5.4 Spark 2000 Ul English

Instruction Manual
SPARK 2000 UL
Version 5.4 - November 29, 2017
English Version - Copy of Original (German)

TABLE OF CONTENTS
2
TABLE OF CONTENT S
1. GENERAL INFORMATION ........................................................... 6

1.1 CONTACT............................................................................. 7
1.1.1 WARRANTY DESIGNATION ................................................................ 8
1.1.2 SERVICE ............................................................................................ 8
1.2 INSTRUCTION MANUAL REFERENCES..................................... 9

1.2.1 USED SYMBOLS AND SIGNAL WORDS ............................................. 10
1.3 DEVICE DESCRIPTION .......................................................... 11

1.4 SCOPE OF DELIVERY ........................................................... 12
2. TRANSPORT ............................................................................. 13
3. SAFETY ..................................................................................... 14
3.1 OZONE PRODUCTION ....................................................... 15
3.2 HANDLING ACTIVE CURRENT .............................................. 16
3.3 PEOPLE WITH HEART PACEMAKER/DEFIBRILLATOR ................ 17
3.4 USAGE OF ORIGINAL COMPONENTS ................................. 18
3.5 INTENDED USE OF THE DEVICE ........................................... 19
3.5.1 PLACE OF OPERATION.................................................................... 19
3.5.2 SAFETY RELEVANT ENVIRONMENT CONDITIONS ............................. 19
3.5.3 SAFETY LABELING AT DEVICE ........................................................... 19
3.5.4 REQUIREMENT FOR OPERATOR ....................................................... 20
3.5.5 FORESEEABLE MISUSE ..................................................................... 21
3.5.6 BEHAVIOR IN CASE OF EMERGENCY ............................................... 21
3.5.7 CONSIDERATION OF THE INSTRUCTION MANUAL........................... 22
3.5.8 RESIDUAL RISK AND PRECAUTIONS .................................................. 22
3.6 DECLARATION OF CONFORMITY ........................................ 23
4. INSTALLATION ......................................................................... 24
4.1 PLACE OF INSTALLATION..................................................... 25
4.2 DEVICE ASSEMBLY ............................................................... 26
4.2.1 DEVICE STAND |OPTION| .............................................................. 27
4.3 ELECTRICAL CONNECTIONS ............................................... 28
INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

ENGLISH VERSION - COPY OF ORIGINAL (GERMAN)
SPARK 2000 UL
TABLE OF CONTENTS
3
4.3.1 GROUNDING ................................................................................. 29
4.3.1.A DEVICE STAND |OPTION| ............................................................. 30
4.3.2 VOLTAGE SUPPLY ............................................................................ 31
4.3.3 SIGNAL LINES ................................................................................. 32
4.4 OZONE EXHAUST DEVICE.................................................... 33

4.5 MOUNTING REMOTE/DISPLAY 2000 |OPTION| .................. 33
4.6 OPERATION MODE CONFIGURATION ................................ 34
4.6.1 MAIN PCB....................................................................................... 35
4.6.2 MAIN PCB WITH PROFIBUS DP ......................................................... 36
4.6.3 BAUD RATE ..................................................................................... 37
4.6.3.A S2 AT POSITION 1 ......................................................................... 37
4.6.3.B S2 AT POSITION 2 ......................................................................... 37
4.7 CONNECTION ECOCONTROL DISPLAY DEVICE .................. 38

4.7.1 PROCEEDING ................................................................................. 38
5. INTERFACES ............................................................................. 41
5.1 CONNECTIONS OVERVIEW ................................................. 42
5.2 CONNECTION CABLES TO SIKORA DISPLAY DEVICES .......... 43
5.2.1 CONNECTION TO ECOCONTROL.................................................. 43
5.2.2 CONNECTION TO REMOTE 2000 / DISPLAY 2000 ........................... 43
5.3 SIKORA DIAGNOSTIC SOFTWARE ........................................ 44

5.3.1 RS232 CONNECTION CABLE FOR SETUP/DIAGNOSTIC ................... 45
5.4 PROFIBUS DP |OPTION| ..................................................... 46

5.4.1 INTERFACE ..................................................................................... 47
5.4.2 TELEGRAM STRUCTURE ................................................................... 48
5.4.3 DATA MODULE ............................................................................... 48
5.4.3.A IN DATEN (VOM GERÄT) ................................................................ 48
5.4.3.B OUT DATA (TO DEVICE) ................................................................. 49
5.5 ANALOGUE INPUT/OUTPUT ................................................ 50

5.6 RELAY CONTACTS/EXTERNAL CONTACT HV ON/OFF .......... 50
5.7 SC400 (ASCII) PROTOCOL................................................... 51
5.7.1 TELEGRAM STRUCTURE ................................................................... 52
5.7.2 VALUE SETTINGS ............................................................................. 53
5.7.3 CHECKSUM BYTE BCC .................................................................... 53

SPARK 2000 UL
TABLE OF CONTENTS
4
5.7.4 TIME OUT ....................................................................................... 53
5.7.5 RECEIVING TELEGRAM SLAVE (MEASURING DEVICE) ......................... 54
5.7.6 SENDING TELEGRAM SLAVE (MEASURING DEVICE) ........................... 54
6. OPERATION ............................................................................. 55
6.1 EXTERNAL SAFETY CIRCUIT HV ON/OFF ............................... 55
6.2 COVER................................................................................ 56
6.3 LED INDICATOR LAMP ......................................................... 56
6.4 SWITCH DEVICE ON / OFF .................................................. 57
6.4.1 SWITCH DEVICE ON ....................................................................... 57
6.4.2 SWITCH DEVICE OFF ...................................................................... 57
6.5 CONTROL MODES .............................................................. 58

6.5.1 DIGITAL CONTROL MODE .............................................................. 59
6.5.2 ANALOG CONTROL MODE ............................................................ 60
6.6 TEST OPERATION ................................................................ 61

6.7 INLINE OPERATION ............................................................. 62
7. MAINTENANCE ........................................................................ 63
7.1 CLEANING ELECTRODE PLATE ............................................. 64
7.2 DEVICE CHECK WITH EXTERNAL TESTING DEVICES ............... 65
8. STORING AND DISPOSAL ........................................................ 66

8.1 USE AFTER LONG-TERM STORING ....................................... 67
8.2 DISPOSAL ............................................................................ 67
9. TECHNICAL DATA .................................................................... 68

9.1 TECHNICAL DRAWINGS ....................................................... 69
9.1.1 SPARK 2030 UL ............................................................................... 70
9.1.2 SPARK 2030 UL WITH STAND ........................................................... 71
9.1.3 CABLE AND CONFIGURATION PLAN ............................................... 72
9.1.4 SIEMENS RS485 REPEATER (PROFIBUS CONNECTION) ...................... 73
10. GLOSSARY ............................................................................... 74

SPARK 2000 UL
TABLE OF CONTENTS
5
11. REVISION STATUS .................................................................... 76
12. INDEX ...................................................................................... 77

SPARK 2000 UL
GENERAL INFORMATION
6
1. GENERAL INFORMATION
Thank you for your decision for a SIKORA AG product.
The following document should help you to start up, operate and maintenance the device and its
components. Furthermore it contains important references for a safe use of the device and
arrangements for potential dangerous situations.
The SIKORA AG recommends to completely and carefully read this document, to know all aspects
of the device and its components.
There are different searching options to find particular chapter or content in this document. The
following examples should explain the different searching:
 You search a particular chapter? Use the table of contents. There you can find all relevant
information of the device and its components divided in main and sub chapters.
 You search for a special operation or function? The index at the end of this document shows
an alphabetic list of all chapters and important terms. There you can find the corresponding
side number for the desired content.
 A digital version of this document offers further search functions depending on the respectively
used program (PDF). You can learn more about it at the help of the program.

SPARK 2000 UL
GENERAL INFORMATION
CONTACT 7
1.1 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

SPARK 2000 UL
GENERAL INFORMATION
CONTACT 8
1.1.1 WARRANTY DESIGNATION
This document conforms to the technical status of the device at the moment of publishing. The
content of this document is no subject of the contract, but used for information.
All supplies and services of the SIKORA AG are at the basis of the general conditions of delivery for
electrical industry products as well as the general conditions of sales of the SIKORA AG. This is
conditional on the device and its components being used as intended and described in this
document.
The warranty applies not to damages caused by incorrect or wrong use of the device and its
components, by external mechanical influences or by nonobservance the operating conditions.
Also a warranty claim is invalid as soon as the device or its components is changed or modified
without former authorization of the SIKORA AG. In particular the use of other components and
replacement parts than the approved from the SIKORA AG, lead to immediately lost of a
guarantee and warranty right.
1.1.2 SERVICE
In case of error or problems using your SIKORA device, we recommend reading the corresponding
chapters of this document 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!
An present overview for all sales and service offices can be found on the website at Contact.
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

SPARK 2000 UL
GENERAL INFORMATION
INSTRUCTION MANUAL REFERENCES 9
1.2 INSTRUCTION MANUAL REFERENCES
This instruction manual is a copy of the german original version. All rights are reserved by the
SIKORA AG. Information in this instruction manual is subject to change without notice and does
not represent a commitment on the part of SIKORA AG.
Neither this document nor parts of it may be reproduced, processed, duplicated or broadcasted in
any form without the prior permission of the SIKORA AG.
All contents and appendices have been produced with the appropriate care. The instruction
manual 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 for an instruction manual only. There is no
obligation to use this guidelines for development, production and maintenance of the
corresponding SIKORA devices.
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 or the
documentation department of the SIKORA AG to check, correct and 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.
Product names appearing here, which are no parts of the SIKORA AG, are mentioned for
identification purpose only. All named trademarks, product names and brand names are
(registered) property of their respective owners and should be treated so.

SPARK 2000 UL
GENERAL INFORMATION
INSTRUCTION MANUAL REFERENCES 10
1.2.1 USED SYMBOLS AND SIGNAL WORDS
The advices / safety instructions 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.
NOTE Device specific advice

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

with corresponding about operating procedures, events or material.
pictograph
Shown information must be absolutely observe.
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 nonobservance.
WARNING Safety instruction 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!

SPARK 2000 UL
GENERAL INFORMATION
DEVICE DESCRIPTION 11
1.3 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 sinusoidal voltage which is

continuously monitored and regulated. This voltage can be set
within a range 0.75 ... 15 kV AC (at 15 kV devices) resp. 0.75
... 10 kV AC (at 10 kV devices) via one of the various device
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.

SPARK 2000 UL
GENERAL INFORMATION
SCOPE OF DELIVERY 12
1.4 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.
The delivery takes place with one consignment. All necessary documentation for the device/system
is in the box of equipment.
The following components of the SIKORA device are always part of the delivery.
 Device unit with integral HV electrode

 Connection socket for power cable, referring to IEC 320
 SIKORA device medium with documentation, device files and SIKORA DIAGNOSTIC software
Depending on order, more components can be optional part of the delivery.
 Article 90-1101 Small bead-chain electrode with 2.5 mm | 0.1 inch diameter (instead
standard 5 mm | 0.2 inch)
 Article 99-0001 Special electrode for measurement at flat products
 Article 90-3001 2 kHz frequency
 Article 90-1202 Mounting brackets for REMOTE 2000 / DISPLAY 2000
 Article 90-0201 Protocol printer (needs REMOTE 2000)
 Article 90-0141 Device stand for electrode
 Article 07-2004 Display device REMOTE 2000 with connection cable
 Article 07-2005 Display device DISPLAY 2000 with connection cable

SPARK 2000 UL
TRANSPORT
13
2. TRANSPORT
NOTE Original packing
If possible, always transport the device inside the original packing to
the destined location.
This will guarantee a safe transport of the device and its components. It
prevents from needless damaging of the device, components or the
inside electronic.
Note to always disconnect all cables and connections from the device before you transport it. It
prevents from damaging the plugs and attachments.
Try to use a suitable packaging for a longer transport of the device and its components. Note
especially for components of glass (e.g. viewing windows) or movable parts. An improper transport
can damage this components and lead to lower functionality of the device.
HINT The SIKORA AG recommend to keep

the original packing of the device!
This is most suitable for a safe transport as well as a possible storage
later.

SPARK 2000 UL
SAFETY
14
3. SAFETY
Read this chapter carefully. It contains all general instructions for a safe and intended use of the
device and its components.
 Safe use describes the handling of the device without endanger yourselves or your
environment. But also to prevent the device and its components from damaging is part of a
safe use.
 Intended use describes the handling and operation of the device it is provided and produced
for. Part of it are the requirements for staff and environment as well as particular attitudes and
arrangements. The intended use is the basis for the safe use and the safe operation of the
device.
This chapter is the basis for a correct, safe and intended use of the device and its components.
Therefore each operator of the device has to known this chapter.
Special and detailed safety aspects for individual functions and/or operations are separately
defined at the corresponding chapters. They are always well readable set at the corresponding
function or operation.

SPARK 2000 UL
SAFETY
OZONE PRODUCTION 15
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.
Connect an ozon exhaust device at the designated device opening. A description for the ozon
exhaust device can be found at the installation chapter of this instruction manual.

SPARK 2000 UL
SAFETY
HANDLING ACTIVE CURRENT 16
3.2 HANDLING ACTIVE CURRENT
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.
During the process, the conductor of the tested wire is loaded via the bead chain high voltage
electrode with an active current.
Special design of the internal circuitry assures a defined limited maximum active 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.
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 conjunction 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!

SPARK 2000 UL
SAFETY
PEOPLE WITH HEART PACEMAKER/DEFIBRILLATOR 17
3.3 PEOPLE WITH HEART PACEMAKER/DEFIBRILLATOR
WARNING Danger for

heart pacemaker and defibrillator
through electric field!
The SPARK tester induces an electric field through high frequency
currents.
This can lead to potential dangerous interference to persons with active
implants like heart pacemaker or defibrillator.
Safety distance is
30 cm | 1 ft
Persons with active implants like heart pacemaker or
defibrillator are not allowed to be closer to an operating
device as the defined safety distance!

SPARK 2000 UL
SAFETY
USAGE OF ORIGINAL COMPONENTS 18
3.4 USAGE OF ORIGINAL COMPONENTS
WARNING Use original components from SIKORA only!
Note that only the usage of original components and

original replacement parts from SIKORA guarantee the
intended use and the corresponding correct conditions
to operate the device!
The use of other components and replacement parts than the approved
from the SIKORA AG is strictly forbidden!
At contravention, the operating license for that device expires

immediately as well as any guarantee and warranty right to the SIKORA
AG.
Furthermore, the SIKORA AG must, for the reasons of compatibility and

safety aspects, refuse the repair of devices which have been modified or
equipped with firm external replacement parts by the customer himself!

SPARK 2000 UL
SAFETY
INTENDED USE OF THE DEVICE 19
3.5 INTENDED USE OF THE DEVICE
3.5.1 PLACE OF OPERATION

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.
3.5.2 SAFETY RELEVANT ENVIRONMENT CONDITIONS

Safety relevant environment conditions apply corresponding to workplace protection provision (e.g.
working with high voltage devices).
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" on page 15) and
properly installed equipment (see "Ozone Exhaust Device" on page 33).
3.5.3 SAFETY LABELING AT DEVICE

Note the accordant safety labeling at device and its components.
If the safety labeling is not observed, an intended use can not be guaranteed. SIKORA AG will
assume no liability for generated damage through incorrect use or nonobservance of labeled
safety signs.

SPARK 2000 UL
SAFETY
3.5.4 REQUIREMENT FOR OPERATOR
In general the same workplace conditions apply as for the device place of installation. These have
to be provided for the staff by the customer.
Before using the device / system, read this instruction manual and all relevant additional
information (if available).
A basic instruction for the staff will be performed during an optionally initial operation (depending
on customer order), according to the locally necessity. A direct training of the operation staff by the
SIKORA AG is at the discretion of the customer himself. A safety training is not necessary.
The device or its components should be maintained by skilled specialists only.
Only the SIKORA AG itself or from the SIKORA AG authorized specialists are allowed to repair the
device or its components. Also note the instructions at the maintenance chapter.
NOTE Regard that service activities or device configuration are to be carried

out by qualified personnel only!

SPARK 2000 UL
SAFETY
3.5.5 FORESEEABLE MISUSE
The following practice is not permitted for the device and its components:
 The use of the device with not designated components or improperly installation.
 The use of the device and its components with improper installed and/or not for it specified
supply (current; voltage; feeding air or water).
 The use of the device or its components as hand tool or striking tool.
 The use of the device or its components as throwing object.
 The use of the device frame as a seat or footstep.
Further foreseeable misuses for the device / system and its components were not known to the
SIKORA AG at the time of compilation of this instruction manual.
If possible foreseeable misuses become known, the SIKORA AG should be informed immediately,
to assume those can be documented to guarantee the intended use of the device / system and its
components. The SIKORA AG will accept no liability for not known foreseeable misuses.
3.5.6 BEHAVIOR IN CASE OF EMERGENCY

In case of emergency immediately de-energize the device!
Thus prevents from further damage or hazard sources.
Proceed according to the instructions of your designated specialists (safety delegate, radiation
protection officer or other specialist). They are generally recorded at the instructions for workplace
conditions of the production line. Ask the destined specialist for the instructions, if you are not
familiar with it.

SPARK 2000 UL
SAFETY
3.5.7 CONSIDERATION OF THE INSTRUCTION MANUAL
The safety instructions and guidelines of this instruction manual have to be obeyed!
If noted precautions of this documentation are not observed, an intended use can not be
guaranteed. The SIKORA AG will assume no liability for generated damages through incorrect
device use or nonobservance of noted safety instructions. 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 instructions, contact the respective SIKORA AG contact
person (sales or service), so we can add your information to future documentation updates.
3.5.8 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 instructions 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 SIKORA AG contact person to add it to
future documentation updates.

SPARK 2000 UL
SAFETY
DECLARATION OF CONFORMITY 23
3.6 DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
We confirm that the product
Spark Tester
SPARK 2000 UL
is in conformity with the EC directives 2014/35/EU and 2014/30/EU.
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 note 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, Germany
Bruchweide 2
28307 Bremen/Germany
+49 421 48900 0
sales@sikora.net
www.sikora.net 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 and can vary in layout from the original.

SPARK 2000 UL
INSTALLATION
DECLARATION OF CONFORMITY 24
4. 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!

SPARK 2000 UL
INSTALLATION
PLACE OF INSTALLATION 25
4.1 PLACE OF INSTALLATION
The measuring device can be installed in an extrusion line at any point after the cooling trough.
This can be done by using the device stand for electrodes or by fixing the device on a suitable
mounting base construction.
CAUTION Sufficient ventilated area

Install the SPARK device at a sufficient ventilated area, where air is
exchanged in regular intervals by incoming air openings.
The smaller the space at place of installation, the more frequent the
space has to be ventilated.
NOTE 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.

SPARK 2000 UL
INSTALLATION
DEVICE ASSEMBLY 26
4.2 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

SPARK 2000 UL
INSTALLATION
DEVICE ASSEMBLY 27
4.2.1 DEVICE STAND |OPTION|
The optional SIKORA device stand consists of a profiled aluminum pipe with base and carrier for
the measuring gauge.
At assembly, the device stand has to be screwed to the ground.

Corresponding drill holes exist at the pedestal.
Using it on uneven ground conditions, the SIKORA AG

recommend to install a plane steel plate first, to mount the stand
on it.
The carrier allows optimal adjustment of the measuring gauge.

High and distance are stepless adjustable and always variable,
e.g. for maintenance.
NOTE The measuring head has to be pillowed during height adjustment, to

prevent it from falling down after loosening the screws.
The SIKORA AG urgently recommend to proceed this
work with a minimum of two persons!
The SIKORA device stands are designed to place the wiring inside after measuring device
installation. This prevents the wiring from damaging.
Therefore the device stand has a rubber sealing, which can

be removed to lead the wiring through the device stand. Do
not forget to refit the sealing to the device stand after
completing the assembly.

SPARK 2000 UL
INSTALLATION
ELECTRICAL CONNECTIONS 28
4.3 ELECTRICAL CONNECTIONS
All SIKORA measuring and display devices are
produced for the TN network (TN-S, TN-C,
TN-C-S).
Note this for the grounding and voltage supply

of the device.
TN network example
NOTE 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 of the electrical connections in the corresponding order of the following sub
chapters. It guarantees an appropriate procedure.

SPARK 2000 UL
INSTALLATION
4.3.1 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.
Note to connect not only the measuring device grounding (PE) correctly, but also provide for the
right voltage potential among conductor L and N.
L and N are allowed maximal device specification voltage

supply compared to the grounding.
Preferable N (Neutral) should possess a zero potential and L

(Line) the specific voltage supply compared to N (see
sketch).
 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 | 0.4 inch² (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.
NOTE Regard the necessary grounding of the test object as demanded by

most of the applicable spark testing standards (see "Ozone Production"
on page 15)!

SPARK 2000 UL
INSTALLATION
4.3.1.A DEVICE STAND |OPTION|
Note while planning to use a SIKORA device at device stand, to ground the device stand also.
It is irrespective which type of stand you are using for the SIKORA device. The grounding has to
occur for a SIKORA device stand as well as a self-constructed device stand.
You can find a separate grounding screw to ground the device stand at the lower area of the
optional SIKORA device stand.
NOTE According to the Low Voltage Direction / EMV directive,

a device stand has to be grounded additional while
using it!
NOTE Sparkover voltage can release incorrect data transfer or damage the
internal serial interfaces! Note it for a competent grounding and cable
laying.

SPARK 2000 UL
INSTALLATION
4.3.2 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.

SPARK 2000 UL
INSTALLATION
4.3.3 SIGNAL LINES
Consider that all signal lines have to be pass and ground accordingly to the low voltage direction /
EMV directive.
Use a strain relief for every signal line.
NOTE Note 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.
When installing the signal lines, note they can pick up interferences that can influence the device
performance. At longer signal lines the effect of interference which affects the cable will increase.
These cables carry data at a high transmission rate. Therefore the cables can be laid next to each
other but should not be laid parallel to other cables which for instance are used for power supply.
If however you decide upon a common path, keep a distance of at least 20 cm | 8 inch to other
cables and avoid placing them near switched inductive loads (relay coils, motors, transformers,
spark testers etc.) as far as their stray magnetic field is of importance. Other signal and measuring
conductors which carry no inductive loads are not dangerous.
A separate installation away from power lines and at sufficient distance to magnetic stray fields will
guarantee reliable device performance.
NOTE Finally make a visual inspection of all lines and cables. The device must
not be taken into operation if any of these is damaged!

SPARK 2000 UL
INSTALLATION
OZONE EXHAUST DEVICE 33
4.4 OZONE EXHAUST DEVICE
The opening for a ozone exhaust device can be found at the rear side of the device. An overview of
all connections can be found at the interfaces chapter.
To exhaust the ozone from the cover, a low pressure of minimum 0.3 Bar is necessary.
NOTE If using an exhaust device, you have to assure to choose the same
earth potential for the device as well as the exhaust device!
4.5 MOUNTING REMOTE/DISPLAY 2000 |OPTION|

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.

SPARK 2000 UL
INSTALLATION
OPERATION MODE CONFIGURATION 34
4.6 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.

SPARK 2000 UL
INSTALLATION
4.6.1 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
DISPLAY 2000 alone, without REMOTE / ECOCONTROL /

1:
PB
S3 2: normal setting
P2 Trimmer for Analog input
P4 Trimmer for Analog output

SPARK 2000 UL
INSTALLATION
4.6.2 MAIN PCB WITH PROFIBUS DP
Construction with optional Profibus DP module
101
S1 Profibus adress setting
-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

SPARK 2000 UL
INSTALLATION
4.6.3 BAUD RATE
Other then the listed baud rates or baud rate combinations are not possible.
4.6.3.A S2 AT POSITION 1
Mode 1 S3 at middle position (SPARK will be responded by REMOTE display device)
Serial interface RS232

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
4.6.3.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

SPARK 2000 UL
INSTALLATION
CONNECTION ECOCONTROL DISPLAY DEVICE 38
4.7 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.
4.7.1 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.

SPARK 2000 UL
INSTALLATION
 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

SPARK 2000 UL
INSTALLATION
 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.

SPARK 2000 UL
INTERFACES
41
5. INTERFACES

-reserved-
D-Sub connections module frame Display device

External PC
(Data protocols)
Profibus DP
Profibus system
|Option| (Data protocols)
Input HV-OFF
safety circuit
Externa contact / switch
IF2
Analog input
External potentiometer or
Connections Main PCB
IF1 voltage supply
Analog output
External display
IF1
Relay contact
External signaler
IF2

SPARK 2000 UL
INTERFACES
CONNECTIONS OVERVIEW 42
5.1 CONNECTIONS OVERVIEW
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

SPARK 2000 UL
INTERFACES
CONNECTION CABLES TO SIKORA DISPLAY DEVICES 43
5.2 CONNECTION CABLES TO SIKORA DISPLAY DEVICES
5.2.1 CONNECTION TO ECOCONTROL
5.2.2 CONNECTION TO REMOTE 2000 / DISPLAY 2000

SPARK 2000 UL
INTERFACES
SIKORA DIAGNOSTIC SOFTWARE 44
5.3 SIKORA DIAGNOSTIC SOFTWARE
A special setup and diagnostic programm from the SIKORA AG gives the possibility to set customer
specific parameters of the device and to select different diagnostic functions.
REFERENCE For a detailed description on the use of the

DIAGNOSTIC software, read the DIAGNOSTIC
software user manual for the corresponding SIKORA
device.
Note to use always the latest version of the DIAGNOSTIC software. It will be found on the device
medium, delivered with the device / system or obtain it by the SIKORA AG service.
Using an older version may cause incorrect function of the DIAGNOSTIC software. The software is
downward compatible; older SIKORA devices can be used with the latest version as well!
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 device
/ system.
HINT If the device is connected to a corresponding

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

SPARK 2000 UL
INTERFACES
SIKORA DIAGNOSTIC SOFTWARE 45
5.3.1 RS232 CONNECTION CABLE FOR SETUP/DIAGNOSTIC
HINT The Serial interface RS232 is for connection and controlling the
SIKORA 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.

SPARK 2000 UL
INTERFACES
PROFIBUS DP |OPTION| 46
5.4 PROFIBUS DP |OPTION|
NOTE To avoid damages absolutely note:

At line stoppage the test voltage must be switched off!
The SIKORA measuring device acts as SLAVE. The SLAVE address is set to 60, this value can be
changed to any value from 0…125 using the diagnostic interface.
The required projecting files for the SIKORA measuring device are supplied on the delivered device
medium. While using the projecting files, you can select from the amount of data modules for data
transmission listed in this instruction manual.
HINT Devices with REMOTE 2000 option:

In this case, the REMOTE 2000 operation mode must be set to SLAVE!

SPARK 2000 UL
INTERFACES
5.4.1 INTERFACE
Profibus interface RS485

Socket Pin Assignment Description
3 Profibus A - (B,P) 9 pol. D-Sub connection
5 GND Configuration via diagnostic interface
6 +5 V
8 Profibus B - (A,N)
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.
HINT To use a Profibus DP interface an accordant hardware

assembly is necessary!
NOTE 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).

SPARK 2000 UL
INTERFACES
5.4.2 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
5.4.3 DATA MODULE

Linear data modules
Module 1
IN data: DB0…DB2
OUT data: DB0
sp2000_1.gsd
5.4.3.A IN DATEN (VOM GERÄT)
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] for 15 kV devices
n * 150 : Actual value of test voltage [Volt] for 10 kV devices
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).

SPARK 2000 UL
INTERFACES
5.4.3.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:
(008dec...150dec) 15 kV devices = nnndec * 100 [Volt] = 0.75 ... 15 kV AC
10 kV devices = nnndec * 150 [Volt] = 0.75 ... 10 kV AC

SPARK 2000 UL
INTERFACES
ANALOGUE INPUT/OUTPUT 50
5.5 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 =
Test voltage 1) 15 kV devices 0.75 ... 15 kV AC / 10 kV devices 0.75 ... 10 kV AC
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, Main PCB (page 35)
2) Adjustable with trimmer P2, Main PCB (page 35)
5.6 RELAY CONTACTS/EXTERNAL CONTACT HV ON/OFF

ST 2 Input for external contact HV ON/OFF 10-pol connector
Relay contacts, max. load 0.5 A / 24 V DC
1
} FAULT Spark detected, signal remains for 0.6 seconds per detected spark
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

SPARK 2000 UL
INTERFACES
SC400 (ASCII) PROTOCOL 51
5.7 SC400 (ASCII) PROTOCOL
NOTE 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.

SPARK 2000 UL
INTERFACES
5.7.1 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)

SPARK 2000 UL
INTERFACES
5.7.2 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
5.7.3 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
5.7.4 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.

SPARK 2000 UL
INTERFACES
5.7.5 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:
(008dec...150dec) 15 kV devices = nnndec * 100 Volt = 0.75 ... 15 kV AC
10 kV devices = nnndec * 150 Volt = 0.75 ... 10 kV AC
5.7.6 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 (15 kV) / n * 150 (10 kV) : nominal value of test voltage [Volt]
DB2 n * 100 (15 kV) / n * 150 (10 kV) : actual value of test voltage [Volt]
DB3...DB12 for service only
DB13...DB15 synchronizing Bytes, always 255

SPARK 2000 UL
OPERATION
EXTERNAL SAFETY CIRCUIT HV ON/OFF 55
6. OPERATION
This chapter describes all necessary and available information to operate the device / system and
its components.
6.1 EXTERNAL SAFETY CIRCUIT 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!

SPARK 2000 UL
OPERATION
COVER 56
6.2 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 the corresponding protocol (see "SC400 (ASCII) Protocol" on page 51).
6.3 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 circuit or opening the cover the LED indicator
lamp will turn off

SPARK 2000 UL
OPERATION
SWITCH DEVICE ON / OFF 57
6.4 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)?
6.4.1 SWITCH DEVICE ON

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

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

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

SPARK 2000 UL
OPERATION
CONTROL MODES 58
6.5 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.

SPARK 2000 UL
OPERATION
CONTROL MODES 59
6.5.1 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.

SPARK 2000 UL
OPERATION
CONTROL MODES 60
6.5.2 ANALOG CONTROL MODE
During analog 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. 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. The common
mode voltage range of the signal inputs 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 analog 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 analog 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 analog 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!

SPARK 2000 UL
OPERATION
TEST OPERATION 61
6.6 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 / 10 kV (depending on device) 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 / 10 kV (depending on device).
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.

SPARK 2000 UL
OPERATION
INLINE OPERATION 62
6.7 INLINE OPERATION
NOTE 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.

SPARK 2000 UL
MAINTENANCE
63
7. MAINTENANCE
NOTE Customer changes or repairs
of the SIKORA device / system,
which are not explicitly documented in this chapter for customer
procedure, 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 service of the SIKORA AG.
 Do not operate the device if it seems to be damaged! Contact the service of the SIKORA AG!
 As a precaution check the device regularly, for instance after each production.

SPARK 2000 UL
MAINTENANCE
CLEANING ELECTRODE PLATE 64
7.1 CLEANING ELECTRODE PLATE
Clean the electrode plate of the SPARK device in regular
intervals from dust, dirt and water. Use a clean cloth,
without own strand/fluff or arrears.
A clean electrode plate not only guarantees a proper measuring result. It prevents from arrears
with disruptive, conductive or potential aflame character during operation.
NOTE Carefully execute the cleaning with deactivated voltage supply only.

SPARK 2000 UL
MAINTENANCE
DEVICE CHECK WITH EXTERNAL TESTING DEVICES 65
7.2 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.

SPARK 2000 UL
STORING AND DISPOSAL
66
8. STORING AND DISPOSAL
Temperature range +5 ... +50 °C | +41 ... +122 °F
Air humidity Air humidity
Note the device specified environmental conditions at storing. This prevents from lower
functionality of the device as well as damages on its components during long-term storing.
Especially devices with diverse liquids for cooling or otherwise use should keep the temperature
conditions of the specifications. Otherwise an accordingly use of the components is not guaranteed
for further use of the device.
A outdoor storing should strictly be prevent. This also could lead to damages or functionality
reduction of the device and its components through local weather conditions.
Always remove all cables and connections from the device before storing it. It prevents from
damages at plugs and attachments.
HINT Storing inside the original packing.

The SIKORA AG recommend to use the original packing of the device
while storing it. The packing is especially designed for a safe transport
of the device. Therefore it is most suited to prevent from damages while
transporting to/from installation location and during storing.
If the original packing is no longer available, the SIKORA AG

recommend to use a similar package with similar qualities.
Note for storage to not mechanically or electrically damage the device and its components with
other devices or not fixed storing. Guarantee a storage in an extra separated place for it with
suffice safety.
Furthermore the storage place should not be directly in a public place or operation place. It
prevents from improperly use or transport of the device with following damaging.

SPARK 2000 UL
STORING AND DISPOSAL
USE AFTER LONG-TERM STORING 67
8.1 USE AFTER LONG-TERM STORING
If the device and its components are operated after a long-term storing, first check it for possible
damages. Especially look for damages at plugs and attachments as well as the corresponding
cables and connections.
For the inspection, also consult the chapter maintenance and proceed like the accordant described
arrangements.
8.2 DISPOSAL
The disposal has to be conform to the local statutory law for the used device and its components.
Dispose all components conform to their designation for the

respective product and material. In particular used liquids have to be
removed conform to the corresponding legislations for disposal. But
also electrical devices have to be separately disposed depending on
Do not dispose into local legislations.

household garbage
The SIKORA AG is not responsible for the disposal of the device and its components at customer
place. The responsibility is assigned to the customer through the purchasing and use of the device
and its components as well as spare parts and attachments. It has to be done provided by the
customer. The SIKORA AG assumes no liabilities or responsibility for false or deficient disposal of
the device or its components at customer place.
At return consignment of the device and components, the SIKORA AG can assume the professional
disposal if desired. This do not apply for additional components or used resources / liquids used by
the customer. They have to be removed before the return consignment and disposed by the
customer himself.

SPARK 2000 UL
TECHNICAL DATA
68
9. 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 15 kV devices = 0.75 ... 15 kV AC / 10 kV devices = 0.75 ... 10 kV AC
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

SPARK 2000 UL
TECHNICAL DATA
TECHNICAL DRAWINGS 69
9.1 TECHNICAL DRAWINGS
You find all relevant technical drawings for the SIKORA devices in this chapter.
 SPARK 2030 UL (page 70)

 SPARK 2030 UL with stand (page 71)
 Cable and configuration plan (page 72)
 SIEMENS RS485 repeater (profibus connection) (page 73)
HINT This listing of technical drawings has a required selection of all SIKORA
devices / systems. A completeness of all available device types and
components is not guarenteed.
If you miss a technical drawing at this documentation or need a

separate drawing, contact the SIKORA AG service.

SPARK 2000 UL
TECHNICAL DATA
9.1.1 SPARK 2030 UL

SPARK 2000 UL
TECHNICAL DATA
9.1.2 SPARK 2030 UL WITH STAND

SPARK 2000 UL
TECHNICAL DATA
9.1.3 CABLE AND CONFIGURATION PLAN

SPARK 2000 UL
TECHNICAL DATA
9.1.4 SIEMENS RS485 REPEATER (PROFIBUS CONNECTION)

SPARK 2000 UL
GLOSSARY
74
10. GLOSSARY H
HV
A = High volate
Electric voltage over 1 kV, which requires specific
ABS handling.
= Absolute value
The absolut value is determined from the single values
and has no sign. Often also written as |value|.
I
INS
AC / DC
= Insulation
AC = Alternating current / voltage
DC = Direct current / voltage IR
= Infrared
C Special range at light spectrum.
CCD
ISC
= Charge-coupled device
Light sensitive, electronic component. = Inner semi conductor
D L
DM LED
= Diameter = Light-emitted diode
A diode emitting light by flowing current (as infrared
radiation or ultraviolet radiation, depending on type).
DSP
= Digital signal processor
Used for continuous processing of digital signals.
M
MEASURING AXES
E Measuring axes denotation:
X-axis = Blue axis = Vertical
ECC Y-axis = Magenta axis = Horizontal
= Eccentricity Z-axis = Brown axis (for T measuring heads)
EMV O
= Electromagnetic compatibility OSC
Describes the freedom from interferences for electrical
or electronic devices with their environment. = Outer semi conductor
F P
FFT PE
= Fast Fourier Transformation = Protective earth
An algorithm for efficiently calculation of values from a Electric conductor for safety purpose (protection against
Discrete Fourier Transformation (DFT) electric strike).
G Q
GND QGE
= Ground (Earth) = Quartz crystal generator
Reference potential for signal and operating voltage.

SPARK 2000 UL
GLOSSARY
75
Special high frequency generator for diverse SIKORA
measuring devices.
S
SRL
= Structural Return Loss
The structural return loss occurrence at wired and
optical transmitting medium. It is a logarithmically
measure for the relation of send to reflected energy.
T
TFT
= Thin-film transistor
Special monitor version with flat screen.
TOUCH PANEL
Gives the possibility to make all inputs and controls
directly via display device by pressing the
corresponding function on the monitor. No keyboard or
mouse for usage is necessary.
U
UNIT OF LENGTH
At the manual all corresponding lengths are stated as
metrical and american unit of length.
1 meter (m) = 3.28 feet (ft)
1 millimeter (mm) = 0.039 inch (inch)
1 micrometer (µm) = 0.039 Mil (mil)
W
WT
= Wall thickness

SPARK 2000 UL
REVISION STATUS
76
11. REVISION STATUS
INSTALLATION • ADVICE FOR LEAKAGE CURRENT
INSTANDHALTUNG • ADVICE DEVICE CHECK WITH EXTERNAL
TESTING DEVICE
CHRONOLOGICAL CHANGE OVERVIEW FOR ALL VERSION STATES OF THIS

DOCUMENT. VERSION 4.11 09.02.2012
CHANGED CHAPTER
INSTALLATION • GROUNDING
VERSION 5.4 29.11.2017
TECHNICAL DATA • TEST VOLTAGE
ADDED CHAPTER
MAINTENANCE • CLEANING ELECTRODE PLATE
CHANGED CHAPTER VERSION 4.1 11.10.2010
SAFETY • OZONE PRODUCTION NEW GRAPHICS / NEW LAYOUT
• HANDLING CAPACITIVE CURRENT
• DECLARATION OF CONFORMITY
INSTALLATION • PLACE OF INSTALLATION
• DEVICE ASSEMBLY
• OZONE EXHAUST DEVICE
VERSION 5.3 17.06.2016

NEW DOCUMENT STRUCTURE / NEW LAYOUT
ADDED CHAPTER
SAFETY • PEOPLE WITH HEART PACEMAKER /
DEFIBRILLATOR
CHANGED CHAPTER
GENERAL INFORMATION • SCOPE OF DELIVERY
INTERFACES
TECHNICAL DATA • TECHNICAL DRAWINGS
VERSION 5.2 18.06.2015

CHANGED CHAPTER
DEVICE DESCRIPTION • SCOPE OF DELIVERY
INSTALLATION • WIRING
INITIATION • DEVICE CONNECTIONS
• CONNECTION CABLES TO SIKORA DISPLAY
DEVICES
• PROFIBUS DP
VERSION 5.1 11.08.2014

NEW DOCUMENT STRUCTURE
CHANGED CHAPTER
PROFIBUS DP • OUT DATA
VERSION 5.01 20.02.2014

CHANGED CHAPTER
INSTALLATION • DEVICE ASSEMBLY
VERSION 5.0 13.02.2014

SAFETY INDICATIONS AT ALL CHAPTER ADAPTED TO ANSI Z535
CHANGED CHAPTER
DATA COMMUNICATION
TECHNICAL DATA
VERSION 4.2 11.03.2013

ADDED CHAPTER
INSTALLATION • OZONE EXHAUST DEVICE
CHANGED CHAPTER
INSTALLATION • REMOTE 2000 MOUNTING
TECHNICAL DATA
SCOPE OF DELIVERY • OPTIONAL COMPONENTS
DECLARATION OF CONFORMITY
TECHNICAL DRAWINGS
VERSION 4.14 04.09.2012

ADDED CHAPTER
INTENDED USE • FORESEEABLE MISSUSE
TECHNICAL DATA • ALARM CONTACT
VERSION 4.13 28.06.2012

CHANGED CHAPTER
SCOPE OF DELIVERY
CONFIGURATION • S3
TECHNICAL DATA
VERSION 4.12 07.05.2012

ADDED CHAPTER

SPARK 2000 UL
INDEX
77
12. INDEX H
HANDLING ACTIVE CURRENT ..................................................... 16
A HV ............................................................................................ 74
ABS ........................................................................................... 74 I
AC / DC .................................................................................... 74
IN DATEN (VOM GERÄT) ............................................................ 48
ANALOG CONTROL MODE ....................................................... 60
INLINE OPERATION ................................................................... 62
ANALOGUE INPUT/OUTPUT ...................................................... 50
INS ............................................................................................ 74
B INSTALLATION ........................................................................... 24
INSTRUCTION MANUAL REFERENCES ........................................... 9
BAUD RATE ................................................................................ 37
INTENDED USE OF THE DEVICE ................................................. 19
BEHAVIOR IN CASE OF EMERGENCY ......................................... 21
INTERFACE ................................................................................ 47
C INTERFACES .............................................................................. 41
IR .............................................................................................. 74
CABLE AND CONFIGURATION PLAN .....................................69, 72 ISC ............................................................................................ 74
CCD ......................................................................................... 74
CHECKSUM BYTE BCC ............................................................... 53 L
CLEANING ELECTRODE PLATE .................................................... 64
LED ........................................................................................... 74
CONNECTION CABLES TO SIKORA DISPLAY DEVICES ................. 43
LED INDICATOR LAMP................................................................ 56
CONNECTION ECOCONTROL DISPLAY DEVICE ......................... 38
CONNECTION TO ECOCONTROL ............................................ 43 M
CONNECTION TO REMOTE 2000 / DISPLAY 2000 ..................... 43
MAIN PCB ............................................................................35, 50
CONNECTIONS OVERVIEW ....................................................... 42
MAIN PCB WITH PROFIBUS DP ................................................... 36
CONSIDERATION OF THE INSTRUCTION MANUAL ..................... 22
MAINTENANCE .......................................................................... 63
CONTACT ................................................................................... 7
MEASURING AXES ...................................................................... 74
CONTROL MODES .................................................................... 58
MOUNTING REMOTE/DISPLAY 2000 |OPTION| ......................... 33
COVER ...................................................................................... 56
D O
OPERATION .............................................................................. 55
DATA MODULE .......................................................................... 48
OPERATION MODE CONFIGURATION ....................................... 34
DECLARATION OF CONFORMITY .............................................. 23
OSC.......................................................................................... 74
DEVICE ASSEMBLY ..................................................................... 26
OUT DATA (TO DEVICE) ............................................................. 49
DEVICE CHECK WITH EXTERNAL TESTING DEVICES ..................... 65
OZONE EXHAUST DEVICE .....................................................19, 33
DEVICE DESCRIPTION ................................................................ 11
OZONE PRODUCTION ...................................................15, 19, 29
DEVICE STAND |OPTION| ....................................................27, 30
DIGITAL CONTROL MODE ......................................................... 59
DISPOSAL .................................................................................. 67
P
DM............................................................................................ 74 PE ............................................................................................. 74
DSP ........................................................................................... 74 PEOPLE WITH HEART PACEMAKER/DEFIBRILLATOR ...................... 17
PLACE OF INSTALLATION ........................................................... 25
E PLACE OF OPERATION .............................................................. 19
PROCEEDING ............................................................................ 38
ECC .......................................................................................... 74
PROFIBUS DP |OPTION| ........................................................... 46
ELECTRICAL CONNECTIONS...................................................... 28
EMV .......................................................................................... 74
EXTERNAL SAFETY CIRCUIT HV ON/OFF ..................................... 55
Q
QGE ......................................................................................... 74
F
FFT ............................................................................................ 74
R
FORESEEABLE MISUSE ................................................................ 21 RECEIVING TELEGRAM SLAVE (MEASURING DEVICE) ................... 54
RELAY CONTACTS/EXTERNAL CONTACT HV ON/OFF ................. 50
G REQUIREMENT FOR OPERATOR ................................................. 20
RESIDUAL RISK AND PRECAUTIONS ............................................ 22
GENERAL INFORMATION ............................................................. 6
REVISION STATUS ...................................................................... 76
GND ......................................................................................... 74
RS232 CONNECTION CABLE FOR SETUP/DIAGNOSTIC ............. 45
GROUNDING ............................................................................ 29
S
S2 AT POSITION 1 ..................................................................... 37

SPARK 2000 UL
INDEX
78
S2 AT POSITION 2 ..................................................................... 37
SAFETY ...................................................................................... 14
SAFETY LABELING AT DEVICE ..................................................... 19
SAFETY RELEVANT ENVIRONMENT CONDITIONS ........................ 19
SC400 (ASCII) PROTOCOL ....................................................51, 56
SCOPE OF DELIVERY .................................................................. 12
SENDING TELEGRAM SLAVE (MEASURING DEVICE) ..................... 54
SERVICE....................................................................................... 8
SIEMENS RS485 REPEATER (PROFIBUS CONNECTION) ...........69, 73
SIGNAL LINES ............................................................................ 32
SIKORA DIAGNOSTIC SOFTWARE .............................................. 44
SPARK 2030 UL .....................................................................69, 70
SPARK 2030 UL WITH STAND ................................................69, 71
SRL ............................................................................................ 75
STORING AND DISPOSAL........................................................... 66
SWITCH DEVICE OFF ................................................................. 57
SWITCH DEVICE ON .................................................................. 57
SWITCH DEVICE ON / OFF ........................................................ 57
T
TECHNICAL DATA ...................................................................... 68
TECHNICAL DRAWINGS ............................................................. 69
TELEGRAM STRUCTURE .........................................................48, 52
TEST OPERATION ...................................................................... 61
TFT ............................................................................................ 75
TIME OUT.................................................................................. 53
TOUCH PANEL .......................................................................... 75
TRANSPORT ............................................................................... 13
U
UNIT OF LENGTH ...................................................................... 75
USAGE OF ORIGINAL COMPONENTS ........................................ 18
USE AFTER LONG-TERM STORING ............................................. 67
USED SYMBOLS AND SIGNAL WORDS ........................................ 10
V
VALUE SETTINGS ....................................................................... 53
VOLTAGE SUPPLY ...................................................................... 31
W
WARRANTY DESIGNATION ........................................................... 8
WT ............................................................................................ 75

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Instruction Manual

English Version - Copy of Original (German)

1. GENERAL INFORMATION ........................................................... 6

1.2 INSTRUCTION MANUAL REFERENCES..................................... 9

1.3 DEVICE DESCRIPTION .......................................................... 11

3.6 DECLARATION OF CONFORMITY ........................................ 23

4.3 ELECTRICAL CONNECTIONS ............................................... 28

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

4.4 OZONE EXHAUST DEVICE.................................................... 33

4.7 CONNECTION ECOCONTROL DISPLAY DEVICE .................. 38

5.3 SIKORA DIAGNOSTIC SOFTWARE ........................................ 44

5.4 PROFIBUS DP |OPTION| ..................................................... 46

5.5 ANALOGUE INPUT/OUTPUT ................................................ 50

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

6.5 CONTROL MODES .............................................................. 58

6.6 TEST OPERATION ................................................................ 61

8. STORING AND DISPOSAL ........................................................ 66

9. TECHNICAL DATA .................................................................... 68

10. GLOSSARY ............................................................................... 74

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

12. INDEX ...................................................................................... 77

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

 Phone : +49 (0) 421 / 48 900 - 0

 Fax : +49 (0) 421 / 48 900 - 90

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

 Phone : +49 (0) 421 / 48 900 - 50

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

HINT Special remark to corresponding text passage.

REFERENCE Cross reference to another chapter or external documentation.

NOTE Device specific advice

to physical device damage.

CAUTION Safety instruction or warning advice

Non-compliance can lead to device damages or to slight, moderate injuries!

WARNING Safety instruction or warning advice

Non-compliance can lead to device damages or to heavily injuries up to death!

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

The device housing contains the bead chain high voltage

Insulation testing is done using a sinusoidal voltage which is

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

HINT Check the parts after unpacking carefully

 Device unit with integral HV electrode

Depending on order, more components can be optional part of the delivery.

 Article 99-0001 Special electrode for measurement at flat products

 Article 90-3001 2 kHz frequency

 Article 90-1202 Mounting brackets for REMOTE 2000 / DISPLAY 2000

 Article 90-0201 Protocol printer (needs REMOTE 2000)

 Article 90-0141 Device stand for electrode

 Article 07-2004 Display device REMOTE 2000 with connection cable

 Article 07-2005 Display device DISPLAY 2000 with connection cable

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

to physical device damage.

HINT The SIKORA AG recommend to keep

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

CAUTION POTENTIAL OZONE PRODUCTION!

Non-compliance can lead to device damages or to slight, moderate injuries!

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

CAUTION Careful grounding!

Non-compliance can lead to device damages or to slight, moderate injuries!

HINT An operate protection / safety hood guarantees, using

INSTRUCTION MANUAL - VERSION 5.4 - NOVEMBER 29, 2017

WARNING Danger for