Page 3 Limited Warranty & Limitation of Liability Seaward Group guarantees this product for a period of one year. The period of warranty will be effective at the day of delivery. In order to ensure the continued performance of this product Seaward recommends that this tester be serviced and calibrated on an annual basis, by Seaward Group or any of Seaward authorised service facilities using Seaward approved parts and components.
Page 4 Your Hal tester Your Hal tester Disposal of Old Product Disposal of Old Product This product has been designed and manufactured with high quality This product has been designed and manufactured with high quality materials and components that can be recycled and reused. materials and components that can be recycled and reused.
Page 5: Table Of Contents
Your Hal tester Table of Contents DECLARATION OF CONFORMITY ............. 6 BEFORE STARTING ................7 Safety ..................8 CHAPTER 1 INTRODUCING THE TESTER........10 Hal 100 ..................10 Hal 101 ..................11 Hal 102 ..................12 Hal 103 ..................13 Hal 104 ..................
Page 8: Before Starting
Upon receipt of your HiPot Tester Check, Observe and / or do the ng: - owing: - owing: - owing: - following: - H100 Part H100 H100 H100 H100 H101 H101 H101 H101 H102 H101 H102 H102 H102 H103 H102 H103...
Page 9: Safety
Your Hal tester Safety Note Please read the following Safety Instructions before use! Safety Precautions The manual contains specific warning and caution statements where they apply. A Warning will identify the conditions and actions that pose hazard(s) to the user. A caution will identify the conditions and actions that may damage the Tester.
Page 11: Chapter 1 Introducing The Tester
Hal 101 The Hal 100 provides a comprehensive range of Earth / Ground Bond The Clare Hal 101 Tester is a powerful tool to assist in the analysis of the safety of electrical and electronic equipment. A range of tests are tests for use in production lines and type testing laboratories.
Page 12: Hal 101
Your Hal tester Hal 102 The Clare H102 HiPot Tester is an extended product range which encapsulates not only all the benefits and versatility of the original Hal HiPot Tester but also includes more pairs of output test terminals to facilitate multi-channels/multi-points testing capability.
Page 13: Hal 102
Your Hal tester Hal 103 The Clare Hal 103 Safety Electrical Tester is a powerful tool to assist in the analysis of the safety of electrical and electronic equipment. A range of tests are provided, with innovative features to aid difficult test situations, which allow testing of a wide variety of equipment.
Page 14: Hal 103
Your Hal tester Hal 104 The Clare Hal 104 Safety Electrical Tester is a powerful tool to assist in the analysis of the safety of electrical and electronic equipment. A range of tests are provided, with innovative features to aid difficult test situations, which allow testing of a wide variety of equipment.
Page 15: The Front Fascia
Your Hal tester The Front Fascia The user is provided with a 320 x 240 1/4 VGA Graphical Liquid Crystal Display (LCD). To the bottom of the screen are four function keys which allow the user fast access to options displayed on the Display There is a rotary encoder used to navigate the menus.
Page 16: The Rear Panel (Hal101)
Your Hal tester The Rear Panel (Hal101) Beacon – For connection to external warning beacon (optional item). Comms 1 – Communication port 1 for connection to a PC. Comms 2 - Communication port 2 for connection to a compatible Barcode reader or scanner. Comms 3 - Communication port 3 for connection to a Printer.
Page 17: The Rear Panel (Hal 102)
Your Hal tester The Rear Panel (Hal 102) Beacon – For connection to external warning beacon (optional item). Comms 1 – Communication port 1 for connection to a PC. Comms 2 - Communication port 2 for connection to a compatible Barcode reader or scanner.
Page 18: The Rear Panel (Hal 103)
Your HAL tester Your Hal tester The Rear Panel (Hal 103) Beacon – for connection to external warning beacon. Comms 1 – Communication port 1 for connection to a PC. Comms 2 - Communication port 2 for connection to a compatible Barcode reader or scanner.
Page 19: The Rear Panel (Hal 104)
Your Hal tester The Rear Panel (Hal 104) F20A(HRC) F16A(HRC) Aux Input 80-300V 50-60 Hz Beacon – for connection to external warning beacon. Comms 1 – Communication port 1 for connection to a PC. Comms 2 - Communication port 2 for connection to a compatible Barcode reader or scanner.
Page 20: Definitions
These are used to select menu options displayed on the screen. Tester - The Clare Hal 100 101 102 103 and 104 Un-powered Tests - The EUT is the subject of electrical tests using stimuli generated within the Tester.
Page 21 Your Hal tester Editing User Level and Novice Mode The Tester is delivered with the default setting of novice user level. To change this setting: from the MAIN MENU select SETUP, select EDIT USER LIST/OPTIONS, select USER (Name) from list, select USER LEVEL, select the desired level by selecting either NOVICE or ADVANCED.
Page 22 Your Hal tester Using Symbols in Text Fields Although there is an option to use non-ASCII symbols as Product numbers, Site & Location descriptions, User names and comments does not guarantee that your computer software will support them. If you are unsure avoid using symbols. 15 Digit Restriction The maximum Product ID length is 15 characters while the maximum line for the comments is extended to 20 characters per line.
Page 23: Chapter 2 Connecting The Tester
Your Hal tester Chapter 2 Connecting the Tester Connecting the tester The Tester may be powered by either a 230V or an 115V supply. This is selected on the rear panel of the instrument. The supply must include an earth connection (e.g. via a 3-pin plug). When switched on, the Tester will carry out a short self-test procedure (approximately 2 seconds).
Page 24: Chapter 3 Using The Tester
Your Hal tester Chapter 3 Using the Tester Introduction Once the start-up procedure of the Tester has been completed, the following screen will appear: - Navigation through the menus is by dedicated keys: - Function Encoder Cursor Right Cursor Down Encoder anti- Cursor Left Cursor Up...
Page 25 Your Hal tester At every start-up the System Setup is Password Protected if a password has been set up. To select an option from the Main Menu, use the encoder or the relevant fast keys command. The selected option will be highlighted by a light-coloured bar. The highlighted selection is activated by pressing the Green button.
Page 26 Your Hal tester How to..The remainder of this chapter has been sub-divided into sections to describe the Tester in terms of the essential functions to be performed. A summary is shown below: - • How to perform Automatic tests •...
Page 27: How To Perform Automatic Tests
Your Hal tester How to perform Automatic Tests Warning: In order to prevent any unwarranted safety hazards occurring during testing, ensure that the appropriate test conditions are set in accordance to requirements. Proper safety procedures must be in place before performing any Automatic test. It is important to establish the setup of the current or default test settings in relation to the test conditions formatted.
Page 28 Your Hal tester Depending on the System Configuration setup and Test type setup different prompt responses may be displayed e.g. Enter Password, Select Test options lists etc. Once the Product data is entered press Green to display the test Meter screen.
Page 29 Your Hal tester Test Settings If the user has not fixed the test type in the system configuration the Select Test settings menu will be display each time after New Test is pressed and the product number entered. The user has the ability to: - - Set a specific test sequence by selecting DEFAULT SEQUENCE - Allow use of TESTCODES to determine the test to be carried out - Use any preprogrammed sequences for specific EUTS, e.g.
Page 30 Your Hal tester Default Sequence When you first enter this menu all of the previous values are displayed and one of the field descriptions is highlighted. Use the encoder highlight a field to be changed and press the Rotate Field fast key to activate the encoder. Rotate Field will be highlighted. Turning the encoder will now cycle through all the available values for the field.
Page 31 Your Hal tester The second column holds the test ramp profile times (3 fields) for completing a level of test sequence: Time up or Ramp Time (to terminal voltage) Time Hold (for the test at terminal voltage) Time Down (for final terminal voltage) The third column indicates the terminal voltage (corresponds to Time up) that the test should ramp to after the ramp up time is reached, and the second voltage (corresponds to Time Down) is the final termination...
Page 32 Your Hal tester caution Therefore you must take while selecting (linking) this test repeat loops especially when other levels of test sequence may not be of the same test type nature e.g. DC IR , DC Hipot etc. For H102 only integers Notice that the 1 test sequence level will show the...
Page 33 Your Hal tester For all units: - The last icon denotes the Start conditions for the test. They are as Fig. 1. Reset External safety guard switch to ‘Closed’, followed by pressing Green to start each repeat of the test. (Start Ext+Green) 2.
Page 34 Your Hal tester Use Test codes This option bypasses the need to edit a specific test sequence, allowing direct entry of a Test code through the barcode scanner. From the Select Test Setting menu choose Use Test codes or press Use Tcodes fast key.
Page 35 Your Hal tester Perform Test Use the encoder to highlight the OK field and press Green to perform the test. Pressing the Red Button will return to the previous menu. The screen will change to the Meter Display (see separate section - How to use the Meter Display for an explanation).
Page 36 Your Hal tester However if an Abort warning signals during any test indicating an interruption detected due to Over current, Arc detected or any other reason that causes a tester system fault the test will be aborted immediately with the buzzer beeping continuously until the Green or Reset button is pressed.
Page 37 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Your Hal tester Options after Test Options after Test Options after Test Options after Test Options after Test The options menu is selected by entering ‘After Test: Menu’ in the The options menu is selected by entering ‘After Test: Menu’...
Page 38 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Your Hal tester Download Test Results Download Test Results Download Test Results Download Test Results Download Test Results When selected a Download Options menu displayed will allow user to When selected a Download Options menu displayed will allow user to When selected a Download Options menu displayed will allow user to When selected a Download Options menu displayed will allow user to...
Page 39: Restart Test
Your Hal tester Your Hal tester Your Hal tester Abort Actions Abort Actions Abort Actions During an Automatic test, opening the guard switch or pressing the During an Automatic test, opening the guard switch or pressing the During an Automatic test, opening the guard switch or pressing the Red Button immediately stops the test in progress and displays the Red Button immediately stops the test in progress and displays the Red Button immediately stops the test in progress and displays the...
Page 40: How To Use The Meter Display
Your Hal tester Your Hal tester Your Hal tester Your Hal tester How to use the Meter Display How to use the Meter Display How to use the Meter Display How to use the Meter Display The Meter screen is displayed prior to tests commencing in both The Meter screen is displayed prior to tests commencing in both The Meter screen is displayed prior to tests commencing in both The Meter screen is displayed prior to tests commencing in both...
Page 41 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Leak Hi – this is the upper limit for the leakage current. Leak Hi – this is the upper limit for the leakage current. Leak Hi – this is the upper limit for the leakage current. Leak Hi –...
Page 42 Your Hal tester Your Hal tester Your Hal tester Your Hal tester The bar graphs are clearly marked, and include dashed lines to indicate The bar graphs are clearly marked, and include dashed lines to indicate The bar graphs are clearly marked, and include dashed lines to indicate The bar graphs are clearly marked, and include dashed lines to indicate the limit points.
Page 43 Your Hal tester Your Hal tester Sample Automatic Mode Meter Display Sample Automatic Mode Meter Display The screen will be similar to that for manual mode as described earlier. The screen will be similar to that for manual mode as described earlier. However there are a number of extra features denoted as follow:- However there are a number of extra features denoted as follow:- line (18) –...
Page 44: How To View (Search) Test Results
Your Hal tester Your Hal tester Your Hal tester How to view (search) Test Results How to view (search) Test Results How to view (search) Test Results To view test results stored in memory, press View Data fast key or use To view test results stored in memory, press View Data fast key or use To view test results stored in memory, press View Data fast key or use the encoder to highlight the View Test Results option on the Main Menu...
Page 45 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Search result through Site Name Search result through Site Name Search result through Site Name Search result through Site Name At the Search for Data menu highlight Site and press Green to display At the Search for Data menu highlight Site and press Green to display At the Search for Data menu highlight Site and press Green to display At the Search for Data menu highlight Site and press Green to display...
Page 46 Your Hal tester Your Hal tester Your Hal tester Search result through User Name Search result through User Name Search result through User Name At the Search for Data menu highlight User and press Green to display At the Search for Data menu highlight User and press Green to display At the Search for Data menu highlight User and press Green to display the User list.
Page 47 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Date From Date From Date From Date From This option allows the user to search for test results after the selected This option allows the user to search for test results after the selected This option allows the user to search for test results after the selected This option allows the user to search for test results after the selected date.
Page 48 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Your Hal tester Start Search Start Search Start Search Start Search Start Search After all the search parameters have been set, press Start Search to After all the search parameters have been set, press Start Search to After all the search parameters have been set, press Start Search to After all the search parameters have been set, press Start Search to After all the search parameters have been set, press Start Search to...
Page 49 Your Hal tester How to perform Manual Tests Manual mode provides the user with direct access to the tests. In this mode individual tests can be selected and performed. Product numbers, sites, users and test codes can still be assigned to Products if required;...
Page 50 Your Hal tester Your Hal tester Your Hal tester Create Product Number Create Product Number Create Product Number This allows all manual tests performed to be stored against the Product This allows all manual tests performed to be stored against the Product This allows all manual tests performed to be stored against the Product number until the Product number is changed.
Page 51 Your Hal tester Your Hal tester Your Hal tester Performing a Manual Test Performing a Manual Test Performing a Manual Test After selecting the manual test display, you can set test parameters. After selecting the manual test display, you can set test parameters. After selecting the manual test display, you can set test parameters.
Page 52 Your Hal tester Your Hal tester If a Product Number has been created, the test result will be stored If a Product Number has been created, the test result will be stored under the entered number. To store tests to memory choose Enter under the entered number.
Page 53 – (H101, H102 & H103 only) Seaward super system, format – (H101, H102 & H103 only) Seaward super system, format – (H101, H102 & H103 only) Seaward super system, format – (H101, H102 & H103 only) Seaward super system,...
Page 54 Your Hal tester Your Hal tester Your Hal tester For downloading to a compatible Roll printer, including ‘till roll’ and For downloading to a compatible Roll printer, including ‘till roll’ and For downloading to a compatible Roll printer, including ‘till roll’ and thermal printers the user has the option of sending data as a thermal printers the user has the option of sending data as a thermal printers the user has the option of sending data as a...
Page 55: User Name
Your Hal tester Product Number When prompted enter a Product number to search for specific results. If the Product number field is left blank then the character ‘ * ’ will be inserted, indicating to search for all of the Products. See Fig. 8 Site Name Use the encoder to highlight a Site name and press Green to select the desired option.
Page 56 Your Hal tester Fig. 8 Fig. 9 Fig.10 Fig. 11 Printing NOTES search all When in Download data mode, do not by entering the character ‘ ’ for all the six fields as this would download (print out) all the product results for all the parameters indicated. This will not stop until all printing has completed.
Page 57 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Date From Date From Date From Date From This option allows the user to search for test results after the selected This option allows the user to search for test results after the selected This option allows the user to search for test results after the selected This option allows the user to search for test results after the selected date.
Page 58 Your Hal tester Your Hal tester Your Hal tester Search Search Search After all the search parameters have been set, connect the appropriate After all the search parameters have been set, connect the appropriate After all the search parameters have been set, connect the appropriate printer or device.
Page 59 Your Hal tester Your Hal tester Your Hal tester Your Hal tester How to print Barcode Labels and Test codes How to print Barcode Labels and Test codes How to print Barcode Labels and Test codes How to print Barcode Labels and Test codes The Hal is capable of printing barcode labels in conjunction with a The Hal is capable of printing barcode labels in conjunction with a The Hal is capable of printing barcode labels in conjunction with a...
Page 60 Your Hal tester Your Hal tester To print barcode Product & Test Type To print barcode Product & Test Type From the Barcode print menu select Product & Test Type, press Green From the Barcode print menu select Product & Test Type, press Green to display the product &...
Page 61 Your Hal tester Your Hal tester Your Hal tester How to use Setup How to use Setup How to use Setup To set up the Tester, use the cursor keys to highlight the Setup option To set up the Tester, use the cursor keys to highlight the Setup option To set up the Tester, use the cursor keys to highlight the Setup option on the Main Menu and press Green to display the following menu: - on the Main Menu and press Green to display the following menu: -...
Page 62 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Edit Test Settings Edit Test Settings Edit Test Settings Edit Test Settings This allows the user to add, modify, remove or confirm test settings This allows the user to add, modify, remove or confirm test settings This allows the user to add, modify, remove or confirm test settings This allows the user to add, modify, remove or confirm test settings that can then be selected during automatic testing.
Page 63 Your Hal tester Use the encoder to highlight a field to be changed and press Green to select the desired option. Use the fast key to highlight the desired field, and the encoder to cycle through the range of permissible values for the test parameter.
Page 64 Your Hal tester Your Hal tester Your Hal tester Your Hal tester PRINTING TESTCODES PRINTING TESTCODES PRINTING TESTCODES PRINTING TESTCODES WORKING…. WORKING…. WORKING…. WORKING…. On completion of downloading, the system will return to the Test On completion of downloading, the system will return to the Test On completion of downloading, the system will return to the Test On completion of downloading, the system will return to the Test Settings Editor menu.
Page 65 Your Hal tester Your Hal tester Your Hal tester Edit User List / Options Edit User List / Options Edit User List / Options Note Note Note If you change the name of the user during testing all of the If you change the name of the user during testing all of the If you change the name of the user during testing all of the previous tests will still be referenced to the old user name;...
Page 68 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Your Hal tester Edit Site List Edit Site List Edit Site List Edit Site List Edit Site List Note Note Note Note Note If you change the name of the site during testing all of the If you change the name of the site during testing all of the If you change the name of the site during testing all of the If you change the name of the site during testing all of the...
Page 69 Your Hal tester Your Hal tester Your Hal tester Your Hal tester Your Hal tester Edit Location List Edit Location List Edit Location List Edit Location List Edit Location List Note Note Note Note Note If you change the name of the location during testing all of the If you change the name of the location during testing all of the If you change the name of the location during testing all of the If you change the name of the location during testing all of the...
Page 70 Your Hal tester Your Hal tester Change Date / Time Change Date / Time This option allows the user to change the Date and Time. Use Rotate This option allows the user to change the Date and Time. Use Rotate Cursor (to select or deselect cursor tracking) and use encoder to move Cursor (to select or deselect cursor tracking) and use encoder to move to desired fields for edition.
Page 71: System Configuration
Your Hal tester Your Hal tester Your Hal tester System Configuration System Configuration System Configuration The Test Settings are included to cover the wide range of options that The Test Settings are included to cover the wide range of options that The Test Settings are included to cover the wide range of options that may be country or company specific.
Page 72 Your Hal tester On Test Failure: (Two options) • Failure Menu This gives user the option of having a menu for a failure within an automatic test sequence. The menu will give user the option of retrying a failed test (Restart Test), revise Product detail (Restart Product), end the test (End Product) and aborting the test on the product (Abort Product).
Page 73 Your Hal tester Your Hal tester Your Hal tester However the ‘next’ product ID details displayed after each test will However the ‘next’ product ID details displayed after each test will However the ‘next’ product ID details displayed after each test will depend on the Product Number options selected.
Page 74: Factory Settings
Your Hal tester Change Password It is possible to Password protect the Test Sequence Editor and the Country Settings. If you currently do not have password protection you will be asked to enter a new password twice, once for confirmation. If you currently do have password protection then you will be asked for the old password before entering a new one, again you will be asked for the new password twice.
Page 75 Your Hal tester Your Hal tester Your Hal tester Your Hal tester How to use the Memory How to use the Memory How to use the Memory How to use the Memory To use the memory tests and functions, use the encoder to highlight To use the memory tests and functions, use the encoder to highlight To use the memory tests and functions, use the encoder to highlight To use the memory tests and functions, use the encoder to highlight...
Page 76 Your Hal tester Your Hal tester Perform Memory Test Perform Memory Test Once the, 'Perform memory test', option is highlighted press Green. Once the, 'Perform memory test', option is highlighted press Green. The memory test checks all of the Product results against their The memory test checks all of the Product results against their checksums.
Page 77 Your Hal tester Your Hal tester Your Hal tester Delete Single Product Delete Single Product Delete Single Product Enter the Product number to delete a single Product and press Green. Enter the Product number to delete a single Product and press Green. Enter the Product number to delete a single Product and press Green.
Page 78 Your Hal tester Your Hal tester Clear Results Memory Clear Results Memory This option will delete (permanently) the entire test results of all This option will delete (permanently) the entire test results of all Products tested and currently stored in memory and should be used Products tested and currently stored in memory and should be used with CAUTION! with CAUTION!
Page 79 Your Hal tester Your Hal tester Your Hal tester How to Change User Name How to Change User Name How to Change User Name At the Main Menu screen select Change User and press Green (or At the Main Menu screen select Change User and press Green (or At the Main Menu screen select Change User and press Green (or press Change User fast key).
Page 80 Your Hal tester Your Hal tester Your Hal tester How to Change Site Name How to Change Site Name How to Change Site Name At the Main Menu screen select Change Site and press Green. Use the At the Main Menu screen select Change Site and press Green. Use the At the Main Menu screen select Change Site and press Green.
Page 81 Your Hal tester Your Hal tester Edit Location Name Edit Location Name To edit Location name see sections on How to use Setup & Edit To edit Location name see sections on How to use Setup & Edit Location list. Location list.
Page 82 Your Hal tester Your Hal tester Your Hal tester How to use Help How to use Help How to use Help The Tester is provided with an on-line help function, which can be The Tester is provided with an on-line help function, which can be The Tester is provided with an on-line help function, which can be called up at during the test screens by pressing the Help fast key.
Page 83 Your Hal tester Note: This topic will cover one or two pages depending on the connection options available (Insulation and Hipot can be Class 1 or Class 2). Each connection option will have a new page of information. Why tests fail The final page of information provides guidance on why a test may fail e.g.
Page 84 Your Hal tester Chapter 4 Tips & Troubleshooting Power -On Self tests: When the tester is powered on, a number of messages can possibly appear as the tester performs safety tests on itself and the mains power supply. Temperature monitoring The tester is provided with temperature monitoring facilities to ensure that prolonged tests do not overheat sensitive components.
Page 85 Your Hal tester Interfacing The Tester provides three interfacing ports: - For connection to a PC, printer or Barcode Reader To avoid any problems during download, ensure that leads are undamaged and correctly wired. The Connector pin-outs for Serial ports are shown below: - Parallel - The Hal range features a serial port.
Page 86 Your Hal tester Downloading to Computer Software Serial Port The serial port uses a standard 9-way D-type connector Description N.C. N.C. N.C. Baud Rate: 9600, 19200, 28800 (selectable) Start Bits: Data Bits Stop Bits: 1 (2 Scan) Parity: None Flow-control Xon/Xoff (not on Scan) Inter-character Delay: 20ms...
Page 87 Your Hal tester Chapter 5 Maintaining the Tester Cleaning the Tester The Tester case can be cleaned with a damp cloth, with if necessary, a small amount of mild detergent. Prevent excessive moisture around the socket panel or in the lead storage area. Do not allow liquid inside the Tester, or near the socket panel.
Page 88 Your Hal tester For Service and calibration contact:- Service Dept., Seaward Group. 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...
Page 89 Your Hal tester Your Hal tester Your Hal tester Accessory Accessory Accessory Accessory Accessory Part Part Part Part Part H100 H100 H100 H100 H101 H101 H101 H101 H100 H101 H102 H102 H102 H102 H102 H103 H103 H103 H103 H103 H104...
Page 90 Your Hal tester Your Hal tester Optional Accessories Your Hal tester Optional Accessories Part Accessory Number Optional Accessories Part Accessory Hipot Probe + lead 03918/2 Number Part Accessory Number Ground Bond Clip Lead 01521/1 Hipot Probe + lead 03918/2 Hand Held Guard Switch Hipot Probe + lead DCS317 03918/2...
Page 91 50/60 Hz 50/60 Hz Fuse Fuse 3 amps 250V H101 & H102 3 amps 250V H101 & H102 5 amps 250V H103 5 amps 250V H103 2 x 5 amps 250V, 2 x F16A HRC 300V, 2 x 20A HRC 300V HAL 104...
Page 92 Your Hal tester Your Hal tester Your Hal tester Earth / Ground Bond Test Earth / Ground Bond Test Earth / Ground Bond Test Test Voltage Test Voltage Nominal 6V AC Nominal 6V AC Frequency Independent of Supply Frequency Independent of Supply 50 or 60 Hz) 50 or 60 Hz) Test Voltage...
Page 93 AC HiPot Test AC HiPot Test Programmable Voltage Range Programmable Voltage Range 0.10 kV-5.00 kV (10V/Step) 0.10 kV-5.00 kV (10V/Step) 00 kV (10V/Step) Frequency Independent of Supply Frequency Independent of Supply 50 or 60 Hz 50 or 60 Hz or 60 Hz Voltage Display and Accuracy Voltage Display and Accuracy 0.10 kV-5.00kV ±1% ±...
Page 94 Your Hal tester Your Hal tester Powered Leakage Tests Powered Leakage Tests Your Hal tester Your Hal tester Power Output Rating Power Output Rating Test Voltage Test Voltage 110V – 230V AC 20A nominal (Vin- 110V – 230V AC 20A nominal (Vin- Vout) Vout) Maximum Power Output...
Page 95 Your Hal tester Mechanical Size 370mm x 300mm x 204mm Weight 15kg Environmental Operating 0ºC to 40ºC (non condensing) Storage -10ºC to 50ºC (non condensing) Maximum R.H Protection Level CAT II 300V Pollution Degree 1 as per EN61010-1...
Page 96: Insulation Test
Your Hal tester Appendix A Purpose of Tests Insulation Test Warning 1000V, 500 V, and 250 V D.C. test voltage This test is used to verify that adequate insulation exists between the mains supply pins and earth. During the insulation test, a HV DC voltage is applied between the earth pin and both the live and neutral pins of the Product mains supply plug.
Page 97 Your Hal tester Ground (Earth) Bond Test Caution 6V (no-load) 0- 40A AC test Current This test is to ensure that the connection between the earth pin in the mains plug of the appliance and the metal casing of the appliance is satisfactory and of sufficiently low resistance.
Page 98 Your Hal tester Powered Load and Leakage Test Caution The Powered Leakage tests provide four main measurements:- 1 - Power Measurement This is the power drawn when the EUT is supplied with the nominal MAINS voltage. 2 – Power Factor Power factor is often used to ensure that products using motors have been constructed correctly and that there is no likelihood that moving parts such as motor bearings have been damages or seated incorrectly.
Page 99 Your Hal tester Appendix B Reference Factory-set Test Sequences 1. Name - Default AC Hipot Rise Time – 2.0 s Hold Time – 10 s Fall Time – 2.0 s Output Voltage - 2.5 kV a.c. Low Trip Level – 7.0 mA High Trip Level –...
Page 100 H102 channel 1 – only relevant if the test code is at the top of a loop. If no channels are explicitly encoded for use then channel 1 will be used. H101 Digit 2 : Test Type ‘0’...
Page 101 Your Hal tester H102 Digit 2 : Test Type H102 Channel 1 Test Type Use Channel 1 Do Not Use Channel 1 Skip ‘0’ ‘G’ AC Hipot 50Hz ‘1’ ‘H’ AC Hipot 60Hz ‘2’ ‘I’ DC Hipot ‘3’ ‘J’ DC IR ‘4’...
Page 102 Your Hal tester HAL104 Notes Skip ‘0’ AC HIPOT 50Hz ‘1’ ‘H’ AC HIPOT 60Hz ‘2’ ‘I’ DC HIPOT ‘3’ ‘J’ DC IR ‘4’ ‘K’ EBOND 50Hz ‘5’ EBOND 60Hz ‘6’ Power + Leakage ‘7’ Power + Touch ‘8’ Leakage Spare ‘9’...
Page 103 Your Hal tester Digit 3 – Start Conditions & Base Target Voltage Digit 3 is a combination of the start conditions for the test and the base target voltage (to which the value encoded in digit 4 is added). Digit 3 Base Target Voltage 0.0kV 1.6kV...
Page 104 Your Hal tester For PWR tests digit 3 also specifies part of the loops index value. Characters in columns C0, C1, C2, C3, and C4 add 0, 1, 2, 3, 4 respectively to the loops index value. See the explanation of digit 11 for HI-POT and EBOND tests for the settings applicable to each loop index and an explanation of loop functionality.
Page 105 Your Hal tester Digit 4 – Target Voltage Offset Digit 4 represents the output voltage offset to be added to the base target voltage. The target voltage is achieved at the end of the ‘Ramp to Target’ time and is maintained during the ‘Hold’ time. During VARIABLE Tests (digit 5 = ‘Z’...
Page 106 Your Hal tester H101 & H102 Digit 4 : Target Voltage Offset ‘0’ 0.00kV ‘1’ 0.05kV ‘2’ 0.10kV ‘3’ 0.15kV ‘4’ 0.20kV ‘5’ 0.25kV ‘6’ 0.30kV ‘7’ 0.35kV ‘8’ 0.40kV ‘9’ 0.45kV ‘A’ 0.50kV ‘B’ 0.55kV ‘C’ 0.60kV ‘D’ 0.65kV ‘E’...
Page 107 Your Hal tester H103 Digit 4 : HV Test Digit 4 : EBOND Test Target Voltage Offset Current Level ‘0’ 0.00kV 0.0A ‘1’ 0.05kV 0.1A ‘2’ 0.10kV 0.2A ‘3’ 0.15kV 0.3A ‘4’ 0.20kV 0.4A ‘5’ 0.25kV 0.5A ‘6’ 0.30kV 0.6A ‘7’...
Page 108 Your Hal tester Digit 5 – Ramp to Target Time Digit 6 – Hold Time Digit 7 – Ramp to Zero Time Digits 5, 6 and 7 represent times during which the out voltage is ramped to the target voltage, held at the target voltage and finally ramped down to zero. All the times are in seconds.
Page 109 Your Hal tester ‘R’ 240.0 240.0 240.0 ‘S’ 300.0 300.0 300.0 ‘T’ – ‘Y’ Not Used Not Used Not Used Specifies the output Specifies an The current output voltage is VARIABLE up to infinite duration voltage is used as the target voltage using hold time, until the the start value for the rotary encoder.
Page 110 Your Hal tester Digit 8 – Lower Trip Limit (H103 – AC/DC Hipot & DC IR) Digit 9 – Upper Trip Limit (H103 – AC/DC Hipot & DC IR) Digits 8 and 9 represent the lower and upper trip limits respectively. AC Hipot DC Hipot DC IR...
Page 111 Your Hal tester ‘U’ 200MΩ ‘V’ 500MΩ ‘W’ 750MΩ ‘X’ 1000MΩ H103 Digit 8 – Lower Trip Limit (Ebond) Digit 9 – Upper Trip Limit (Ebond) Digit 10 – Lower/Upper Limit (Ebond) Digits 8, 9, and 10 are used to encode the indices into a lookup table of earth bond limits for the lower limit and the higher limit.
Page 112 Your Hal tester ‘ Z ’ + 3 5 + 3 5 + 1 8 0 + 1 8 0 ‘F’ + 15 + 15 + 108 + 72 ‘ Y ’ + 3 4 + 3 4 + 1 4 4 + 1 8 0 ‘G’...
Page 113 Your Hal tester Your Hal tester The earth bond limit lookup table contains the following milli-ohm The earth bond limit lookup table contains the following milli-ohm values: values: + 108 + 108 + 144 + 144 + 180 + 180 + 36 + 36 + 72...
Page 114 Your Hal tester + 33 1300 + 34 1400 + 35 1500 Note 1: The lookup index of 0 is used to represent 0 milli-ohms for the lower limit, and 9999 milli-ohms for the upper limit. The power limit lookup table contains the following kVA values:...
Page 115 Your Hal tester + 108 + 144 + 180 + 36 + 72 0.090 0.290 0.875 2.050 4.700 Note 0.095 0.300 0.900 2.100 4.800 0.001 0.100 0.310 0.925 2.150 4.900 0.002 0.105 0.320 0.950 2.200 5.000 0.003 0.110 0.330 0.975 2.250 5.250 0.004...
Page 116 Your Hal tester 0.270 0.825 1.950 4.500 12.750 + 34 0.080 0.280 0.850 2.000 4.600 13.000 + 35 0.085 Note 1: The lookup index of 0 is used to represent 0.000 kVA for the lower limit, and 99.99 kVA for the upper limit.
Page 117 Your Hal tester Your Hal tester Digit 8 Digit 8 Lower Power Factor Limit (PWRLK & PWRTLK) Lower Power Factor Limit (PWRLK & PWRTLK) Digit 9 Digit 9 Upper Power Factor Limit (PWRLK & PWRTLK) Upper Power Factor Limit (PWRLK & PWRTLK) Digit 8 Digit 8 Digit 9...
Page 118 Your Hal tester 0.850 0.875 0.900 0.925 0.950 0.975...
Page 119 Your Hal tester Digit 10 Arc Detection Sensitivity (AC/DC HIPOT & DC IR) For high-voltage test types digit 10 represents a level of arcing to be detected by the unit. A test is completed when an arc is detected. For high-voltage test types digit 10 also encodes the status of H102 channels 2 and 3 –...
Page 120 Your Hal tester Digit 10 – Arc Detection Level (Hal) Digit 10 represents a level of arcing detection, which will terminate the current test sequence when selected level is reached. Digit 10 : Arc Detection Level ‘X’ Disabled / Off ‘1’...
Page 121 Your Hal tester Digit 10 – Arc Detection Level (H102) Digit 10 represents a level of arcing detection, which will terminate the current test sequence when selected arc level is reached. Digit 10 also encodes the status of H102 channels 2 and 3 – only relevant if the test code is at the top of a loop.
Page 122 Your Hal tester Digit 10 – Arc Detection Level (H101, H103 H104 AC/DC Hipot & DC IR) Digit 10 represents a level of arcing detection, which will terminate the current test sequence when selected level is reached. Digit 10 : Arc Detection Level ‘0’...
Page 123 Your Hal tester H100, H101, H103 & H104 Digit 11 : Loops to Perform ‘0’ ‘Follow-On’ Test. A value of ‘0’ in the first test code is inappropriate and interpreted as ‘1’ ‘1’ ‘2’ ‘3’ ‘4’ ‘5’ ‘6’ ‘7’ ‘8’...
Page 124 Addendum Notes HAL Series Remote Connection for Pass/Fail Indications and Remote Fault Reset The HAL Tester can be ordered with this additional option. This option will appear as two additional rear sockets for remote ‘Pass/Fail Status’ and for ‘Remote Fault Reset and Start’. Mode Contacts Status Indicators...
Page 125 The absolute maximum ratings for the internal opto-isolators are associated with the top socket are: Maximum Forward Voltage - 55 Vdc Maximum Reverse Voltage - 7 Vdc Current per Switch – 50 mA Total Power – 100 mW On resistance typically is 140 Ohms, off being open circuit Operation beyond these values will damage the opto-isolators.
Page 126 PASS CONDITION Ohms PASS ≈140 Ohms FAIL ≈140 TIME TEST TEST START STOP (PASS) FAIL CONDITION Ohms PASS ≈140 Ohms FAIL ≈140 TIME TEST TEST RESET START STOP (FAIL)
Page 127 The ‘Mode Contacts’ socket may be connected to a remote push- button switch or no-volt contact for resetting any fault status on the Hal, by activating the button or contact once only. Any further activation in this mode will default the Hal to its main menu. This is the same for the GREEN button which can be operated externally, in this way.
Page 128 Hal 104 Control Ports Hal 104 Control Ports 19 Way Connector 19 Way Connector Connector Connector Signal Signal Wire Style Wire Style H104 Position H104 Position Position Position Brown 16s Brown 16s CN6 PIN 1 CN6 PIN 1 Red 16s Red 16s CN6 PIN 2 CN6 PIN 2...
Page 129 12 Way Connector 12 Way Connector Connector Connector Signal Signal Wire Style Wire Style H104 Position H104 Position Position Position +12V +12V Brown 16s Brown 16s CN5 PIN 1 CN5 PIN 1 Control 1 Control 1 Red 16s Red 16s CN5 PIN 2 CN5 PIN 2 Control 2...
Page 130 Remote Command Protocol 1. Protocol Description The Remote Command Protocol is an RS232 protocol that allows Clare testers to be reliably and quickly configured from a remote host and also allows the remote host to send commands to the instrument in order for the system to automatically perform electrical tests.
Page 131 responses generated. If the tester receives a command with a command sequence number the same as that for the previously correctly decoded command, then the tester simply re-sends its last response without performing any action – this deals with the situation where an ACK/NAK/InterimACK is corrupted before being received by the host.
Page 132 <data> Ascii hex representation of the NAK reason code (for NAK response code), contents, or the requested data (for ACK or interim ACK response codes). Some ACKs and interim ACKs do not return any data, in which case <datasz> will be zero. <crc16>...
Page 133 2. Data Representation Integer values Commands or responses that require a single, discrete, integer value, may provide the value as between 1 and 4 bytes, encoded as between 2 and 8 ASCII hex characters. As has already been discussed, multi- byte values are encoded and transmitted in big-endian order.
Page 134 Date and time structure This structure is used when getting/setting the tester’s date and time, or when reading the date and time at which the tester was calibrated. typedef struct _ssscmddata_datetime { u16 year; // 1999,2001, etc, etc (sent/received in big-endian order) u8 month;...
Page 135 3. Response Codes There is a restricted set of response codes that can be generated by the tester. These response codes are always distinct from command codes. SSSRSP_NAK (response code 0x00) This response code is sent by the tester when a command is properly formatted in terms of the protocol wrapper (length, CRC, etc), but does not contain a properly formatted command (incorrect amount of data, unknown command, incorrect item id or item instance, etc), or if the...
Page 136 SSSRSP_ACK_FINAL (response code 0x01) This response code is issued for commands successfully received and completely processed by the tester. A final ACK may, or may not, contain response data. The data content depends on the command for which the response is being generated. For certain commands the SSSRSP_ACK_FINAL will be proceeded by one or more SSSRSP_ACK_INTERIM.
Page 137 4. General Protocol Commands SSSCMD_SESSION_START (command code 0x10) The “session start” command must be issued before any other protocol commands. This command is used to: • Ascertain that the host and tester SSSCMD protocol implementation • versions are compatible. • Specify the baud rate for subsequent command exchanges.
Page 138 baud_code The required baud rate for subsequent communications: 0 = 9600 baud 1 = 19200 baud 2 = 28800 baud. Any other value will cause the command to be rejected with SSSRSP_NAK with the reason code set to SSSNAK_INVALID_VALUE. The tester sends the ACK or NAK at the prevailing baud rate before switching to the new baud rate.
Page 139 password If the host is supplying a password, then ‘password_seed’ must be non-zero, and the supplied password must be scrambled using the combination of the CRC lookup tables and the defined seed value. This allows passwords to be exchanged without them being readable on RS232 data loggers etc.
Page 140 If the ‘itemd id’, ‘instance’, or amount of supplied data is non-zero, then the tester will respond with SSSRSP_NAK and the appropriate reason code. SSSCMD_RESET_SCREEN (command code 0x14) This command turns off the tester’s buzzer, clears the tester’s display, and then re-displays the default session message. If the ‘itemd id’, ‘instance’, or amount of supplied data is non-zero, then the tester will respond with SSSRSP_NAK and the appropriate reason code.
Page 141 supplied (host supplies only 2 data bytes), then the host is defining a single empty string. Each string is placed at the beginning of a line, and the remainder of the line is cleared. If text is required to be placed towards the right- hand side of the display, then the text must be preceded by spaces.
Page 142 5. System settings commands The system settings may be read or modified using the commands defined in this section. Each system setting is identified with the ‘item_id’, and where items are array based the ‘instance’ is used to determine which array element is being addressed. The tester is aware of the data type, the maximum array element ‘instance’...
Page 143 SSSCMD_SS_SET_UINT (command code 0x23) This command is used to update a system setting that is stored within the tester as an integer. The host may supply between 1 and 4 data bytes. When more than 1 byte is provided, the bytes must be in big- endian order.
Page 144 6. System Settings Identifiers SSSID_SOFTWARE_VERSION (Item_id = 0) This read-only item is a string representing the software version number (eg "SNEU.26a", "AUNZSA.26a_beta3"). SSSID_HARDWARE_VERSION (Item_id = 1) This read-only item is a string representing the hardware version (eg 1.23, 7.24, etc). SSSID_SERIAL_NO (Item_id = 2) This read-only item is a string representing the tester's serial number.
Page 145 SSSID_TOTAL_TESTS (Item_id = 8) This read-only item is an unsigned integer representing the total number of electrical tests that have been tested by the tester. The value will be returned using up to 4 bytes. Many electrical tests may be performed for each product/appliance tested.
Page 146 Each user name can contain up to a maximum of up to 10 non-null ASCII characters. SSSID_USER_BUZZER (Item_id = 22) This read/write item is an array of 8-bit unsigned integers defining how the buzzer should be used for each user. This item is password protected if the user list is password protected.
Page 147 SSSID_SITE (Item_id = 31) This read/write item is an array of strings representing the available site names. The valid range of instances is 0 through 19. Note that instance 0 is for the 'new...' menu entry. Normal list entries start at instance 1. Each site name can contain up to a maximum of up to 15 non-null ASCII characters.
Page 148 SSSID_TEST_ENTRY (Item_id = 37) This item represents an array of predefined tests. The information is encoded as two strings: the first is the test name, and the second is the testcode. The valid range of instances is between 0 and 19 inclusive. A testname can have a maximum of 16 non-null characters.
Page 149 SSSID_DL_SETTINGS (Item_id = 42) This read/write item is an array of structures representing the configuration of downloads. Each structure contains exactly 7 bytes. Valid instances are 0 through 1 inclusive. Instance 0 defines the settings to be used for normal downloads, while instance 1 defines the settings to be used when performing an auto-download after a test.
Page 150 SSSID_APP_NUMBER_HANDLING (Item_id = 48) This read/write item is an 8-bit unsigned integer representing how to generate the initially offered product/appliance test numbers within the 'new appliance' menu. This item cannot be written unless the session is unrestricted. Valid values are 0 through 2 inclusive. 0=show a blank product/appliance number, 1=show the last used product/appliance number, 2=show an incremented version of the last used product/appliance number.
Page 151 SSSID_SYS_FLAGS (Item_id = 52) This read/write item is a 16-bit unsigned integer containing various system settings flags. This item cannot be written unless the session is unrestricted. Bit 0, if set: date and time to be shown in American mm/dd/yyyy format SSSID_PASSWD_PROTECT_FLAGS (Item_id = 53) This read/write item is a 16-bit unsigned integer containing various password protection flags.
Page 152 Valid values are in the range 0 through 19 inclusive. SSSID_PASS_FAIL_TITLE (Item_id = 56) This read/write item is a string representing the title to be used for pass/fail labels. This item cannot be written unless the session is unrestricted. The string may be up to a maximum of 30 non-null characters. SSSID_PRODUCT_TEST_TITLE (Item_id = 57) This read/write item is a string representing the title to be used for product / testcode labels.
Page 153 SSSID_MANMODE_SELECTION (Item_id = 61) This read/write item is an 8-bit unsigned integer representing the manual mode 'memory' to recall when next powering the tester. This item cannot be written unless the session is unrestricted. Valid values are in the range 0 through 9 inclusive. 7.
Page 154 SSSCMD_TESTFILE_SAVE_NOW (command code 0x32) This command is used to commit the SRAM testfile assembly area into flash memory. The tester will respond with an interim ACK before eventually issuing a final ACK or NAK. If the ‘itemd id’, ‘instance’, or amount of supplied data is non-zero, then the tester will respond with SSSRSP_NAK and the appropriate reason code.
Page 155 SSSVAL_BARCODE_OR_KEY_TIMEOUT 0x00 SSSVAL_BARCODE_OR_KEY_F1 0x06 SSSVAL_BARCODE_OR_KEY_F2 0x07 SSSVAL_BARCODE_OR_KEY_F3 0x08 SSSVAL_BARCODE_OR_KEY_F4 0x09 SSSVAL_BARCODE_OR_KEY_ABORT 0x0B SSSVAL_BARCODE_OR_KEY_START 0x0C SSSVAL_BARCODE_OR_KEY_BARCODE 0x1F If, and only if, the first byte is SSSVAL_BARCODE_OR_KEY_BARCODE, then the tester will also return the string data for the barcode. This barcode will be of variable length, and the tester does not return the null-terminator.
Page 156 u16 time_ramp_zero; // Time in tenths of a second to ramp to zero volts union { float r; // Generic access float milli_amps; // HIPOT. Used only at end of test for pass/fail determination. float mega_ohms; // DCIR. Used only at end of test for pass/fail determination.
Page 157 For PWR tests this field is reserved and should be set to zero. time_hold` For HV and EBOND tests this is the length of the hold phase in tenths of a second. For PWR tests this is the duration for which power is applied in tenths of a second.
Page 158 arc_detect For HV tests this is the arc detection level, 0 through 9. Set to 0 to disable arc detection, otherwise 1 is the most sensitive detection level, and 9 is the least sensitive level. For EBOND and PWR tests this field is reserved and should be set to zero.
Page 159 There are two distinct sets of test states: those that can be sent as part of an interim ACK, and those that can be sent as part of a final ACK: Test states only sent as part of an interim ACK These states have the highest bit clear to differentiate them from final result states: SSSVAL_HAL_TSTATE_COMMAND_RECEIVED...
Page 160 SSSVAL_HAL_TSTATE_ABORTED_FEEDBACK 0xA6 Test aborted: no data from Measurement SSSVAL_HAL_TSTATE_ABORTED_GUI_TIMEOUT 0xA7 Test aborted: no data from GUI (inter- packet-gap timeout) SSSVAL_HAL_TSTATE_ABORTED_GUI_REQUEST 0xA8 Test aborted: received a STOP request SSSVAL_HAL_TSTATE_ABORTED_SOFTWARE_ERROR 0xA9 Test aborted: invalid conditions found (glitch etc) SSSVAL_HAL_TSTATE_ABORTED_ESCAPE 0xAA Test aborted: ESC character received on the serial port SSSVAL_HAL_TSTATE_ABORTED_NO_READING...
Page 161 CLARE is a division of SEAWARD G R O U P...

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