CLARE B255 Power tool & Appliance Test Station
Contents
1. Con ie amp FIG 2 Supplied Accessories 14 Clare B255 Power Tool amp Appliance Test Station Operating Manual SOCKET BOX OUTLET GUARD swen 110V INLET FIG 3 Rear Panel Connectors Rear Panel Connections The various connectors shown in the illustration opposite are numbered where appropriate to correspond with the accessories described on the preceding pages other connectors are described below a Guard Safety Switch used to connect the guard door switch from the Test Area barrier or other external safety interlock system a mating plug top is supplied for wiring purposes Switch contacts must be normally open closing to start and be volt free but with a minimum rating of 2A 24Vd c As an alternative to the guard switch a remote manually operated Safety switch can be supplied as an optional accessory Where no guard or safety switch is to be used a shorting link must be wired across the contact terminal pins b Beacon Port this socket can be used to connect any standard Green Red 2 lamp safety beacon fitted with 24V 5W bulbs The mating plug should be wired in accordance with the adjacent wiring diagram on the label The beacon provides a visual indication of instrument status Green light shows that the instrument is switched ON with power on and safety interlock closed and ready for test application The Red lig2. The Hire Industry however must ensure compliance with safety regulations each and every time a power tool or appliance is hired out Repairers of power tools and appliances also have statutory obligations to ensure that the repaired item complies fully with original manufacturer s specifications and the relevant standards As well as being aware of the legal requirements it also helps to appreciate the reasons for testing if there is a clear understanding of how construction and test requirements aim to provide Electrical Safety Methods of Construction for Electrical Safety To provide the user with protection against electric shock general methods of construction must ensure firstly that all live parts are insulated and secondly that should this basic insulation fail the live parts are prevented form creating a hazard to the user This second level of protection is achieved either by earthing all accessible conductive surfaces or by providing double insulation in the form of a second insulating layer or by reinforcing the primary insulating layer Earthed equipment is referred to as Class Earthing is achieved by connecting all accessible conductive surfaces the tool body or outer casing and associated fixings etc to the supply earth via a low impedance protective conductor Then if any live part comes into contact with these surfaces the hazardous current is drawn harmlessly to earth through th
3. Clare B255 Power Tool amp Appliance Test Station Operating Manual E SEAWARD Bracken Hill South West Industrial Estate Peterlee Co Durham SR8 2SW England Tel 44 0 191 586 3511 Fax 44 0 191 586 0227 www seaward co uk sales seaward co uk calibration seaward co uk Clare B255 Power Tool amp Appliance Test Station Operating Manual Limited Warranty amp Limitation of Liability Seaward Electronic Ltd guarantees this product for a period of 1 year The period of warranty will be effective at the day of delivery c Copyright 2013 All rights reserved Nothing from this edition may be multiplied or made public in any form or manner either electronically mechanically by photocopying recording or in any manner without prior written consent from Seaward This also applies to accompanying drawings and diagrams E amp OE The information contained within this manual is given in good faith and is provided for guidance only Although all reasonable care has been taken to ensure accuracy of the information Seaward Electronic Ltd their agents and distributors accept no responsibility for any errors or omissions within this document nor for any misinterpretations by the user For clarification on any part of this document please contact Seaward Electronic Ltd or your local agent before operating the instrument Due to a policy of continuous development Seaward Electronic Ltd reserve the right to alter or amend
4. tight bearings or even a tight gear train A really serious fault such as a short circuit will trip the SUPPLY mcb on the instrument or external supply and may even blow supply fuses Disconnect the appliance before re setting the mcb and also check plug top and switch board fuses if the instrument SUPPLY lamp now fails to operate All suspected faults must be investigated and corrected by qualified personnel and the product FULLY re tested 27 Clare B255 Power Tool amp Appliance Test Station Operating Manual 8 Instrument Integrity Calibration Regulatory authorities require that test instruments are re calibrated at least annually Seaward Electronic Ltd offer a full calibration service for this instrument although any other suitably approved test establishment can be used Operational Checks As well as the instrument undergoing annual or more frequent re calibration by qualified personnel The user must check the safety test circuits at regular intervals to determine the operational integrity The B255 is supplied with a FAULT SIMULATOR model Y250 specifically for this purpose The simulator is designed for direct plug in connection to the test output box using the 13A 230V Test Socket and by applying the following series of simple check routines can be used to check both Earth and Flash Safety tests It is recommended that such operational checks are carried out at least weekly if not daily before use N
5. 5mA lower scale of the meter The leakage value must fall within the appliance manufacturer s specifications or conform to other relevant standards typical values are shown in the chart opposite Release product switches and the LOAD TEST button as soon as a reading has been taken Typical Earth Leakage Values Hand held Tools Household Luminaires IT Equipment Appliances To BS EN 50144 To BS EN 60335 To BS EN 60598 To EN 60950 Class I portable appliances 0 75mA 0 75mA per Class I stationary appliances kilowatt Class Il appliances 0 25mA The values above are for guidance only product specific values must be determined from manufacturer data 25 Clare B255 Power Tool amp Appliance Test Station Operating Manual Load Run Current Measurement It is advisable to only apply a Load Test if the product has successfully undergone a Safety Test first Check that the product to be tested is connected to the correct test output socket for the supply voltage required 230V or 110V and for 110V products that a suitable external supply source is connected to the instrument NOTE For 230V appliances the maximum permissible load current is 15A and for 110V equipment the maximum measurable current is 25A provided that the external supply is suitably rated Ensure that the appliance cannot move and is adequately guarded to prevent any hazard being caused by or to moving parts or heating elem
6. and function switches set for each operating mode Earth Leakage Current For equipment fitted with contactor relay or low voltage electronic start switching devices often referred to as dead mans handles typically those that require mains voltage to be applied before all operating circuits are made it may be impractical to apply a Flash Test to the complete wiring system of the product In such cases it may be more appropriate to measure the Earth Leakage current when the equipment is powered up and running Clare B255 Power Tool amp Appliance Test Station Operating Manual Functional Operation Having established that the tool or appliance offers adequate protection to the user it is also necessary to ensure that it operates correctly in all available modes Although many tools and appliances can be seen to be working correctly in that they turn in the right direction or blow and suck when required etc such visual checks do not always tell the full story or give any indication of impending failure It is therefore recommended that measurements are also made to determine the load currents of each function to check that they are within the normal operating limits For motor driven tools such as drills saws and angle grinders etc the current measurement is usually taken with the tool running in an off load condition This will generally give load current readings significantly lower than that shown on the equipment
7. away the Earth Return clip lead and get the safety Flash Probe out ready for the next check Set the test selector to 3000v Flash depress and hold the Test button and note that the green Flash PASS lamp comes on With the Test button still depressed apply the tip of the safety Flash Probe to the HT PROBE test point on the simulator the warning buzzer and the red Flash FAIL lamp should come on continuously Release the Test button Set the test selector to 3750v Flash depress and hold the Test button and note that the red Flash FAIL lamp comes on Interlock functionality test check Disconnect Guard Switch from the socket located at the rear panel Make sure the output box is plugged into the B255 Make sure the selector switch is set to Stand By position Set up test as per Earth Continuity Check Procedure Switch B255 on Select Earth Continuity test using the rotary selector switch Depress Test button in order to start the test Makes sure the test doesn t start and the reading on the scale remains at O position Only if the above test is successful perform the following test Connect Guard Switch link provided Disconnect the output box Make sure the selector switch is set to Stand By position Switch B255 on Select Earth Continuity test using the rotary selector switch AN Do not select any other test functionality Depress Test button in order to start the test Makes sure the test doesn t start and the re
8. of the meter The leakage value must fall within the appliance manufacturer s specifications or conform to other relevant standards typical values are shown in the chart opposite Release product switches and the LOAD TEST button as soon as a reading has been taken 24 Clare B255 Power Tool amp Appliance Test Station Operating Manual Earth Leakage Test Class 2 Double Insulated Products This test is intended as an alternative to the relevant Flash Test for equipment fitted with contactor relay or low voltage electronic start switching devices often referred to as dead mans handles i e typically those products that require the mains voltage to be present BEFORE any function switches can operate WARNING During the following test the equipment being measured will be in it s normal operating state Power tools and rotating machinery must be made safe BEFORE starting the test ensure that portable equipment is properly secure and that any moving parts are adequately guarded to prevent damage or injury Set the Test Selector to the Earth Leakage position connect the green clip lead to the green banana socket on the test output box Attach the clip end to the accessible metal of the item under test NOTE do not connect the clip to any moving parts Depress amp hold the LOAD TEST button Now operate the product function switch es for normal running the Earth Leakage current will be displayed on the 0
9. to indicate that no flash over has occurred at that point to which the probe tip is applied If the Flash FAIL lamp and audible alarm come on the insulation between the Line or Neutral paths and the point of test has failed to withstand the applied voltage The appliance must be considered unsafe It should be clearly marked to show this and withdrawn for full workshop investigation and repair It must be FULLY re tested following repair 23 Clare B255 Power Tool amp Appliance Test Station Operating Manual Earth Leakage Test Class 1 Earthed Grounded Products This test is intended as an alternative to the relevant Flash Test for equipment fitted with contactor relay or low voltage electronic start switching devices often referred to as dead mans handles i e typically those products that require the mains voltage to be present BEFORE any function switches can operate During the following test the equipment being measured will be in it s normal operating state Power tools and rotating A machinery must be made safe BEFORE starting the test ensure that portable equipment is properly secure and that any moving parts are adequately guarded to prevent damage or injury Set the Test Selector to the Earth Leakage position and then depress amp hold the LOAD TEST button Now operate the product function switch es for normal running the Earth Leakage current will be displayed on the 0 5mA lower scale
10. Ensure the B255 is positioned so that the mains supply lead can be easily disconnected from the mains supply 18 Clare B255 Power Tool amp Appliance Test Station Operating Manual 7 Test Application Output box must be plugged into the equipment before use AN The output box is required to enable equipment test functionality Before use confirm that the internal part of the interlock system functions correctly Check Instrument Integrity section for details A Before use confirm the B255 functions correctly Check Instrument Integrity section for details Visual Inspection Before applying any electrical tests a thorough visual inspection of the appliance must be carried out This may well form the greater part 75 or more of any test routine Casing Check for signs of undue wear cracks or dents missing components such as guards covers or hand grips etc Ensure that all screws and catches are present and secure Check for evidence of excessive dirt build up especially in and around any ventilation slots Also ensure that all movable guards operate smoothly Supply Lead Check for any signs of damage or fraying along the entire length This should also include any extension lead that may be regularly used with the appliance Ensure that any cable entry or connector is sound and secure Plugs and Fuses Thoroughly check plug tops for damage and ensure that all wires are correctly connected Ensure t
11. Hire Industry being BS EN 50144 for hand held power tools and BS EN 60335 1 for general appliances however clear guidance should be sought from the manufacturer or importer to determine appropriate requirements Earth Bond Continuity Most type testing standards including those referred to above require that the earth bond resistance between all accessible conductive surfaces and the Earthing terminal within the item does not exceed 0 1 Ohm Compliance should be checked by resistance measurement using a test current equal to 1 5 times the rated current or to 25A whichever is the greater from an a c voltage source not exceeding 12V In practice routine testing will always include the supply lead and the measurement will be made between the earth pin of the supply plug and exposed metal conductive surfaces of the tool As a generalisation most power tools will still meet the 0 1 Ohm limit and an earth bond resistance up to 0 3 Ohms may be acceptable when supply leads up to 5 metres in length are included This figure can be further increased by 0 1 Ohm for each additional 5 metres of supply lead length but this may also be dependent on the cross sectional area csa of the conductor being used NOTE Where exposed metal parts cannot be seen to form a continuos surface with all other exposed metal such as a metal grille in a plastic housing or aremote switch panel OR where moving guards or detachable accessories are also made o
12. OTE The Y250 must be kept with the instrument at all times and should be included in the full calibration programme Check Procedure Earth Continuity Connect and set up the Appliance Tester in the normal way and then plug the Y250 into the 13A test socket on the test output box Attach the Earth Return clip lead from the tester across BOTH of the metal tags on the simulator so that they are shorted together NOTE do not permanently short these tags by bending them together or creating a soldered link Set the test selector to Earth Test close the guard switch and depress the PRESS TO TEST push button for 3 seconds The instrument meter should indicate a value of approximately 0 2 Ohms on the upper scale Release the button 28 Clare B255 Power Tool amp Appliance Test Station Operating Manual Check Procedure Flash Test Trips AN Electric shock risk Do not touch B255 and Y250 during flash tests With the Pip lead still attached across the simulator terminals select 500v Flash and depress the Test button The green Flash PASS lamp should come on Release the Test button Now select 1250v Flash and depress the Test button This time the warning ee and the red Flash FAIL lamp should come on continuously Release the est button With 1250v Flash still selected now depress and hold the 10mA TRIP button and then depress the Test button This time the green Flash PASS lamp should come on Release both buttons Detach and put
13. ading on the scale remains at O position 29 Clare B255 Power Tool amp Appliance Test Station 9 Electrical Specification Earth Continuity Test Display Range Measured Range Accuracy Duration Recommended Duration Test Current 500V Flash Test Voltage Trip Current Duration Recommended Duration 1250V Flash Test Voltage Trip Current Duration Recommended Duration 3000V Flash Test Voltage Trip Current Duration Recommended Duration 3750V Flash Test Voltage Trip Current Duration Recommended Duration Load Test Display Range Accuracy Voltage Test Current Duration Leakage Test Display Range Accuracy Voltage Duration Operating Manual OQ to Infinity INF 0 to 12 10 of the reading Unlimited up to 5 seconds with 2 minute intervals up to 25A into 0 12 500v AC 10 5mA 10mA Unlimited up to 5 seconds 1250V AC 10 5mA 10mA Unlimited up to 5 seconds 3000V AC 10 5mA Unlimited up to 5 seconds 3750V AC 10 5mA Unlimited up to 5 seconds 0 to 25A 5 full scale 230V or 110V 50 60Hz up to 15A 230V up to 16A 110V Unlimited 0 to 5mA 5 full scale 230V or 110V 50 60Hz Unlimited 30 Clare B255 Power Tool amp Appliance Test Station Operating Manual 10 Maintenance A Under no circumstances should the enclosure covers be removed Ensure the B255 is kept dry with no surface moisture on eith
14. ation procedures and should not normally be re adjusted by the user Clare B255 Power Tool amp Appliance Test Station Operating Manual Accessories 1 Mains Lead fitted with a standard BS1363 square pin 13A plug top for connection to an Earthed supply outlet It is also recommended that the outlet is fitted with an RCD protection device Test Output Socket Box the standard box is fitted with sockets to accept 230V 13A and industrial 110V 16A plugs When testing 110V products an external supply source will be required to carry out Earth Leakage and Load Current tests Other connector combinations can be catered for as optional extras and to special order Earth Return clip lead this green clip lead is used to complete the Earth Continuity test path when testing Earthed Class 1 equipment the lead is not required when testing Double Insulated Class 2 equipment Flash Test Probe a high voltage safety probe for use when applying the 3000V and 3750V LN Probe flash tests to Double Insulated Class 2 products the probe is not required when testing Earthed Class1 equipment Fault Simulator used to check the correct operation of the Flash test trips and Earth Continuity measuring circuits This simple to use device should be used on a regular basis even daily to ensure that the B255 continues to provide accurate safety test results See under Operating Procedures for instructions
15. d receivers within a distance of 30 metres e Computer and other control equipment within a distance of 10 metres e Safety critical equipment i e the guarding of industrial machinery e The health of people in the surrounding area Of approximately 2 3 metres that is the use of hearing aids pacemakers etc e Delicate electronic equipment used for calibration or measurement The size of the surrounding area to be considered will depend on the overall structure of the building and other activities taking place It is important to note that the surrounding area may well extend beyond the boundaries of the premises Position the equipment with adequate ventilation and easy access to all sides of the equipment for maintenance purposes Generally this means not enclosing the equipment unless specifically designed so or burying it under other test equipment Clare B255 Power Tool amp Appliance Test Station Operating Manual Safe Application of Test Equipment Any person operating electrical test equipment should be 18 years or over and should have had adequate training in the use of the particular piece of equipment The degree of training should be appropriate for the competence and experience of the operator Position the test equipment in a clearly defined test area with access limited to the operator only Construct all test benches of insulated material preferably wood Use steel benches covered in insulating material under c
16. e or additional instructions to the above recommendations Clare B255 Power Tool amp Appliance Test Station Operating Manual 3 Environmental Conditions The B255 has been designed to perform tests and measurements in a dry environment Maximum barometric elevation at which measurements can be recorded is 2000m Contamination degree 2 according to IEC 61010 1 Protective system IP40 according to IEC 60529 Supply rating is specified as 240VAC 50HzZ 60Hz 16A Electromagnetic compatibility EMC Immunity and emissions interference conform to BS EN 61326 1 Operating temperature range of 5 C to 40 C without moisture condensation The B255 can be stored at any temperature in the range 25 C to 65 C relative humidity up to 90 Clare B255 Power Tool amp Appliance Test Station Operating Manual 4 Introduction to Safety Testing Under the requirements of the Health and Safety at Work Acts it is the responsibility of the supplier of electrical equipment to ensure that it is electrically safe The supplier can be the Manufacturer the Importer or the Hirer and by inference the Repairer Manufacturers and Importers generally satisfy their obligations by ensuring conformity to the relevant safety standards prior to placing the equipment on the market and have little or no further interest in the continuing in service maintenance and routine testing of the product other than in responding to customer feed back and enquiry
17. e presence of a high leakage suppression filter or high brightness neon in the supply circuit gives rise to a total leakage current in excess of the nominal 5mA at test voltage The appliance should be considered unsafe clearly marked as such and withdrawn for full workshop investigation and repair It must be FULLY re tested following repair NOTE Tools and appliances that fall into category c and some heavy duty equipment particularly the larger power tools such as 2500W angle grinders etc may have inherently higher leakages which require a pass level of up to 10mA at test voltage If this is the case and provided that the manufacturer advises testing this to a higher threshold the 10mA Flash trip can be employed Testing in this 10mA mode increases the hazard to the operator remember Do not touch the item under test To apply the Flash Test using the increased trip threshold first depress the red 10mA button and hold it in then also depress the white PRESS TO TEST button for 5 seconds in the normal way The green FLASH PASS lamp should light Release both buttons at the end of the 5 second test period If the appliance still fails and the FLASH FAIL lamp and alarm come on the product must be considered unsafe It should be clearly marked to show this and withdrawn for full workshop investigation and repair It must be FULLY re tested again following repair 22 Clare B255 Power Tool amp Appliance Test Sta
18. e protective conductor rather than the person holding the tool The protective conductor is the green yellow earth wire in standard 3 core mains supply leads Double Insulated equipment is referred to as Class Il All accessible conductive surfaces are additionally insulated from internal live parts and components No earth wire is present in the supply lead All such equipment is clearly identified by a prominent square within a square symbol Clare B255 Power Tool amp Appliance Test Station Operating Manual Test Requirements to Determine Electrical Safety The most appropriate way of verifying Electrical Safety is to carry out a series of routine Safety Tests that both reflect those tests used in the manufacturing process and particularly in the Hire Industry take into account the effects of normal wear and tear Visual Inspection It is important when carrying out routine testing to first check for signs of undue wear and tear by a thorough visual inspection a nick in the supply cable or a cracked casing etc can easily lead to hazardous situations when the power tool or appliance is in use Electrical Safety The tests to verify satisfactory earth bonding and insulation levels will depend on a The basic construction of the tool Class Earthed or Class II Double Insulated and b The original standard that it was manufactured to the most common British Standards relating to equipment used in the
19. ents during the application of the test supply voltage Set the Test Selector to any of the safety test ranges but NOT Earth Leakage Depress amp hold the LOAD TEST button and then operate the product allow sufficient time for the product to reach a steady state condition and then read the current being indicated on the 0 25A middle scale of the meter To improve readability of low current values below 2 5A also depress the 2 5A button to expand the readout range the previous value is now multiplied by 10 The indicated value should be within the limits specified by the manufacturer for off load operation 26 Clare B255 Power Tool amp Appliance Test Station Operating Manual Fault Indication A zero current reading and non operation of the product may indicate an open circuit Line or Neutral path release the test button first and check that switches on the product operate correctly If the switches appear to operate correctly there may be a break in the supply lead and if this is the case any previous safety tests will be invalid On the other hand if any switches are not operating correctly they may well have been OFF during the safety tests again creating an invalid test In either case complete re testing will be required once the problem has been resolved A current in excess of the manufacturer s specifications may indicate among other things a short circuit heating element out of balance field coil windings
20. equipment specifications and descriptions outlined in this publication without prior notice No part of this publication shall be deemed to form or be part of any contract for the equipment unless specifically referred to as an inclusion within such contract Clare B255 Power Tool amp Appliance Test Station Operating Manual Disposal of Old Product This product has been designed and manufactured with high quality materials and components that can be recycled and reused When the crossed out wheelie bin symbol is attached to a product it means the product is covered by the European Directive 2012 19 EU Please familiarise yourself with the appropriate local separate collection system for electrical and electronic products Please dispose of this product according to local regulations Do not dispose of this product along with normal waste material The correct disposal of this product will help prevent potential negative consequences for the environment and human health User Note AN These Operating Instructions are intended for the use of Competent Personnel Clare B255 Power Tool amp Appliance Test Station Contents Declaration of Conformity 2 General Guidance Notes Safety Installation and use of Test Equipment Assessment of Test Area Safe Application of Test Equipment Maintenance Summary of Safety Information 3 Environmental Conditions 4 Introduction to Safety Testing Methods of Construction for Electrical Safet
21. er the enclosure or cable assemblies The B255 enclosure should be regularly inspected to ensure no deep scratches or physical damage has occurred The B255 cable assemblies and accessories should be regularly inspected to ensure no deep scratches or physical damage has occurred If any of the above conditions have been observed then the B255 must be disconnected from any test or measurement functional testing and secured to prevent any further use 11 Cleaning Clean the external case of the B255 with a clean dry cloth Avoid using solvents and abrasive scouring agents to clean the external case of the B255 31 Clare B255 Power Tool amp Appliance Test Station Operating Manual 12 Additional Information Useful Reference Material The following short list of British Standards Legislative Documents and Guidance Notes is intended as a pointer to reference material that will assist in a greater understanding of the whys and wherefores of Electrical Safety Testing References made to such documents within this Manual are for guidance and illustration only and as such are generalised interpretations of the spirit of the various regulations If any conflict arises from the text of this Manual then the relevant Standards or Legislation must take precedence Statutory Legislation The Health and Safety At Work Act 1974 ISBN 0 10 543774 3 The Electricity At Work Regulation 1989 ISBN 0 11 096635 X The Plugs and Sockets Safety Reg
22. ertain circumstances only The item under test must be on an insulated surface where possible as with large or unwieldy items this may not be possible Do not touch or come into contact with the instrument case or any other Earthed metalwork for example conduit or metal AN trunking etc whilst applying the safety tests The operator should also be on an insulated surface such as British Standard approved rubber matting or nail free duckboard h The item under test must not be touched whilst the flash tests are applied This instrument incorporates an ac Flash trip device that defaults to 5mA The trip mechanism operates within 10 milliseconds to safeguard the operator and make the flash test non lethal and non destructive Maintenance Seaward Electronic Ltd supplies a guarantee against defective material and faulty manufacture for a twelve month period from the date of delivery Prior to despatch the equipment undergoes careful inspection and comprehensive testing Report any defect discovered with the equipment in respect of materials or workmanship within the guarantee period We undertake to put right the defect at our expense subject to our standard conditions of sale Our responsibility is limited in all cases to the cost of making good the defect in the equipment This does not apply to defects caused by abnormal conditions of working accident misuse neglect or wear and tear Clare B255 Power Tool amp Appliance Test S
23. est Station Operating Manual DECLARATION OF CONFORMITY As the manufacturer of the apparatus listed declare under our sole responsibility that the product B255 To which this declaration relates are in conformity with the relevant clauses of the following standard BS EN 61010 1 2010 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements BS EN 61326 1 2013 Electrical equipment for measurement control and laboratory use EMC Requirements Performance The instrument operates within specification when used under the conditions in the above EMC and Safety Standards The product identified above conforms to the requirements of Council Directive 2004 108 EC and 2006 95 EC This conformity is indicated by the symbol i e Conformit Europ enne Seaward Electronic Ltd is registered under BS EN ISO9001 2000 Certificate No Q05356 Clare B255 Power Tool amp Appliance Test Station Operating Manual 2 General Guidance Notes Safety The design of the B255 Portable Appliance Tester meets the European Commission Directive No 2006 95 EC relating to the Low Voltage Directive This is in accordance with BS EN 61010 1 2010 Safety requirements for electrical equipment for measurement control and laboratory use This unit is also compliant with EN 50191 Draft The user MUST follow the remainder of this section on safety installation guidance a
24. f metal measurements must be taken from all surfaces back to the Earth pin of the plug top 10 Clare B255 Power Tool amp Appliance Test Station Operating Manual Electrical Insulation To check the insulation between the live conductors Line and Neutral and all exposed metal surfaces a high voltage a c Flash Test is applied The voltage will depend on the construction class of the tool or appliance 1250V for standard Class Earthed tools and appliances 3000V for routine testing of Class II double insulated equipment 3750V for Class II equipment following repair or reconditioning operations A Caution 230V and 110V test sockets are also used as sources of flash test voltage of up to 1250V Under normal conditions the leakage current at the appropriate Flash Test voltage should not exceed 5mA Some Class equipment may suffer from the effects of high capacitive leakages associated with exceptionally long supply leads or certain methods of suppression filtering or a combination of the two Under these conditions a reduced test voltage of 500V or an increased leakage level of up to 10mA may be permissible if in doubt advice must be sought from the equipment manufacturer All safety tests must be carried out with the supply switch of the tool or appliance in the ON position to ensure that all live parts are included when checking insulation Multi function tools and appliances must be FULLY tested with supply
25. hat cable grips and strain relief bushes are properly secure Check that the correctly rated fuses are fitted even a 5A fuse fitted in place of a recommended 3A fuse may give rise to a potentially dangerous fault condition Clare B255 Power Tool amp Appliance Test Station Operating Manual Switches and Function Selectors Ensure that all switches including rotary selector devices operate smoothly and in the expected manner Set supply switches to the ON position in preparation for the Safety Test Multi function appliances such as a two heat two speed heater will require testing in each operating mode Any fault or irregularity found by the visual inspection must be corrected BEFORE electrical testing is carried out Electrical Safety Tests General Remember Electrical safety testing can be dangerous Ensure that you are aware of all potential hazards Plug the power cord of the product to be tested into the appropriate 230V 13A or 110V 16A socket on the Test Output Box Various other test socket combinations can be supplied as optional extras or alternatively adaptors to convert the relevant socket to suit other equipment plug styles can be used if required If intending to apply Earth Leakage and Load Run tests to 110V equipment ensure that a suitable external 110V safety isolating supply is connected to the 110V 32A Inlet on the back panel of the test set The B255 is mainly intended for single phase equipment b
26. ht shows that a test is being applied A pre wired status beacon can be supplied as an optional extra c 110V 32A Inlet when applying Earth Leakage or Load Current tests to 110V industrial equipment an external supply source is required Any standard single phase 240 110V safety isolating transformer can be used provided that it has a VA rating to suit the product s to be tested 15 Clare B255 Power Tool amp Appliance Test Station Operating Manual 6 Set Up Procedures RCD protect supply outlet Earth free partition walls Storage for test leads Insulated bench top and flooring Access barrier with guard switch FIG 4 Suggested Test Area The Test Area Appliance testing can be hazardous and various common sense precautions must be observed Never come into bodily contact with an appliance being tested Ensure that the test area is clearly defined and offers limited access to persons other than the tester At the same time it is advisable to have somebody else in the near vicinity who can give assistance should anything go wrong Ensure that the appliance to be tested is on an insulated workbench never use a metal bench a robust wooden bench with a securely fitted rubberised worktop is best The floor surface of the test area should also be insulated with rubber matting to provide protection to the operator and to permit larger equipment to be stood on the floor for testi
27. l Instrument Set Up Ensure that the rotary Test Selector switch is set to either STANDBY position Connect the supply lead into the Supply socket on the back of the instrument and connect to an Earthed 230V 50Hz supply outlet It is recommended that the outlet to be used is protected with an Earth Leakage Circuit Breaker Switch on the instrument by firmly depressing the green button on the front mounted SUPPLY switch the green button will light and if the status beacon is connected the green beacon lamp will also light to warn that the test set is powered up The following set up procedure may need the use of a small flat bladed screwdriver Ensure that the green Earth Return clip lead is isolated not clipped to anything and set the rotary Test Selector to EARTH TEST Close the Guard switch the red beacon light will come on to warn that a test is about to be applied Depress the white PRESS TO TEST button and watch the pointer on the panel meter It should move up scale to the right and come to rest on the INF mark if it does no adjustment is necessary Release the test button If the meter pointer doesn t reach the INF mark keep the test button depressed and use a small flat bladed screwdriver to adjust the SET INF control see FIG 1 Item 2 on page 20 until the pointer is correctly set Release the test button Reset the test selector to the STANDBY position The test set is now ready for test application
28. nd maintenance to guarantee safe operation and to maintain the equipment in a safe condition Any interruption of the protective earth conductor mains A input earth inside or outside the equipment is likely to make the equipment dangerous The user must not intentionally interrupt the protective earth conductor When connected to the mains supply internal terminals of the equipment may be live and the opening of covers or removal of parts is likely to expose live parts The user must disconnect the equipment from ALL voltage sources before any adjustment replacement maintenance or repair The user must not use makeshift fuses or short circuit fuse holders The user should carry out manual handling of test equipment in accordance with regulatory guidance notes That is those supplied by the Health amp Safety Executive or Croner s and the Health amp Safety at Work Act h Caution risk of electric shock Indicates instructions must be followed to avoid danger to persons Caution risk of danger The operating instructions must be adhered in order to avoid danger Always use B255 with accessories and cable assemblies provided If the B255 is used in a manner not specified by this document then the protection provided by the equipment may be impaired A Do not touch equipment under test during tests Clare B255 Power Tool amp Appliance Test Station Operating Manual Installation and use of Test Equipment Electrical safe
29. ng Walls and partitions should also be made of insulating materials Arrange the test bench so that test instrument controls can be operated without having to reach over or lean across the tool or appliance during testing This is particularly important when testing motorised equipment such as drills and lawn mowers etc Ensure adequate warning to others that testing is in progress The B255 is fitted with a beacon port which can be used to drive a standard 2 lamp beacon available as an optional extra If used this should be sited so that it can be clearly seen by other people in the immediate vicinity of the test area 16 Clare B255 Power Tool amp Appliance Test Station Operating Manual It is recommended that the supply sockets in workshops and especially those used in any test area are protected by an Earth Leakage Circuit Breaker Ensure that the person responsible for testing is competent and fully trained in both the general principles of Safety Testing and the correct use of the required test instruments or is closely supervised by someone of the required competence Never leave an appliance connected to the test set when un attended Always check that the intended test is suitable for the appliance if the Class Il Double Insulated symbol is not clearly visible the appliance must be assumed to be of Class Earthed construction Some electronic equipment may not be constructed to withstand the high cu
30. ply Switch an illuminated two button device for controlling the incoming supply to the instrument Firmly depress the upper green button to turn the instrument ON button illuminates and the lower red button to turn it OFF This switch also acts as a miniature circuit breaker mcb to protect internal wiring Flash Test Result indicators a green PASS lamp and red FAIL lamp indicate test status whenever any of the Flash tests are applied a flash fault is also indicated by a high pitched audible alarm Safety Test buttons the white momentary action PRESS TO TEST button is used to apply the selected Earth or Flash test The adjacent red 10mA button can be used to increase the standard 5mA trip level for the 500V and 1250V LN E tests only this button must be depressed and held BEFORE the main TEST button is depressed Load Test buttons the LOAD TEST button is used to apply mains voltage to the product under test and the resultant run current is displayed on the middle 0 25A scale For readings below 2 5A the meter range can be expanded to read 0 2 5A full scale by also depressing the 2 5A button The LOAD TEST button is also used to apply a selected EARTH LEAKAGE test which again requires the product to be powered The measured leakage current will be displayed on the lower 0 5mA meter scale 8 Set Zero control used to set mechanical zero on the meter This is carried out during factory build and calibr
31. rating plate which is the maximum on load current The advice of the equipment manufacturer should be sought for meaningful current values for all functions including off load running The manufacturer can also sometimes provide useful tips and hints as to the probable causes for out of limit readings A satisfactory load test as well as showing that the tool runs or operates also acts to validate the preceding Flash Test by proving that the supply switch was ON and the circuit complete 5 Introducing the B255 i SAFETY TEST ater to Uner Manual for Range Selection and Tet Procedures PRESS To TEST q a USE wm CAUTION DO oT HAND FIG 1 Facia Controls 12 Clare B255 Power Tool amp Appliance Test Station Operating Manual Facia Controls 1 Display Meter multi scale meter to show Earth Circuit Resistance Load Current and Leakage Current values Set Inf Control used for setting the full scale INF indication of the meter to compensate for mains fluctuations or differences from location to location Please refer to Set Up Procedures for adjustment details Test Selector a rotary switch for selecting the required test When connecting or disconnecting items to be tested OR when the instrument is to be left un attended or tests are not being applied always set this switch to one of the STANDBY positions the test buttons are then disabled Sup
32. roduct and routine re testing procedures Training The Seaward Training Department have formulated a variety of courses covering all aspects of Electrical Safety Testing from choosing the right equipment to safe test areas to meaningful test application etc Courses are generally designed to be held at the customer s facility and include comprehensive course notes and practical demonstrations with all trainees participating in hands on practical sessions For full details please contact our Training Department 33 Clare B255 Power Tool amp Appliance Test Station Operating Manual For Technical Support Contact Tel 44 0 191 587 8718 For Service and Calibration Contact Service Department Seaward Electronic Ltd Unit 11 Bracken Hill South West Industrial Estate Peterlee Co Durham SR8 2LS England Tel 44 0 191 587 8739 Fax 44 0 191 587 8737 E mail service seaward co uk CLARE is a division of E SEAWARD 34 465A551 Rev 3
33. rrent earth bond or high voltage flash tests applied by this instrument IF IN DOUBT refer to the appliance manufacturers recommendations or seek qualified advice Instrument Wiring and Connections Site the instrument in accordance with the General Guidance Notes and other recommendations elsewhere in this Manual and to satisfy operator safety and ease of use Connect the Test Output box to the rear mounted outlet on the instrument and site the connector box within the test area for easy access Wire your Guard Interlock Safety switch circuit to the input socket on the rear panel using the plug top supplied if no safety interlock is to be employed the plug must be fitted with a shorting link otherwise the instrument won t work Wire your status beacon to the Beacon Port on the rear panel again using the mating plug top supplied Position the beacon so that it can be clearly seen outside the test area To fully test 110V products connect the output lead from your external 240 110V isolating transformer into the 110V Inlet connector on the rear panel of the instrument Connect the Earth Return clip lead and Flash test probe into their respective sockets on the rear panel It is recommended that provision is made within the test area for storage of the clip and probe when not in use rather than just leave them thrown down on the bench top Clare B255 Power Tool amp Appliance Test Station Operating Manua
34. t other tests The high Earth test current will cause a certain amount of self heating to both the appliance wiring and the test circuitry To keep this within acceptable limits and prevent over heating A Do not apply earth tests for more than 5 seconds or more than 2 tests per minute NOTE Where exposed metal parts do not form part of a continuous surface with all other exposed metal the Earth test must be repeated with the earth clip attached to each exposed metal surface in turn Flash Test Line Neutral to Earth The supply switch of the tool or appliance must be in the ON position to ensure that all live parts are included when applying a Flash test For contactor or electronic start products refer to the Earth Leakage section Set the Test Selector to 1250V LN E for most normal equipment 500V LN E for heavily suppressed equipment Flash testing can be hazardous Do not touch the product under test Depress the PRESS TO TEST button and observe the TEST RESULT lamps The green FLASH PASS lamp should come on If the red FLASH FAIL lamp glows and the audible alarm sounds one of the following conditions is indicated a The insulation is unsatisfactory permitting a leakage current in excess of the nominal 5mA at test voltage 21 Clare B255 Power Tool amp Appliance Test Station Operating Manual b A flash over has occurred between the Earth path and one or other of the Line and Neutral paths c Th
35. tation Operating Manual Please take adequate care with packing and arrange insurance cover against transit damage or loss when returning the instrument if possible use the original packing box and supports Regularly calibrate all test equipment to meet internal quality or regulatory licensing authority requirements and to keep the equipment in a safe working condition Return the equipment to Seaward Electronic Ltd for this purpose Keep the equipment in a clean condition Examine all input and test output leads and connectors regularly to guarantee they are in a safe working condition The equipment contains parts that are specific to the equipment only therefore order spare parts from the address on the previous page Seaward Electronic Ltd strictly forbid any use of spare parts other than those acquired from the original manufacturer Summary of Safety Information Should there be any doubt about location setting up procedure or operation of the test equipment contact Seaward Electronic Ltd Report any apparent malfunctions immediately Maintain the test equipment in accordance with Health and Safety at Work Act and the Electricity at Work Regulations The supply socket used for connection to the incoming mains system should undergo earth loop impedance measurements in keeping with the regulations to guarantee safe operation NOTE Your Health and Safety Inspector may with the benefit of on site observations offer alternat
36. tion Operating Manual Double Insulated Class II Equipment This test requires the use of the safety Flash Test probe This has a retractable tip which is exposed by depressing the red button on the handle The supply switch of the tool or appliance must be in the ON position to ensure that all live parts are included when applying a Flash test For contactor or electronic start products refer to the Earth Leakage section Ensure that the appliance is secured and positioned so as to allow access to the various test points Flash Test Line Neutral to Probe Set the Test Selector to 3000V LN Probe for routine re testing 3750V LN Probe for repaired or reconditioned equipment Do not allow bodily contact with the appliance its supply lead or the flash probe tip when the following tests are being applied Depress and hold the PRESS TO TEST button and apply the Flash Probe tip to all exposed metal surfaces screw heads casing joints and around switches and cable entries In short anywhere on the outer surface of the product that may become live if an internal fault was present i e loose strands of wire touching exposed metal or poking through body mouldings etc If during testing it becomes necessary to move the appliance for easier access to a test point Remove the probe and release the test button first At each test point observe the TEST RESULT lamps the green FLASH PASS lamp should be on and remain on
37. ty tests particularly Flash Tests are required to comply with Legislative Documents on electrical and electronic product testing which may encroach the EMC Electromagnetic Compatibility requirements This standard came into effect on 1st January 1996 The design of the test equipment will minimise the effects of electromagnetic disturbances but some interference may result from particular applications dependent on the type of product being tested Therefore the user is responsible for installing and using the test equipment according to the manufacturers instructions The user of the test equipment is responsible for detecting electromagnetic disturbances and must resolve the situation with the technical assistance of the manufacturer In some cases it may involve constructing an electromagnetic screen Faraday cage enclosing the test equipment and test pieces complete with associated input filters The user should achieve a reduction in electromagnetic disturbances to a point where they are no longer troublesome Assessment of Test Area Before installing the test equipment the user shall make an assessment of potential electromagnetic disturbance problems in the surrounding area and take the following points into account e Supply cables other than those supplying the test equipment control cables signalling and telephone cables These can be above below or adjacent to the test equipment e Radio and television transmitters an
38. ulation 1987 ISBN 0 11 076603 2 Health amp Safety Executive Guidance Notes Protection Against Electric Shock GS27 Electrical Test Equipment GS38 Electrical Testing HS G 13 Memorandum on the Electricity at Work Regulations 1989 HS R 25 The Safe Use of Portable Electrical Apparatus PM 32 British Standards BS EN 2754 Construction of electrical equipment for protection against electric shock BS EN 50144 Hand held electric motor operated tools BS EN 60335 1 Safety of Household and similar electrical appliances The British Standards Institute publishes an extensive list of other standards relevant to electrical equipment under the designation SL 26 Certain trade organisations and manufacturers also publish useful how to guides and Codes of Practice with particular emphasis on their member or customer requirements or product line 32 Clare B255 Power Tool amp Appliance Test Station Operating Manual Useful Addresses British Standards Institute Head Office 389 Chiswick High Road LONDON W4 4AL 0208 996 9001 Health and Safety Executive Information Centre St Hughs Centre Trinity Road BOOTLE Merseyside L20 3QY 0870 154 5500 H M Stationary Office PO Box 276 LONDON SW8 5DT 0870 600 5522 Hire Association Europe 2 Holland Road West Waterlink BIRMINGHAM B6 4DW 0121 326 6677 For product specific information the product manufacturer is the best source of technical information relating to their p
39. ut can be used for applying the Safety tests Earth and Flash to 3 phase equipment using appropriate adaptors however this instrument CANNOT be used to apply the Leakage and Load Run tests to 3 phase equipment Earthed Class I Equipment Earth Test Set the Test Selector to the Earth Test position Attach the green clip lead from the instrument to clean exposed metal on the appliance Good connections are essential for accurate measurement and to prevent any high current sparks occurring when the test button is depressed Depress and hold the PRESS TO TEST button for 5 seconds whilst observing the EC Ohms scale of meter For most power tools and appliances the meter reading will be below 0 1 Ohm within the white zone Readings up to 0 5 Ohms within the orange zone may be acceptable particularly when supply leads up to 5 metres in length are included although this may also be dependent on the cross sectional area csa of the conductor being used 20 Clare B255 Power Tool amp Appliance Test Station Operating Manual Readings in the red zone usually mean that the Earth wiring of the product is faulty and should be investigated further Similarly if the recorded readings show an increase in value from one routine test to the next it may indicate a loose connection corroded terminals or partially broken Earth wire Again further investigation may be required A Any faults must be repaired or corrected before carrying ou
40. y Test Requirements to Determine Electrical Safety Visual Inspection Electrical Safety Earth Bond Continuity Electrical Insulation Earth Leakage Current Functional Operation 5 Introducing the B255 Facia Controls Accessories Rear Panel Connections 6 Set Up Procedures The Test Area Instrument Wiring and Connections Instrument Set Up Operating Manual NOOO TAH A 10 10 10 10 11 11 12 12 13 14 15 16 16 17 18 Clare B255 Power Tool amp Appliance Test Station 7 8 9 Test Application Visual Inspection Casing Supply Lead Plugs and Fuses Switches and Function Selectors Electrical Safety Tests General Earthed Class l Equipment Earth Test Flash Test Line Neutral to Earth Double Insulated Class II Equipment Flash Test Line Neutral to Probe Earth Leakage Test Class 1 Earthed Grounded Products Earth Leakage Test Class 2 Double Insulated Products Typical Earth Leakage Values Load Run Current Measurement Fault Indication Instrument Integrity Calibration Operational Checks Check Procedure Earth Continuity Check Procedure Flash Test Trips Electrical Specification 10 Maintenance 11 Cleaning 12 Additional Information Useful Reference Material Useful Addresses Training Operating Manual 19 19 19 19 19 20 20 20 20 21 23 23 24 25 25 26 27 28 28 28 28 29 30 31 31 32 32 33 33 Clare B255 Power Tool amp Appliance T
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