Hioki 3153 User manual
3153A981-15
Contents
Introduction i
Inspection i
Safety Notes ii
Notes on Use v
Chapter Summary vi
Chapter 1 Overview 1
1.1 Product Introduction 1
1.2 Names and Functions of Parts 3
1.2.1 Front panel 3
1.2.2 Rubber keys 4
1.2.3 Rear panel 5
1.2.4 9615 H.V. TEST LEAD 6
1.2.5 REMOTE CONTROL BOX 7
1.3 External Dimensions 8
Chapter 2 Testing Arrangements 9
2.1 Connecting the Protective Ground Terminal 9
2.2 Wearing rubber gloves 10
2.3 Connecting the External I/O Connector 10
2.4 Power Cord Connection 11
2.5 Powering On and Off the Unit 12
2.6 Connecting the 9615 H.V. TEST LEAD 14
2.7 Connecting the REMOTE CONTROL BOX 15
2.8 Installation of the Unit 16
2.9 Connection to the Measured Equipment 17
2.10 Startup Inspection 18
Chapter 3 Withstand Voltage ModeTesting Method 19
3.1 Withstand Voltage Mode Display 20
3.2 Displaying the "READY" State 22
3.2.1 Key-lock Function 23
3.3 "SETTING" State 24
3.3.1 Setting the Test Voltage Value 25
3.3.2 Setting the Upper (Lower) Limit Value 26
3.3.3 Setting the Test Time 27
3.3.4 Setting of the Ramp Timer 28
3.3.5 Setting the Type of Test Voltage 29
3.3.6 Examples of Settings 30
3.4 Starting a Test 34
3.4.1 Executing a Test 34
3.4.2 Screening in "TEST" State 36
3.5 "PASS" or "FAIL" Determination 37
3.5.1 "PASS" State 37
3.5.2 Screening in "PASS" State 38
3.5.3 "FAIL" State 39
3.5.4 Screening in "FAIL" State 41
3.6 Automatic Discharge Function 42
Chapter 4 Insulation Resistance Mode Testing Method 43
4.1 Insulation Resistance Mode Display 44
4.2 Displaying the "READY" State 46
4.2.1 Key-lock Function 47
4.3 "SETTING" State 48
4.3.1 Setting the Test Voltage Value 49
4.3.2 Setting the Lower (Upper) Limit Value 50
4.3.3 Setting the Test Time 52
4.3.4 Setting the Delay Time 53
4.3.5 Examples of Settings 54
4.4 Starting a Test 57
4.4.1 Executing a Test 58
4.4.2 Screening in "TEST" State 59
4.5 "PASS" or "FAIL" Determination 60
4.5.1 "PASS" State 60
4.5.2 Screening in "PASS" State 62
4.5.3 "FAIL" State 63
4.5.4 Screening in "FAIL" State 65
4.6 Automatic Discharge Function 66
Chapter 5 Auto Test Mode Testing Method 67
5.1 Auto Test Mode Display 68
5.2 Displaying the "READY" State 70
5.2.1 Key-lock Function 71
5.3 "SETTING" State 72
5.4 Starting a Test 73
5.4.1 Executing a Test 74
5.4.2 Screening in "TEST" State 75
5.5 PASS or FAIL Determination 76
5.5.1 "PASS" State 76
5.5.2 Screening in "PASS" State 78
5.5.3 "FAIL" State 79
5.5.4 Screening in "FAIL" State 81
5.6 Automatic Discharge Function 82
Chapter 6 Program Mode Testing Method 83
6.1 Program Mode Display 84
6.2 Displaying the "READY" State 86
6.2.1 Key-lock Function 87
6.3 Program Setting State 88
6.3.1 Examples of Settings 91
6.4 Program-File Loading 96
6.5 Starting a Test 97
6.5.1 Executing a Test 98
6.5.2 Screening in "TEST" State 99
6.6 PASS or FAIL Determination 100
6.6.1 "PASS" State 100
6.6.2 Screening in "PASS" State 101
6.6.3 "FAIL" State 102
6.6.4 Screening in "FAIL" State 104
6.7 Automatic Discharge Function 105
Chapter 7 Optional Functions 107
7.1 PASS Hold Function 110
7.2 FAIL Hold Function 111
7.3 Hold Function 112
7.4 Momentary Out 114
7.5 Double Action 115
7.6 FAIL Mode 116
7.7 Interface Command "START" 117
7.8 Inter-lock Function 118
7.9 Setting of an Output-Voltage Restricting Value 119
7.10 Insulation Resistance Test Measurement Range 120
7.11 Insulation Resistance Test Termination Mode Settings
121
7.12 Setting for Screening during the Ramp-Up Time 123
7.13 PC Interface 124
7.14 START Protection Function 125
7.15 TEST-Signal Output 126
7.16 Example of Optional Functions Use 127
Chapter 8 Saving/loading Preset Values 129
8.1 Saving Preset Values 129
8.1.1 Procedure for Saving Data 129
8.1.2 Example of Saving 132
8.2 Loading Preset Values 134
8.2.1 Procedure for Loading Data 134
8.2.2 Example of Loading 137
Chapter 9 External Interface 139
9.1 External I/O Terminal 139
9.1.1 Signal Line 140
9.1.2 Example of Input Signal Connection 142
9.1.3 Example of Output Signal Connection 144
9.1.4 Inter-lock Function 146
9.1.5 Selecting a Program Test File 147
9.1.6 Timing Chart of External I/O Terminal 149
9.2 Buzzer 154
Chapter 10 PC Interface 155
10.1 RS-232C Interface 156
10.1.1 Specifications 156
10.1.2 Preparing for Data Transfer 157
10.1.3 RS-232C Command Transfer Methods 159
10.2 Command Table 164
10.3 RS-232C Command Reference 167
10.3.1 Common Command Messages 168
10.3.2 Specific Command Messages 171
10.4 Response Formats 201
10.5 GP-IB Interface 203
10.5.1 Specifications 203
10.5.2 Preparing for Data Transfer 203
10.6 GP-IB Command Transfer Methods 205
10.7 GP-IB Commands 211
10.8 GP-IB Command Reference 212
10.8.1 Command Reference 212
10.8.2 Specific Command Messages 216
Chapter 11 Specifications 219
11.1 Basic Specifications 219
11.1.1 Withstand Voltage test portion 219
11.1.2 Insulation resistance test portion 221
11.1.3 Timer Section 222
11.1.4 Interface 223
11.1.5 Program Function 224
11.1.6 Other Functions 225
11.2 General Specifications 226
Chapter 12 Maintenance and Inspection 227
12.1 Maintenance and Service 227
12.2 Fuse Replacement 229
12.3 Troubleshooting 230
12.4 Displaying Errors 231
12.5 Removing the Lithium Battery 232
12.6 Resetting the System 233
Appendix APPENDIX 1
Appendix 1 9613 REMOTE CONTROL BOX (SINGLE)
APPENDIX 1
Appendix 2 9614 REMOTE CONTROL BOX (DUAL)
APPENDIX 2
Appendix 3 9615 H.V. TEST LEAD (Standard Accessory)
APPENDIX 3
Appendix 4 Insulation Resistance Mode measurement range
APPENDIX 4
INDEX INDEX 1
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NOTE Before using the product, make sure that the insulation on the leads is undamaged
and that no bare conductors are improperly exposed. Using the product in such
conditions could cause an electric shock, so contact your dealer or Hioki
re
p
resentative for re
p
air.
Introduction
Inspection
Thank you for purchasing the HIOKI 3153 AUTOMATIC INSULATION/
WITHSTANDING HiTESTER. To obtain maximum performance from the
product, please read this manual first, and keep it handy for future reference.
When you receive the product, inspect it carefully to ensure that no damage
occurred during shipping. In particular, check the connectors. If damage is
evident, or if it fails to operate according to the specifications, contact your
dealer or Hioki representative.
Accessories
Verify that the following standard accessories are complete.
Instruction Manual 1
Spare fuse (built into the power inlet) 1
Grounded three-core power cord 1
9615 H.V. TEST LEAD (High voltage and return side ) 1
Shipment of the unit
Use the original packing materials when reshipping the product, if possible.
Warranty
HIOKI cannot be responsible for losses caused either directly or indirectly by
the use of the 3153 with other equipment, or if ownership is transferred to a
third party.
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WARNING
This product is designed to conform to IEC 61010 Safety Standards, and
has been thoroughly tested for safety prior to shipment. However,
mishandling during use could result in injury or death, as well as
damage to the product. Be certain that you understand the instructions
and precautions in the manual before use. We disclaim any
responsibility for accidents or injuries not resulting directly from
product defects.
Safety Symbols
The symbol printed on the product indicates that the user should
refer to a corresponding topic in the manual (marked with the
symbol) before using the relevant function.
In the manual, the symbol indicates particularly important
information that the user should read before using the product.
Indicates that dangerous voltage may be present at this terminal.
Indicates a fuse.
Indicates AC (Alternating Current).
Indicates both DC (Direct Current) and AC (Alternating Current).
Indicates a protective conductor terminal.
Indicates a grounding terminal.
Indicates the ON side of the power switch.
Indicates the OFF side of the power switch.
DANGER
Indicates that incorrect operation presents an extreme hazard that
could result in serious injury or death to the user.
WARNING
Indicates that incorrect operation presents a significant hazard that
could result in serious injury or death to the user.
CAUTION Indicates that incorrect operation presents a possibility of injury to
the user or damage to the product.
NOTE Advisory items related to performance or correct operation of the
product.
Safety Notes
This manual contains information and warnings essential for safe operation
of the product and for maintaining it in safe operating condition. Before
using the product, be sure to carefully read the following safety notes.
The following symbols in this manual indicate the relative importance of
cautions and warnings.
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CAT II Primary electrical circuits in equipment connected to
an AC electrical outlet by a power cord (portable
tools, household appliances, etc.)
CAT II covers directly measuring electrical outlet
receptacles.
CAT III Primary electrical circuits of heavy equipment (fixed
installations) connected directly to the distribution
panel, and feeders from the distribution panel to
outlets.
CAT IV The circuit from the service drop to the service
entrance, and to the power meter and primary
overcurrent protection device (distribution panel).
Measurement categories
To ensure safe operation of measurement products, IEC 61010 establishes
safety standards for various electrical environments, categorized as CAT II to
CAT IV, and called measurement categories.
Using a measurement product in an environment designated with a higher-
numbered category than that for which the product is rated could result in a
severe accident, and must be carefully avoided.
Use of a measurement instrument that is not CAT-rated in CAT II to CAT
IV measurement applications could result in a severe accident, and must be
carefully avoided.
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f.s. (maximum display or scale value, or length of scale)
Signifies the maximum display (scale) value or the length of the scale
(in cases where the scale consists of unequal increments or where the
maximum value cannot be defined).
In general, this is the range value (the value written on the range
selector or equivalent) currently in use.
rdg. (displayed or indicated value)
This signifies the value actually being measured, i.e., the value that is
currently indicated or displayed by the measuring instrument.
dgt. (resolution)
Signifies the smallest display unit on a digital measuring instrument,
i.e., the value displayed when the last digit on the digital display is
"1".
Accuracy
The specifications in this manual include figures for "measurement accuracy"
when referring to digital measuring instruments, and for "measurement
tolerance" when referring to analog instruments.
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DANGER
To avoid electric shock, do not remove the product's case. The internal
components of the product carry high voltages and may become very
hot during operation.
The vinyl shield on the 9615 H.V. TEST LEAD alligator clip is not high
voltage insulated. Do not touch when high voltage is applied.
WARNING
To avoid electric shock, do not allow the product to get wet, and do not
use it when your hands are wet.
To avoid electric shock, be sure to connect the protective ground
terminal to a grounded conductor.
To avoid electrical accidents and to maintain the safety specifications
of this instrument, connect the power cord provided only to a 3-contact
(two-conductor + ground) outlet.
Before turning the product on, make sure the source voltage matches
that indicated on the product's power connector. Connection to an
improper supply voltage may damage the product and present an
electrical hazard.
Replace the fuse only with one of the specified characteristics and
voltage and current ratings. Using a non-specified fuse or shorting the
fuse holder may cause a life-threatening hazard.
Fuse type: 250VT10AL (100-120 V), 250VT5AL (200-240 V)
To avoid electric shock when measuring live lines, wear appropriate
protective gear, such as insulated rubber gloves, boots and a safety helmet.
CAUTION To avoid electrocution, turn off the power to all devices before plugging or
unplugging any of the interface connectors.
To avoid damaging the power cord, grasp the plug, not the cord, when
unplugging the cord from the power outlet.
To avoid damaging H.V. TEST LEAD, do not kink or pull on the leads.
For safety reasons, when taking measurements, only use the 9615 H.V.
TEST LEAD provided with the product.
To avoid damage to the product, protect it from vibration or shock during
transport and handling, and be especially careful to avoid dropping.
Failure to observe the following precaution may result in bodily injury.
This instrument weighs approximately 18kg. When lifting or moving the
unit, it is strongly recommended that two capable persons hold the
instrument at both ends of the bottom to prevent drop or damage.
The instrument is heavy. When transporting it, follow your company's
workplace safety standards to assure safety (for example, by wearing non-
slip gloves and protective footwear).
To avoid electric shock, do not exceed the lower of the ratings shown on the
instrument and test leads.
NOTE
Do not use the product near a device that generates a strong electromagnetic field or
electrostatic charge, as these may cause erroneous measurements.
This product may cause interference if used in residential areas. Such use
must be avoided unless the user takes special measures to reduce
electromagnetic emissions to prevent interference to the reception of radio
and television broadcasts.
Notes on Use
Follow these precautions to ensure safe operation and to obtain the full
benefits of the various functions.
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Chapter Summary
Chapter 1 Overview
Describes an overview, features, and the names and functions of the parts of
the product.
Chapter 2 Testing Arrangements
Describes particulars of testing arrangements.
Chapter 3 Withstand Voltage Mode Testing Method
Describes the procedures for setting the withstand-voltage mode testing,
testing method, and test decisions.
Chapter 4 Insulation Resistance Mode Testing Method
Describes the procedures for setting the insulation-resistance mode testing,
testing method, and test decisions.
Chapter 5 Auto Test Mode Testing Method
Describes the procedures for setting the auto test mode testing, testing
method, and test decisions.
Chapter 6 Program Mode Testing Method
Describes the procedures for setting the program mode testing, testing
method, and test decisions.
Chapter 7 Optional Functions
Describes procedures for setting optional functions.
Chapter 8 Saving/Loading Preset Values
Describes procedure for saving and loading test values.
Chapter 9 External Interface
Describes use of the external I/O, and buzzer.
Chapter 10 PC Interface
Describes communication procedures and commands for an RS-232C/GP-IB
interface.
Chapter 11 Specifications
Contains the unit specifications such as the general specifications,
measurement accuracy, etc. of the unit.
Chapter 12 Maintenance and Inspection
Covers the maintenance and inspection, fuse replacement, ultimate disposal,
and system reset.
Appendix
Covers the options of the unit.
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1.1 Product Introduction
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Chapter 1
Overview
1.1 Product Introduction
(1) Easy testing conforming to standards
With the unit insulation-resistance and withstand-voltage tests based on a
wide variety of standards can be performed. Accurate test results can be
obtained by comparative screening functions that use upper- and lower-limit
values, timer functions, and ramp up/down timer functions that control test-
voltage increases/decreases.
(2) Automatic insulation-resistance testing and withstand-voltage
testing
The Continuous Test mode allows consecutive insulation-resistance and
withstand-voltage tests to be performed.
(3) Fluorescent indicator
The large, easy-to-read fluorescent display permits quick checking of the
testing state and result.
(4) Analog Voltage Measurement
The voltage is digitally displayed on the fluorescent indicator. This value can
also be checked on the analog voltmeter.
(5) Saving testing set values (Memory function)
This unit is provided with a function for saving the set values used in a test,
allowing quick switching between different testing set values to meet a
variety of standards and regulations. Up to 10 values may be saved for each
test mode (withstand-voltage mode or insulation-resistance mode). The
values immediately prior to a power shutdown are saved in the unit, and the
unit restarts with these settings the next time.
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1.1 Product Introduction
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(6) REMOTE CONTROL BOX
The 9613 REMOTE CONTROL BOX (single-hand) or the 9614 REMOTE
CONTROL BOX (dual-hand) can be connected to the external switch
terminal to perform 3153 start/stop control.
(7) External I/O
The external I/O terminal generates signals according to the state of the
3153. It can be used to feed signals for the START and STOP key.
(8) RS-232C/GP-IB interface as a standard feature
Automatic testing and saving of the test results are possible with the use of a
computer.
(9) Program test
Withstand-voltage and insulation-resistance tests under various conditions
can be conducted successively at your option. Through the use of a 3930
HIGH VOLTAGE SCANNER, many test points can be tested at one time.
Up to 32 files can be created, with each file containing up to 50 steps.
(10) Switching-power-supply method
The adoption of the PWM switching power supply allows the unit to output
any preset voltage. The test voltage is not affected by fluctuations in the
power-supply voltage of this unit.
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1.2 Names and Functions of Parts
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A
1.2.1 Front panel
WARNING
To prevent electric shock, when the DANGER lamp is lit, never touch the
HIGH or LOW terminals, H.V. TEST LEAD, or the tested object.
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1Analog voltmeter Indicates output-voltage value.
2DANGER lamp This lamp lights to warn that voltage is present between the terminals during
testing.
3HIGH terminal The HIGH terminal is a high-voltage terminal for voltage outputs.
4LOW terminal The LOW terminal is a low-voltage terminal for voltage outputs. It has the same
electric potential as the unit body.
5 External switch
terminal Used for the switch signal line plug for the REMOTE CONTROL BOX.
6I lamp This lamp lights when insulation-resistance mode is selected and during
insulation-resistance testing.
7W lamp This lamp lights when withstand-voltage mode is selected and during withstand-
voltage testing.
8 Rubber keys The 14 rubber keys include 13 function keys and a SHIFT key.
The six function keys offer a variety of settings, used in combination with the
SHIFT key.
9DOWN lamp This lamp lights during ramp-down from withstand-voltage testing.
10 UP/DELAY
lamp This lamp lights during ramp-up to withstand-voltage testing and during
insulation-resistance testing delays. (However, it does not light during time testing
when insulation-resistance test termination mode is set to 0 [initial setting].)
11 Main power switch Powers the 3153 product on or off.
12 STOP key Normally used to terminate a test.
13 START key Used to start a test. This key functions only when the READY lamp is lit.
14 VFD (vacuum
fluorescent display) Displays various information, such as the test state and test results.
1.2 Names and Functions of Parts
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1.2 Names and Functions of Parts
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1.2.2 Rubber keys
12345
678 9 10 11 12
1/key Moves the flashing cursor.
The switching range is preset before shipment:
Withstand-voltage test:
Test-voltage value ⇔Upper-limit value ⇔Lower-limit value ⇔
Test time ⇔Ramp-up time ⇔Ramp-down time ⇔Test-voltage type
Insulation-resistance test:
Test-voltage value ⇔Lower-limit value ⇔Upper-limit value ⇔
Test time ⇔Delay time
To display the flashing cursor, press the /keys. The cursor appears,
displaying the preset comparative voltage value or test-voltage value.
(withstand-voltage test and insulation-resistance test)
2/key Changes the position at which the flashing cursor appears.
3ON/OFF key Switches on/off the set value for the position of the flashing cursor. If
turned off, the set value is not used in testing.
However, the following key can't perform the switching on/off:
Withstand-voltage test: Test-voltage type, Test voltage, Upper-limit value
Insulation-resistance test: Test voltage, Lower-limit value
4LOCK key
(LOCAL key) Used to lock the keys.
When pressed, the LOCK key disables all keys except the START key,
STOP key, and Key Lock Cancel key (LOCK +SHIFT key). See the
"Key-lock Function" section. (Chapter 3 to 6)
In the remote state, this key functions as a LOCAL key. It cancels the
remote state.
5SHIFT key Used in combination with other keys.
①SHIFT +key
Displaying the Preset-data loading screen. (See Chapter 8)
②SHIFT +key
Displaying the Preset-data saving screen. (See Chapter 8)
③SHIFT +UNLOCK key
Disabling the key lock function. Cancels the key lock. When GP-IB is
used for communication, go to LOCAL state.
④SHIFT +/key
Changing the increment size of setting values.
6Wkey
(withstand-voltage test) Performs withstand-voltage tests and settings. (See Chapter 3)
7Ikey
(insulation-resistance test) Performs insulation-resistance tests and settings. (See Chapter 4)
8W→Ikey Tests for withstand-voltage, then insulation-resistance. (See Chapter 5)
9I→Wkey Tests for insulation-resistance, then withstand-voltage. (See Chapter 5)
10 PROG key Creates or edits program tests or their files. (See Chapter 6)
11 PG.LOAD key Used to load program data. (See Chapter 6)
12 ENTER key Used to create or edit program test files. (See Chapter 6)
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1.2 Names and Functions of Parts
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1.2.3 Rear panel
WARNING
To prevent electric shock, when the DANGER lamp is lit, never touch the
HIGH or LOW terminals, H.V. TEST LEAD, or the tested object.
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1Scanner connection
terminal Terminal for connecting the optional 3930 HIGH VOLTAGE
SCANNER. Do not connect any scanner other than the 3930.
2Power inlet Connect the grounded three-core power cord supplied here.
3 Fuse holder Contains a power fuse.
4Protective ground
terminal Used to earth a protective ground wire. Be sure to make grounding
connections before starting a test.
5RS-232C terminal Used for remote control with RS-232C.
6 External I/O
terminal For output of 3153 state and input of start and stop signals.
7GP-IB terminal Used for remote control with GP-IB.
8HIGH terminal A high-voltage terminal for voltage output. Connected to the
HIGH terminal on the front panel.
9LOW terminal A low-voltage terminal for voltage output. Contains the same
electrical potential as this units casing.
10 Buzzer adjustment
knob Used for buzzer sound adjustment. Two knobs are provided: one
for PASS screening and one for FAIL screening.
11 Vent holes Holes for cooling the inside of the unit. Both sides of the unit also
have vent holes.
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1.2 Names and Functions of Parts
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1.2.4 9615 H.V. TEST LEAD
DANGER
The vinyl shield on the 9615 H.V. TEST LEAD alligator clip is not high
voltage insulated. Do not touch when high voltage is applied.
1
2
3
1
High-voltage side (red)
Low-voltage side (black)
1Alligator clip Connect to a test point on the tested object.
2High-voltage output
plug Connect to the HIGH terminal on the unit.
3Low-voltage output
plug Connect to the LOW terminal on the unit.
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1.2 Names and Functions of Parts
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1.2.5 REMOTE CONTROL BOX
9613 REMOTE CONTROL BOX (SINGLE)
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9614 REMOTE CONTROL BOX (DUAL)
1OPERATE switch Used to enable remote-control operation. When this switch is ON,
the START and STOP keys for remote control are active.
2START key Works in the same manner as the START key on the unit. With
the 9614 REMOTE CONTROL BOX (dual-hand), the two START
switches must be pressed.
3 STOP key Works in the same manner as the STOP key on the unit. The
STOP key is ON during a test or when a voltage is being output.
4Switch signal-line
plug Connect to the external switch terminal on the unit.
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