains power line from your main distributes directly
to the device and not to connect any other loads to it. In this way you avoid interferences to a large
extent, even in case of strong spark-overs, corona discharges or mains-borne interferences caused by
other equipment.
Note that the electromagnetic emissions during spark-over and corona discharges are not covered be
any EMI regulation at all! This is because the level of electromagnetic interference depends mainly
on the electrical layout of the production line, like length of the wire, grounding point/s, wire
inductance etc.
Do not connect the device to any other supply voltage than the one stated on the device type plate!
The power connector is located at the device rear.

INSTALLATION
5.2.3 SIGNAL LINES

When installing the signal lines, note they can pick up interferences that can influence measuring
system performance. A separate installation away from power lines and at sufficient distance to
magnetic stray fields will guarantee reliable device performance.
NOTICE Regard the reference potential of the electronics (GND) is insulated

from the protective earth (earth, grounding, housing) and connected to
it according to our guide line only.
5.3 OZONE EXHAUST DEVICE

The opening for a ozone exhaust device can be found at the rear side of the device.
To exhaust the ozone from the cover, a low pressure of minimum - 0.3 Bar is necessary.
NOTICE If using an exhaust device, you have to assure to choose the same earth
potential for the device as well as the exhaust device!

INSTALLATION
5.4 'OPTION | MOUNTING REMOTE 2000
If you use a REMOTE 2000 display device, you

can mount it directly to the housing as shown
on the picture.
The mounting can be easily realized via the

holder connected to the device.
Therefore the delivered attachment is

screwed to the device top side at the
corresponding area with the pilot hole. The
REMOTE 2000 with ball coupling is fixed to
the attachment.

INITIATION
6. INITIATION
6.1 DEVICE CONNECTIONS
Opening for ozone blow-off Serial interface RS485
M6 grounding stud Serial interface RS232
Power connector ST 1 - Pin 1 ... 6

Analog input / Analog output (I/O)
Power switch ON/OFF ST 2 - Pin 1 ... 10

Relay contact,
External contact HV ON/OFF
Profibus DP interface

INITIATION
6.2 OPERATION MODE CONFIGURATION

Before starting operation you have to configure the operation mode analogue / digital depending on
the demands of your production:
 Analogue mode
Which means the test voltage is set exclusively via the analog input nominal value by applying an
according control voltage.
 Digital mode
Which means the test voltage is set exclusively via one of the several digital serial interfaces.
Configuration is done by setting the rotary switch S1 located on the main PCB.

INITIATION
6.2.1 MAIN PCB
Construction without optional Profibus DP module
1: internal
2: digital
S1 3: analogue
1: Connection ECOCONTROL 600

2: Connection ECOCONTROL 2000 / ECOCONTROL 1000
S2 or REMOTE 2000 / DISPLAY 2000
1: DISPLAY 2000 alone, without REMOTE / ECOCONTROL / PB

2: normal setting
S3
P2 Trimmer for Analog input
P4 Trimmer for Analog output

INITIATION
6.2.1.A PCB WITH PROFIBUS DP
Construction with optional Profibus DP module
101 Profibus adress setting

S1 -factory setting-
S3 100 Profibus adress setting

-factory setting-
Yellow diode: Starts shining at switching on (POWER ON) till first successful data
transfer
LEDs Red diode: Shines if Profibus parameter error occurs

- Adress not ok
- DIP setting not ok
Check factory setting

INITIATION
6.2.2 BAUD RATE

Other then the listed baud rates or baud rate combinations are not possible.
6.2.2.A S2 AT POSITION 1
Mode 1 S3 at middle position (SPARK will be responded by REMOTE display device)

REMOTE 115 kBaud
115 kBaud SPARK - Response

REMOTE 115 kBaud
Mode 2 S3 at position 1 (SPARK sends continuous)
Serial interface RS232 115 kBaud SPARK sends all 1.6 seconds
Serial interface RS485 115 kBaud SPARK sends all 1.6 seconds
6.2.2.B S2 AT POSITION 2
Mode 1 S3 at middle position (SPARK will be responded by REMOTE display device)

REMOTE 115 kBaud

REMOTE 153.6 kBaud
153.6 kBaud SPARK - Response
Mode 2 S3 at position 1 (SPARK sends continuous)
Serial interface RS232 153.6 kBaud SPARK sends all 1.6 seconds
Serial interface RS485 153.6 kBaud SPARK sends all 1.6 seconds

INITIATION
6.3 ANALOGUE INPUT/OUTPUT
ST 1 Analog input / Analog output 6-pol connector

Analog output - Actual value of test voltage
Range 0.5 V ... 10 V DC = 0.8 kV ... 15 kV AC test voltage 1)
5 +OUT
6 OUT
Analog input - Nominal value of test voltage
Common-mode range 0 V ... +10 V DC 2)
2 +IN 0 ... +10 V DC
3 -IN
] (bridge) External GND
4 GND
1) Adjustable with trimmer P4, see Main PCB

(page 29)
2)Adjustable with trimmer P2, see Main PCB
(page 29)
6.4 RELAY CONTACTS / EXTERNAL CONTACT HV ON/OFF
Relay contacts,
ST 2 10-pol connector
Input for external contact HV ON/OFF
Relay contacts, max. load 0.5 A / 24 V DC
1
} FAULT Spark detected,signal remains for 0.6 s per each spark detected
2
5
} HV-ON high voltage oscillator in operation,i.e. the electrode carries a test voltage
6
7
} READY Device ready
8
Input for external contact HV ON/OFF -bridged at delivery-
9 Closed: Test voltage on, HV ON
10 Open: Test voltage off, HV OFF

INITIATION
6.5 CONNECTION ECOCONTROL DISPLAY DEVICE

If using the Serial interface RS485 for connecting an ECOCONTROL, check if the baud rate setting is
correct. Usually you do not have to adjust this yourself, as each device leaves our factory with its
customer specific setting already done. However, when exchanging devices at your installation later
on, modifying its baud rate setting may become necessary.
Setting is done with the rotary switch S2 located on the main PCB. Depending on the ECOCONTROL
equipment part number, the baud rate must be set as described below.
6.5.1 PROCEEDING
 Important: Switch off device and disconnect mains supply voltage first.
 Remove device back panel:
Unfasten the six outer cross-head screws (marked here with circles), take off back panel
carefully.
 Then the main PCB

which is situated at
the inner side of
the back panel can
be accessed.

INITIATION
 Set switch S1 on main board.

Note: In case the device is equipped with option Profibus, you have to remove the Profibus DP
module first!
S1
1 : internal
2 : digital
3 : analogue
 If necessary, set switch S2 on main board.

Note: If your device is equipped with option Profibus, remove the Profibus DP module first!
S2
1 : Connection
ECOCONTROL 600
2 : Connection
ECOCONTROL 2000

INITIATION
 If necessary, set switch S3 on main board.

Note: If your device is equipped with option Profibus, remove the Profibus DP module first!
S3
1 : DISPLAY 2000 alone,

without REMOTE /
ECOCONTROL / PB
2 : standard setting
 Put device back panel back.

 Switch on device.

INITIATION
6.6 CONNECTION CABLES TO SIKORA DISPLAY DEVICES
6.6.1 CONNECTION TO ECOCONTROL 6000 / 1000
6.6.2 CONNECTION TO ECOCONTROL 2000

INITIATION
6.6.3 CONNECTION TO ECOCONTROL 600
6.6.4 CONNECTION TO REMOTE 2000 / DISPLAY 2000

INITIATION
6.7 CONFIGURATION VIA DIAGNOSTIC SOFTWARE

A special setup and diagnostic programm from the SIKORA AG gives the possibility to set customer
specific parameters of the measuring device and select different diagnostic functions.
REFERENCE For a detailed description to use the DIAGNOSTIC software, read the
DIAGNOSTIC software user manual for the corresponding measuring
device.
Regard to use always the actual version of the software DIAGNOSTIC. It can be found on the product
CD, delivered with the measuring device or obtain by the SIKORA AG service.
Using an older version, a correct function of the software DIAGNOSTIC with the measuring device can
not be guaranteed. The software is downward compatible; older measuring device can be used with
the actual version also!
The DIAGNOSTIC software is a stand-alone application without need for installation or further
configuration. Copy the software to the desired computer which you want to connect to the
measuring device.
HINT If the measuring device is connected to a corresponding

ECOCONTROL display device, you can directly use and
operate the SIKORA DIAGNOSTIC software at it.

INITIATION
6.7.1 RS232 CONNECTION CABLE FOR SETUP/DIAGNOSTIC
HINT The RS232 interface is for connection and controlling the measuring
device via the SIKORA DIAGNOSTIC software.
To connect (1:1 standard connection) you can use any usable D-Sub
connection system available on market or at the SIKORA AG.

INITIATION
6.8 SC400 (ASCII) TELEGRAM
NOTICE To avoid damages absolutely note:

At line stoppage the test voltage must be switched off!
HINT Depending on your local grounding situation the earth potential could be
influenced by those sparks generated by a test voltage which is set to a
value of more than 5 kV. This may lead to high transient current flowing
through the device used for diagnosis. For this reason we recommend
installing a potential barrier (price on request).
The SC400 data communication between the SIKORA measuring device and other data devices will be
realized via Serial interface RS485 or Ethernet/UDP interface with recorded data transmission.
The appropriate device acts as MASTER and sends request telegrams to the SIKORA measuring
device. The SIKORA measuring device only sends a telegram to the MASTER as reaction answer for
the request.
Theoretically the data transfer rate is limited by the Baud rate only.

INITIATION
6.8.1 TELEGRAM STRUCTURE
Transmission mode START-STOP asynchronous without hardware handshake

Transmission range max. 1000 m (3280 feet)
Connection cable DUE 4503 Li2Y(St)+CY or LIFYCY
Access mode MASTER-SLAVE principle (measuring device as SLAVE)
Data security Parity bit, checksum sign
Format ASCII code 1 2 ............ n x z
1 = Start bit
2 = First data bit LSB
n = last data bit MSB
x = Parity bit
z = Stop bit
The following parameters can be set:

Number of data bit 7/8
Parity bit EVEN / ODD / NO / MARK / SPACE
Stop bit 1 / 1.5 / 2
Transmission speed 2400 / 9600 / 14400 / 19200 / 115200 Baud (bit/s)

INITIATION
6.8.2 VALUE SETTINGS
STX : START OF TEXT 02 hex ETX : END OF TEXT 03 hex

ACK : ACKNOWLEDGE 06 hex SUB : SUBSTITUTE 1A hex
NAK : NEGATIVE ACKNOWLEDGE 15 hex BCC : BLOCK CHECK CHARAKTER
6.8.3 CHECKSUM BYTE BCC

The checksum byte is calculated as follows (xor = Exclusive Or):
Checksum =
IDB1 xor IDB2 ... xor DB1 ...xor DBn
xor ETX with setting sent by MASTER
resp.
IDB1 xor IDB2 xor IDB3 xor ETX with request sent by MASTER
IDB1 xor IDB2 ... xor NAK xor ETX with reaction or setting or if ID is
missing (sent by SLAVE)
DB1 ... xor DBn xor ETX with reaction on request

(sent by SLAVE)
Checksum < 20H?
(yes) (no)
BCC = Checksum + 20H BCC = Checksum
6.8.4 TIME OUT

Data transmission is subject to following time-out criteria:
A. Maximum permissible delay time between two characters within a telegram:
adjustable 200 / 500 / 1000 / 2500 ms
If this criterion is fulfilled, the receiver waits for a new telegram start.
B. Maximum permissible delay time between receiving the last character of a request telegram and
sending the first character of the according reply: 500 ms
If this criterion is fulfilled, the sender reacts by sending a request telegram again.

INITIATION
6.8.5 RECEIVING TELEGRAM SLAVE (MEASURING DEVICE)
DB Content: Default
DB0 01hex (001dec) stop high voltage oscillator, status >> HV ZERO
03hex (003dec) activate high voltage oscillator, reset HV ZERO status
08hex...96hex
set test voltage: nnndec * 100 Volt = 0.8 kV ... 15 kV
(008dec...150dec)
6.8.6 SENDING TELEGRAM SLAVE (MEASURING DEVICE)
DB Content: Actual data

DB0 Status
DB0.0 '1' = Nominal value over 150dec; test voltage set to 0 V.
DB0.1 -
DB0.2 HV OFF The high voltage oscillator is stopped because the connection
between pin 9 and 10 of connector ST2 has been broken
DB0.3 OPEN The high voltage oscillator is stopped because of open cover
DB0.4 Profibus module plugged
DB0.5 HV ZERO The high voltage oscillator has been stopped by sending
001dec, status remains until reset by sending 003dec
DB0.6 -
DB0.7 SPARK A spark has been detected, signal remains for a minimum of
two per second (500 ms distance) for each spark detected
DB1 n * 100 : nominal value of test voltage [Volt]
DB2 n * 100 : actual value of test voltage [Volt]
DB3...DB12 for service only
DB13...DB15 synchronizing Bytes, always 255

INITIATION
6.9 'OPTION | PROFIBUS DP
NOTICE To avoid damages absolutely note:

At line stoppage the test voltage must be switched off!
HINT Devices with REMOTE 2000 option:

In this case, the REMOTE 2000 operation mode must be set to SLAVE!
The SIKORA measuring device acts as SLAVE. The SLAVE address is set to 60 and can not be changed.
The required projecting files for the SIKORA measuring device are supplied on the delivered Device
CD. While using the projecting files, you can select from the amount of data modules for data
transmission listed in this instruction manual.
6.9.1 INTERFACE
Profibus interface RS485 9-pole D-Sub socket

8 Profibus A Configuration via
3 Profibus B set-up and diagnostic interface
5 GND
6 +5V
The device interface supplies the voltage needed for the Profibus load resistances. The load
resistances themselves are not integrated.
In order to keep a reliable system the SIKORA AG recommend installing a terminating element, like
for instance the Siemens "Load Resistance for Profibus" Order No. 6ES7972-0DA00-AA0.
If an Actor or Sensor is used as terminating element for the bus system, removing this element will
not remain without consequences.

INITIATION
HINT To use a Profibus DP interface an accordant hardware

assembly is necessary!
NOTICE To avoid transmission interferences apply four toroidal cores (part of

delivery, SIKORA part number T704) to the connection cable, at the end
away from the device.
HINT Depending on your local grounding situation the earth potential could be
influenced by those sparks generated by a test voltage which is set to a
value of more than 5 kV. This may influence your Profibus system. For
this reason we recommend installing a repeater (Example: SPARK 2000
Profibus Connection via Siemens RS485 Repeater).
6.9.2 TELEGRAM STRUCTURE
Transmission mode L2-Bus (RS485)

Transmission range up to 1,5 Mbit/s with auto detection
Access mode MASTER-SLAVE principle (measuring device as SLAVE)
Data format see Profibus DIN 19245 Part 3

INITIATION
6.9.3 DATA MODULE

Linear data modules
Module 1
IN data: DB0…DB2
OUT data: DB0
sp2000_1.gsd
6.9.3.A IN DATA (FROM DEVICE )
DB Content:
DB0 Status
DB0.0 SPARK
DB0.1 -
DB0.2 HV ZERO
DB0.3 -
DB0.4 OPEN
DB0.5 HV OFF
DB0.6 -
DB0.7 '1' = Nominal value over 150dec; test voltage set to 0 V.
DB1 n * 100 : Actual value of test voltage [Volt]
DB2 not used
HINT At serial data transfer the DB0.0 will be send as first Bit and the DB0.7
will be send as last Bit. The receiver however, will value the first received
Bit as MSB and the last received Bit as LSB.
At PB the Bits DB0.0 … DB0.7 will be send parallel (its valences).
6.9.3.B OUT DATA (TO DEVICE)
DB Content:
DB0 01hex (001dec) stop high voltage oscillator, status >> HV ZERO
03hex (003dec) activate high voltage oscillator, status HV ZERO is reset
08hex...96hex nominal value test voltage: nnndec * 100 [Volt] = 0.8 kV ... 15 kV
(008dec...150dec)

OPERATION
7. OPERATION
7.1 EXTERNAL SAFETY SWITCH HV ON/OFF

For reasons of safety the device is equipped with an independent input HV-OFF to be used by an
external safety switch. This input acts as a master-on/off-switch for the test voltage, i.e. this input
has the highest priority. Pins 9 and 10 (ST2) must be connected to an external safety switch which
when closed enables the test voltage (normal operation) respectively when open disables the test
voltage.
At delivery these two pins are bridged. If you intend to use an external test voltage
master-on/off-switch you have to replace the bridge by a suitable external switch. Removing the
bridge immediately leads to the test voltage together with the warning lamp being turned off and to
Bit "HV OFF" at Status Byte being set. When you connect the two contacts again, the high voltage
oscillator wills immediately start working and the test voltage will rise up to the predefined value
again, the warning lamp lights up and Bit "HV OFF" is reset.
CAUTION Active test voltage!

Take absolute care to open this contact at line standstill and thus
switching off the test voltage!
Only when the line is running, the switch may be closed to enable the
test voltage!

OPERATION
7.2 COVER
Opening the cover during operation leads to the high voltage oscillator being turned down
immediately and test voltage being switched off completely. Bit "OPEN" at Status Byte is set.
The moment the cover is closed again, the high voltage oscillator starts working immediately and the
test voltage rises up to its predefined value again. Bit "OPEN" is reset. (For further information to set
the Bit, read SC400 (ASCII) telegram (page 40).)
7.3 LED INDICATOR LAMP

The device is equipped with a LED indicator lamp mounted on top of the device housing. This lamp
will turn on as soon as the high voltage oscillator starts working, i.e. the electrode carries a test
voltage. Manually disrupting the external safety switch or opening the cover the LED indicator lamp
will turn off

OPERATION
7.4 SWITCH DEVICE ON/OFF

Before you switch on your device check once more the following points:
 Did you install a separate power line for the device?

 Did you supply sufficient grounding?
 Have precautions been taken to keep the test object dry?
 Have precautions been taken to prevent mechanical oscillation of the wire to be tested?
 Is there a switch/contact for switching off the test voltage when your production line stands still?
 Did you connect all cables required (mains, REMOTE 2000, Profibus)?
 Did you ground the housing and the test object (min. 10mm2)?
 Did you configure a suitable operation mode (Digital/Analogue mode)?
 Is the Profibus addressing setting (if relevant) correct?
 Did you configure the correct REMOTE 2000 operation mode (Master/Slave)?
7.4.1 SWITCH DEVICE ON

The SPARK 2000 UL mains input with switch is located at the rear of the housing.
 Plug in power connector.

 Switch on device with power switch.
7.4.2 SWITCH DEVICE OFF

 Switch off device with power switch.
 Pull power connector.

OPERATION
7.5 OPERATING MODES
7.5.1 TEST OPERATION

Switch on your SPARK 2000 UL using the power switch.
If you are testing your SPARK 2000 UL for the first time, we recommend doing so without any wire or
cable being in the bead chain high voltage electrode, i.e. not during production.
 Close the hinged cover and enable the high voltage oscillator in case you have used the "HV OFF"
command or have used the "HV OFF" input.
 Set the nominal test voltage amplitude to 15 kV during digital control mode by sending 150DEC
periodically via one of the serial interfaces or, during analogue control mode, by applying a
control voltage of 10 V DC to the analog input nominal value default.
Now your SPARK 2000 UL must generate a test voltage of 15 kV. Furthermore you should hear the
device high voltage transformer working. You can perform some spark-over tests now by using a
well-grounded and insulated piece of wire. Bring the end of the wire slowly up to the high voltage
electrode until a clearly visible spark-over will occur. This should happen before you have come as
close as about 10 mm.
The SPARK 2000 UL must detect this spark-over immediately. In this case, the high voltage oscillator
stops working for about 0.6 seconds, Bit "SPARK" in byte DB0 is set and the contact "FAULT" is
closed. Please repeat this test using a much lower test voltage, e.g. 1.5 kV.

OPERATION
7.5.2 INLINE OPERATION
NOTICE Make a test operation first. If everything did work well during the tests,
you can insert the wire or cable under production.
 Open the hinged cover and feed the wire to be tested through the bead chain high voltage
electrode. Close the hinged cover again.
 Enable the high voltage oscillator again if you have used the "HV OFF" command before or if you
have interrupted the Master "HV OFF" input pins.
 Set the nominal test voltage amplitude to the required level by periodically transmitting the
corresponding telegrams to one of the serial interfaces or by using the analog nominal input.
 Monitor the actual test voltage amplitude, either by using the output data of the serial interfaces
or by using the analog actual output voltage.
 Monitor the "SPARK" signal, either by using the output data of the serial interfaces or by using
the corresponding "FAULT" relay contact.

OPERATION
7.6 CONTROL MODES

According to configuration the SPARK 2000 UL operation mode is controlled by one of the following
interfaces:
Digital control mode:
 Serial interface RS232 / Serial interface RS485

 Profibus DP (Option)
Analogue control mode:
 Analog input
Signals supplied by the analogue output and the Relay contacts are not affected by the kind of
operation mode selected. The analogue input is ignored during digital control mode.
Sparks detected and device status information are indicated by an accordant telegram via the serial
interface RS232 / RS485 resp. the Profibus-DP interface or the Relay contact.
Use the analogue output to monitor the test voltage. Factory default setting is: an output voltage
range of 0.53 V ... 10 V corresponds to a test voltage of 800 V ... 15kV.
This ratio can be adapted by adjusting the internal trimmer P4.
Display and Operation can also be done using the ECOCONTROL or REMOTE 2000 (Option).
This unit acts according to its configuration as MASTER or SLAVE, i.e. as a control unit for the SPARK
2000 UL or as a mere display unit.

OPERATION
7.6.1 DIGITAL CONTROL MODE

During digital control mode the test voltage is controlled by sending an according telegram via one of
the serial interfaces.
These interfaces are internally OR-wired to one single internal input channel. Thus, it is not possible
to send data simultaneously via these interfaces!
The telegram is used for:
 Setting the test voltage nominal value (by sending 008DEC ... 150DEC)
 Turning on the test voltage (by sending 003DEC)
 Turning off the test voltage (by sending 001DEC)
Note that the lowest value which can be set for the test voltage is about 0.8 kV which is adjusted by
sending 008DEC. If you really want to set the test voltage to zero, then you have to activate "HV ZERO"
state by sendig 001DEC.
During this state, the high voltage oscillator is stopped and the test voltage immediately turned down
to zero. "HV-ZERO" state is maintained until the high voltage oscillator is activated again by sending
003DEC.
Next, you have to adjust the required test voltage again by sending an according telegram.
"HV-ZERO" state is indicated in the output data telegram (Bit "HV-ZERO" in Byte DB0).
The telegram must be transmitted periodically to the SPARK, at least once per second. Otherwise an
internal watch-dog timer turns down the test voltage immediately. Please note that the test voltage
will not be turned off completely but merely turned down to a value of about 800 V. (For some
devices, this is also indicated by the red LED indicator lamp remaining on.)
After each successful transmission of the telegram or after a reset signal generated by the internal
watch-dog timer, the SPARK immediately replies by sending a data telegram as response, to all serial
interfaces simultaneously.

OPERATION
7.6.2 ANALOGUE CONTROL MODE

During analogue control mode the test voltage amplitude is exclusively set by an analog control
voltage. This control voltage has to be connected to the analog input nominal value (plug ST1, pin 1
to 4). This control voltage can be supplied either by an external adjustable voltage source or can be
generated in conjunction with the internal voltage source of the SPARK. In case there is a longer
distance between the SPARK and an external voltage source respectively a potentiometer, the
SIKORA AG recommend using a shielded cable, where the shield should be connected to GND (pin 4
of connector ST1). The common mode voltage range of the signal input pins 2 and 3 of connector ST1
is 0 to +10 V DC.
The nominal test voltage can be set in its range by a control voltage of 0.53V...10V. During operation,
by an external adjustable resistor respectively by a potentiometer of approx. 10kΩ, you can adjust
the matching of the ranges of test voltage and control voltage by adjusting the internal trimmer P2
on the main PCB. Factory default setting is a test voltage of 10V at 10kΩ. During digital mode the
control voltage does not have any influence on the test voltage.
All other functions of the SPARK are available as well, all serial interfaces remain active. Usually,
there is no telegram being sent to the SPARK during analogue control mode. Therefore, the internal
watch-dog timer triggers the sending of a data telegram to the serial interfaces once a second. Hence
you still can monitor all data, even when operating the device in analogue control mode. If this
output data rate is to low for your application, you can speed it up by sending so-called Dummy
telegrams. During analogue control mode the SPARK replies to each Dummy telegram received by
sending a complete data telegram, the contents of which are according to the receiving telegram,
except only values of 001DEC and 003DEC will be accepted, i.e. setting the test voltage is inapplicable.
Even when the analogue nominal input is used to set the nominal value it is still possible to stop the
high voltage oscillator by sending the "HV ZERO" command!

MAINTENANCE
8. MAINTENANCE
NOTICE Customer changes or

repairs of the measuring device
which are not explicit documented at this chapter for customer
processing, are not permitted without prior acceptance of the SIKORA
AG and lead to a loss of all warranty claims!
To validate your warranty claims always contact the SIKORA AG before

these arrangements.
HINT The high voltage testing device

is almost maintenance-free!
However, follow the instructions given below carefully to keep device performance up for many
years of use:
 Always keep the device dry and clean. This is particularly important for the bead chain high
voltage electrode and the insulating plate.
 The bead chains will wear with time. This is a normal effect due to the abrasion caused by the
fast running test object. If necessary replace the bead chain array in time. For spare parts contact
the SIKORA service.
 Do not operate the device if it seems to be damaged! Contact the SIKORA service!
 As a precaution check the device regularly, for instance after each production.

MAINTENANCE
8.1 DEVICE CHECK WITH EXTERNAL TESTING DEVICES
REFERENCE All made details refer to the test standard DIN EN 62230, corresponding
to the tests of high voltage testing devices.
At least one time each year, but also after every reparation or important change, the standard
instructs to check spark tester depending on the compliance with different specifications.
A part of this is for example the test voltage check-up, which tolerances are limited to ± 5%, the
sensitivity check-up of a spark tester depending on its error detection reliability also as the maximum
voltage check-up in case of unintended touching of the testing high voltage.
Checking the spark tester with external testing devices can lead to complete false results, because
these testing devices are developed and calibrated to check devices of the same producer depending
on functionality and compliance of specified attributes and values.
The SIKORA AG is sure with the knowledge depending on the spark tester function, a testing device
can be constructed which can fulfill the named attributes of a spark tester. But the standard DIN EN
62230 gives large leeway to the producer of a spark tester at realization of such a device. This applies
for example to the testing voltage and as the case may be the wave shape of the testing voltage. Also
the detector to identify isolation errors can be realize in different ways. There are detectors which
run the testing voltage during error detection. But there are also detectors which directly stops the
testing voltage during error detection. While the first construction needs an external error voltage
limiter for using a simulated fault, e.g. with the aid of a needlepoint to reduce the applied load of
this needlepoint, an external limiter is the wrong way for the second constructed error detector,
because this detector type has an internal voltage limiter and the high voltage will be shut down
directly after error detection.

APPENDIX
9. APPENDIX
9.1 TECHNICAL DRAWINGS

In this chapter you find all relevant technical drawings for the SIKORA measuring devices of this
instruction manual.
 SPARK 2030 UL (page 60)

 SPARK 2030 UL with stand (page 59)

APPENDIX
9.1.1 SPARK 2030 UL

APPENDIX
9.1.2 SPARK 2030 UL WITH STAND

APPENDIX
9.2 CABLE AND CONFIGURATION PLAN

APPENDIX
9.3 SIEMENS RS485 REPEATER (PROFIBUS CONNECTION)

APPENDIX
9.4 REVISION OVERVIEW
No. Date of release Changes

Chapter Type Content
5.2 18.06.2015 Device description Change Scope of delivery

Installation Change Wiring
Initiation Change Device connections
Connection cables to SIKORA display
devices
Profibus DP
5.1 11.08.2014 All Change New document dtructure
Profibus DP Change OUT data
5.01 20.02.2014 Installation Change Device assembly
5.0 13.02.2014 Safety indications at Change Adaption to ANSI Z535
all chapters
Data Change Chapter separated do single
communication chapters SC400, Profibus DP
All telegrams Change Actualization
Technical data Change Actualization
4.2 11.03.2013 Installation Change REMOTE 2000 mounting
Adding Ozone exhaust device
Technical data Change Dimension, line speed, test voltage
Scope of delivery Change Optional components
Decl. of conformity Change Norms
Technical drawings Change SPARK 2030 UL (with stand)
4.14 04.09.2012 Intended use Adding Foreseeable missuse
Technical data Adding Alarm contact
4.13 28.06.2012 Scope of delivery Change Actualization
Configuration Change S3
Technical data Change Actualization
4.12 07.05.2012 Installation Adding Advice for leakage current
Maintenance Adding Advice device check with external
testing devices
4.11 09.02.2012 Installation Change Grounding
Technical data Change Test voltage
4.1 11.10.2010 All Change New graphics and design

GLOSSARY
10. GLOSSARY 1 meter (m) = 3.28 feet (ft)

1 millimeter (mm) = 0.039 inch (inch)
1 micrometer (µm) = 0.039 Mil (mil)
A
AC / DC
= Alternating current (voltage)
= Direct current (voltage)
D
DSP
= Digital signal processor
Used for continuous processing of digital signals.
E
EMC
= Electromagnetic compatibility
Describes the freedom from interferences for electrical
or electronic devices with their environment.
G
GND
= Ground
Reference potential for signal and operating voltage.
H
HV
= High voltage
I
IR
= Infrared
L
LED
= Light-emitted diode.
A diode emitting light by flowing current (as infrared
radiation or ultraviolet radiation, depending on type).
P
PE
= Protective earth
Electric conductor for safety purpose (protection against
electric strike).
U
Unit of length
At the manual all corresponding lengths are stated as
metrical and american unit of length.

INDEX
11. INDEX
INSTALLATION ........................................................................... 19
INSTRUCTION MANUAL REFERENCES ........................................... 6
INTENDED USE .......................................................................... 12
A INTERFACE ................................................................................ 44
INTERFACES OVERVIEW ............................................................. 17
AC / DC .................................................................................... 63
IR .............................................................................................. 63
ANALOGUE CONTROL MODE ................................................... 54
ANALOGUE INPUT/OUTPUT ...................................................... 32
APPENDIX .................................................................................. 57
L
LED ........................................................................................... 63
B LED INDICATOR LAMP................................................................ 48
BAUD RATE ................................................................................ 31

BEHAVIOR IN CASE OF EMERGENCY ......................................... 13
M
MAIN PCB ................................................................................. 29
C MAINTENANCE .......................................................................... 55
CABLE AND CONFIGURATION PLAN .......................................... 60

CAPACTITVE CURRENT ............................................................... 10
O
CHECKSUM BYTE BCC ............................................................... 42 OPERATING MODES .................................................................. 50
CONFIGURATION VIA DIAGNOSTIC SOFTWARE ........................ 38 OPERATION .............................................................................. 47
CONNECTION CABLES TO SIKORA DISPLAY DEVICES ................. 36 OPERATION MODE CONFIGURATION ....................................... 28
CONNECTION ECOCONTROL DISPLAY DEVICE ......................... 33
CONNECTION TO ECOCONTROL 2000 ................................... 36
'
CONNECTION TO ECOCONTROL 600 ..................................... 37 'OPTION | MOUNTING REMOTE 2000 ...................................... 26
CONNECTION TO ECOCONTROL 6000 / 1000 ........................ 36 'OPTION | PROFIBUS DP ............................................................ 44
CONNECTION TO REMOTE 2000 / DISPLAY 2000 ..................... 37
CONSIDERATION OF THE INSTRUCTION MANUAL ..................... 14 O
CONTACT ................................................................................... 5
OUT DATA (TO DEVICE) ............................................................. 46
CONTROL MODES .................................................................... 52
OZONE EXHAUST DEVICE .......................................................... 25
COVER ...................................................................................... 48
OZONE PRODUCTION ................................................................ 9
D P
DATA MODULE .......................................................................... 46
PCB WITH PROFIBUS DP............................................................. 30
DECLARATION OF CONFORMITY .............................................. 11
PE ............................................................................................. 63
DEVICE ASSEMBLY ..................................................................... 21
PROCEEDING ............................................................................ 33
DEVICE CHECK WITH EXTERNAL TESTING DEVICES ..................... 56
DEVICE CONNECTIONS ............................................................ 27 R
DEVICE DESCRIPTION ................................................................ 15
RECEIVING TELEGRAM SLAVE (MEASURING DEVICE) ................... 43
DIGITAL CONTROL MODE ......................................................... 53
RELAY CONTACTS / EXTERNAL CONTACT HV ON/OFF ............... 32
DSP ........................................................................................... 63
REQUEST FOR PERSONNEL ........................................................ 12
E RESIDUAL RISK AND PRECAUTIONS ............................................ 14

REVISION OVERVIEW ................................................................. 62
EMC .......................................................................................... 63
RS232 CONNECTION CABLE FOR SETUP/DIAGNOSTIC ............. 39
EXTERNAL SAFETY SWITCH HV ON/OFF ..................................... 47
S
F
S2 AT POSITION 1 ..................................................................... 31
FORESEEABLE MISUSE ................................................................ 13
S2 AT POSITION 2 ..................................................................... 31
G SAFETY ADVICES .......................................................................... 9

SAFETY LABELING AT DEVICE ..................................................... 14
GND ......................................................................................... 63 SAFETY RELEVANT ENVIRONMENT CONDITIONS ........................ 12
GROUNDING ............................................................................ 23 SC400 (ASCII) TELEGRAM ........................................................... 40
SCOPE OF DELIVERY .................................................................. 18
H SENDING TELEGRAM SLAVE (MEASURING DEVICE) ..................... 43
HV ............................................................................................ 63 SIEMENS RS485 REPEATER (PROFIBUS CONNECTION) ................ 61
SIGNAL LINES ............................................................................ 25
I SPARK 2030 UL .......................................................................... 58
SPARK 2030 UL WITH STAND ..................................................... 59
IN DATA (FROM DEVICE) ............................................................ 46
STRUCTURE AND CONTENT OF THE MAIN CHAPTERS .................. 8
INITIATION ................................................................................ 27
SWITCH DEVICE OFF ................................................................. 49
INLINE OPERATION ................................................................... 51
SWITCH DEVICE ON .................................................................. 49

INDEX
SWITCH DEVICE ON/OFF .......................................................... 49
T
TECHNICAL DATA ...................................................................... 16
TECHNICAL DRAWINGS ............................................................. 57
TELEGRAM STRUCTURE .........................................................41, 45
TEST OPERATION ...................................................................... 50
TIME OUT.................................................................................. 42
U
UNIT OF LENGTH ...................................................................... 63
USED SIGNAL WORDS AND SYMBOLS .......................................... 7
V
VALUE SETTINGS ....................................................................... 42
VOLTAGE SUPPLY ...................................................................... 24
W
WIRING ..................................................................................... 22


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Instruction Manual

English Version - Copy of Original (German)

2. INSTRUCTION MANUAL REFERENCES .......................................... 6

3. SAFETY ADVICES ........................................................................ 9

4. DEVICE DESCRIPTION ...............................................................15

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

6.2.2.A S2 AT POSITION 1 ....................................................................................................... 31

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

8.1 DEVICE CHECK WITH EXTERNAL TESTING DEVICES ......................................... 56

10. GLOSSARY ...............................................................................63

11. INDEX ......................................................................................64

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

 Fax : +49 (0) 421 / 48 900 - 90

 Phone : +49 (0) 421 / 48 900 - 50

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

2. INSTRUCTION MANUAL REFERENCES

Information in this instruction manual is subject to change without notice

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

2.1 USED SIGNAL WORDS AND SYMBOLS

HINT Special remark to corresponding text passage.

REFERENCE Cross reference to another chapter or external documentation.

NOTICE Device specific andvice

CAUTION Safety indication or warning advice

WARNING Safety indication or warning advice

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

2.2 STRUCTURE AND CONTENT OF THE MAIN CHAPTERS

Main chapter Content

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

3.1 OZONE PRODUCTION

CAUTION POTENTIAL OZONE PRODUCTION!

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

3.2 CAPACTITVE CURRENT

CAUTION Careful grounding!

HINT An operate protection / safety hood guarantees, using

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

3.3 DECLARATION OF CONFORMITY

 EN 61000-6-2 Electromagnetic compatibility (EMC)

 EN 61000-6-4 Electromagnetic compatibility (EMC) Part 6-4:

This declaration is given under the sole responsibility of:

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

3.4 INTENDED USE

3.4.1 REQUEST FOR PERSONNEL

NOTICE Regard that service activities or device configuration are to be carried

3.4.2 SAFETY RELEVANT ENVIRONMENT CONDITIONS

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

3.4.3 FORESEEABLE MISUSE

3.4.4 BEHAVIOR IN CASE OF EMERGENCY

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

3.4.5 CONSIDERATION OF THE INSTRUCTION MANUAL

3.4.6 SAFETY LABELING AT DEVICE

3.4.7 RESIDUAL RISK AND PRECAUTIONS

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

The device housing contains the bead chain high voltage

Insulation testing is done using a direct current voltage which is

INSTRUCTION MANUAL - VERSION 5.2 - JUNE 18, 2015

4.1 TECHNICAL DATA

Voltage supply 115 / 230 V AC ±10%, 50/60 Hz, 300 VA

Measuring range 0.5 to 30 mm | 0.02 to 1.2 inch