Hioki 3158 User manual

3158
Instruction Manual
AC WITHSTANDING
VOLTAGE HiTESTER
EN
Mar. 2019 Revised edition 12
3158A981-12 19-03H

Contents
Inspection i
Safety Notes ii
Notes on Use iv
Contents and Indications of This Manual vi
Chapter 1 Overview 1
1.1 Product Introduction 2
1.2 Names and Functions of Parts 3
Chapter 2 Testing Arrangements 7
2.1 Connecting the Protective Ground Terminal 7
2.2 Wearing rubber gloves 8
2.3 Connecting the External I/O Connector 9
2.4 Power Cord Connection 10
2.5 Powering On and Off the Unit 11
2.6 Connecting the 9615 H.V. TEST LEAD 12
2.7 Connecting the REMOTE CONTROL BOX 14
2.8 Installation of the Unit 15
2.9 Connection to the Measured Equipment 16
2.10 Startup Inspection 17
Chapter 3 Testing Method 19
3.1 State of the 3158 and Preset Parameters 20
3.2 Making Testing Arrangements (in READY State) 22
3.2.1 Selecting an Output-Voltage Range 23
3.2.2 Key-lock Function 23
3.2.3 Initial Settings for Optional Functions 24
3.3 Setting the "SETTING" State 25
3.3.1 Setting the Comparative Voltage Value 26
3.3.2 Setting the Upper (Lower) Level Value 27
3.3.3 Setting the Test Time 28
3.3.4 Examples of Settings 29
3.4 Starting a Test 32
3.4.1 Setting the Output Voltage 33
3.4.2 Executing a Test 35
3.4.3 Screening in "TEST State" 37
3.5 PASS or FAIL Determination 38
3.5.1 "PASS" State 38
3.5.2 Screening in "PASS" State 39
3158A981-12

3.5.3 "FAIL" State 40
3.5.4 Screening in "FAIL" State 43
Chapter 4 Optional Functions 45
4.1 PASS Hold Function 48
4.2 FAIL Hold Function 49
4.3 Hold Function 50
4.4 Momentary Out 52
4.5 Double Action 53
4.6 FAIL Mode 54
4.7 RS Command [START] 55
4.8 Inter-lock Function 56
4.9 Voltage Comparator Position 57
4.10 Example of Optional Function Settings 58
4.11 Example of Optional Functions Use 59
Chapter 5 Saving/Loading Preset Values 61
5.1 Saving Preset Values 62
5.1.1 Procedure for Saving Data 63
5.1.2 Example of Saving 64
5.2 Loading Preset Values 66
5.2.1 Procedure for Loading Data 67
5.2.2 Example of Loading 68
Chapter 6 External Interface 71
6.1 External I/O Terminal 71
6.1.1 Signal Line 72
6.1.2 Example of Input Signal Connection 74
6.1.3 Example of Output Signal Connection 76
6.1.4 Inter-lock Function 78
6.1.5 Timing Chart of External I/O Terminal 80
6.2 Buzzer 83
Chapter 7 RS-232C Interface 85
7.1 Specifications 85
7.2 Connection Method 86
7.3 Command Transfer Methods 87
7.4 Command 89
7.5 Transmission and Response Formats 100
7.6 Command Summary 101

Chapter 8 Maintenance and Inspection 103
8.1 Maintenance 104
8.2 Fuse Replacement 105
8.3 Troubleshooting 106
8.4 Displaying Errors 107
8.5 Resetting the System 107
8.6 External Dimensions 108
Chapter 9 Specifications 109
9.1 Basic Specifications 109
9.2 General Specifications 113
Appendix APPENDIX1
9613 REMOTE CONTROL BOX (SINGLE) APPENDIX1
9614 REMOTE CONTROL BOX (DUAL) APPENDIX2
9615 H.V. TEST LEAD (Standard Accessory) APPENDIX3
Table of Optional Functions APPENDIX4

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Introduction
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NOTE
Introduction
Inspection
Thank you for purchasing the HIOKI "3158 AC WITHSTANDING VOLTAGE
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 accessories, panel switches, and
connectors. If damage is evident, or if it fails to operate according to the
specifications, contact your dealer or Hioki representative.
Checking the main unit and accessories
Main unit
"3158 AC WITHSTANDING VOLTAGE HiTESTER."
Accessories
Verify that the following standard accessories are complete.
(1) Instruction Manual 1
(2) Spare fuse (built into the power inlet) 1
(3) Grounded three-core power cord 1
(4) 9615 H.V. TEST LEAD
(High voltage and return side ) 1
Shipment of the unit
If reshipping the unit, preferably use the original packing.
Warranty
HIOKI cannot be responsible for losses caused either directly or indirectly by the
use of the 3158 with other equipment, or if ownership is transferred to a third party.
Before using the product, make sure that the insulation on the test 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 representative for repair.

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Introduction
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DANGER Thisproduct is designed to comply with 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. However, using the product in a way not described in this
manual may negate the provided safety features.
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.
･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 a protective conductor terminal.
Indicates a functional earth terminal.
Indicates the ON side of the power switch.
Indicates the OFF side of the power switch.
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.
Safety symbols

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Introduction
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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.
DANGER ･Using a measuring instrument in an environment designated with a
higher-numbered category than that for which the instrument is rated
could result in a severe accident, and must be carefully avoided.
･Never use a measuring instrument that lacks category labeling in a
CAT II to CAT IV measurement environment. Doing so could result in
a serious accident.
CAT II: When directly measuring the electrical outlet receptacles of the primary
electrical circuits in equipment connected to an AC electrical outlet by a power
cord (portable tools, household appliances, etc.)
CAT III: When measuring the primary electrical circuits of heavy equipment (fixed
installations) connected directly to the distribution panel, and feeders from the
distribution panel to outlets
CAT IV: When measuring the circuit from the service drop to the service entrance, and to
the power meter and primary overcurrent protection device (distribution panel)
The following symbols in this manual indicate the relative importance of cautions
and warnings.
Measurement categories
To ensure safe operation of measuring instruments, IEC 61010 establishes safety
standards for various electrical environments, categorized as CAT II to CAT IV, and
called measurement categories.

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Introduction
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DANGER To avoid any life-threatening electric shock accidents, ensure that the
following rules are observed.
･The AC Withstanding Voltage Hitester is a dangerous product which
discharges high voltages. To prevent getting electrocuted, always
wear high-voltage protective rubber gloves when carrying out any
operation.
･Be careful when using the product and ensure that you do not touch
this product, any tested object that is connected or any H.V. TEST
LEAD, etc.
･To avoid electric shock, do not remove the cover panel. The internal
components of the product carry high voltages and may become very
hot during operation.
･Vinyl shield on 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, be sure to connect the protective ground
terminal to a grounded conductor.
･The unit is constructed so as to be connected to a ground line via a
three-core power cord that is supplied with the unit. To avoid
electric shock and ensure safe operation, connect the power cable to
a grounded (3-contact) 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.
･To avoid electric shock, do not allow the product to get wet, and do
not use it when your hands are wet.
･This product should be installed and operated indoors only, between
0℃and 40℃and 80%RH max. Do not use the unit in direct sunlight,
dusty conditions, or in the presence of corrosive gases.
･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: 250VT8AL（3158-01）
250VT4AL（3158-03 to 3158-05）
Notes on Use
Follow these precautions to ensure safe operation and to obtain the full benefits of
the various functions.

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Introduction
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CAUTION ･Do not insert a board other than optional interface boards into the Interface
slot. The unit software or calibration data may be lost.
･To avoid electrocution, turn off the power to all devices before pluggingor
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 test leads, do not kink or pull on the leads.
･Keep in mind that, in some cases, conductors to be measured may be hot.
･Take care not to block the ventilation openings on the sides of the unit.
･For safety reasons, only use the 9615 H.V. TEST LEAD for measurement.
･To avoid damage to the product, protect it from vibration or shock during
transport and handling, and be especially careful to avoid dropping.
･In the event that the equipment malfunctions in any manner during use,
turn off the power immediately, and contact your dealer or HIOKI
representative.
･To avoid electric shock, do not exceed the lower of the ratings shown on
the instrument and test leads.
NOTE ･Do not use the unit near any device which generates strong electromagnetic
radiation or near a static electrical charge, as these may cause errors.
･This instrument 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.

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Introduction
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Contents and Indications of This Manual
Chapter 1: Overview
Describes an overview, features, and the names and functions of the parts of the
unit.
Chapter 2: Testing Arrangements
Describes particulars of testing arrangements.
Chapter 3: Testing Method
Describes procedures for setting, testing, and test results judgment.
Chapter 4: Optional Functions
Describes procedures for setting optional functions.
Chapter 5: Saving/Loading Preset Values
Describes procedure for saving and loading test values.
Chapter 6: External Interface
Describes use of the external I/O and REMOTE CONTROL BOX.
Chapter 7: RS-232C Interface
This chapter explains the testing procedure using RS-232C.
Chapter 8: Maintenance and Inspection
Covers the maintenance and inspection, fuse replacement, and ultimate disposal.
Chapter 9: Specifications
Contains the unit specifications such as the general specifications, measurement
accuracy, etc. of the unit.
Appendix:
Covers the options of the unit.

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Chapter 1
Overview

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1.1 Product Introduction
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1.1 Product Introduction
(1) Easy testing conforming to standards
The unit allows pressure tests based on a wide variety of standards to be conducted.
The timer function and the comparative screening function using upper- and lower-
level values provide accurate test results. The unit does not operate until the output
voltage preset using the voltage adjustment knob is within ±5% (output voltage ≦
1kV:±50 V) of the comparative voltage value, thus further ensuring accurate
readings.
(2) Fluorescent indicator
The large, easy-to-read fluorescent display permits quick checking of the testing
state and result.
(3) Analog Voltage Measurement
The voltage is digitally displayed on the fluorescent indicator. This value can also
be checked on the analog voltmeter.
(4) Zero-Toggle Switch
This function ensure that test voltage can be toggled on and off only at a sine wave
zero crossings, to prevent damage to the device under test if it happens to be faulty.
(5) Saving testing set values
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 20 values may be saved.
The values immediately prior to a power shutdown are saved in the unit. These
values are valid at the next startup.
(6) REMOTE CONTROL BOX
The 9613 REMOTE CONTROL BOX (SINGLE) or the 9614 REMOTE CONTROL
BOX (DUAL) can be connected to the external switch terminal to perform 3158
start/stop control.
(7) External I/O
The external I/O terminal generates signals according to the state of the 3158. It
can be used to feed signals for the start and stop key.
(8) RS-232C interface as a standard feature
Automatic testing and saving of the test results are possible with the use of a
computer.

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1.2 Names and Functions of Parts
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1.2 Names and Functions of Parts
Front panel
1 Analog voltmeter
Indicates output voltage.
2 Danger Lamp
This lamp lights to warn that voltage is present between the terminals during
testing.
When the DANGER lamp is lit, never touch the HIGH terminal, probe, or
tested object.
3LOWTerminal
The LOW terminal is a low-voltage terminal for voltage outputs. It has the same
electric potential as the unit body.
4 HIGH Terminal
The HIGH terminal is a high-voltage terminal for voltage outputs. A high voltage
is generated between this terminal and the LOW terminal.
When the DANGER lamp is lit, never touch this terminal.
5 External Switch Terminal
Used for the signal line for the remote-control box.
6 Range Selection switch
Used to switch among output-voltage ranges.
7 VFD ( Vacuum Fluorescent Display )
Displays various kinds of information, such as test state and results.
8 START key
Used to start a test. This key functions only when the READY lamp is lit.
9 STOP key
Normally used to terminate a test.

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1.2 Names and Functions of Parts
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1 2 3 4 5
10 Rubber keys
The seven rubber keys include six function keys and a SHIFT key.
The six function keys offer a variety of settings, used in combination with the
SHIFT key.
11 Output Voltage Knob
Sets the output voltage.
12 Main power switch
Powers the 3158 on or off.
Rubber keys
1 Left/Right cursor key
Moves the flashing cursor. The switching range is preset before shipment:
Preset Comparative voltage value Upper limit Value Test time.
To display the flashing cursor, press the /keys. The cursor appears,
displaying the preset comparative voltage value.
2 Up/Down cursor key
Changes the position at which the flashing cursor appears.
3 ON/OFF key
Switches on/off the set value for the position of the flashing cursor.
However, this key can't perform the switching on/off of the preset Upper level
Value. If turned off, the set value is not used in testing.
4 LOCK 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. See 3.2.2, "Key-lock
Function."
5 SHIFT key
Used in combination with other keys.
（1）Displaying the Preset-data loading screen
Press SHIFT +keys to display the Preset-data loading screen. For more
information, see Chapter 5, "Saving/loading the Parameters Set."
（2）Displaying the Preset-data saving screen
Press SHIFT +keys to display the Preset-data saving screen. For more
information, see Chapter 5, "Saving/Loading Preset Values."
（3）Disabling the key lock function
To disable the key lock function, press the SHIFT +LOCK keys.

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1.2 Names and Functions of Parts
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Rear panel
1 Fuse Holder
Contains a power fuse.
2 Power inlet
Connect the grounded three-core power cord supplied here. Integrated with a fuse
holder.
3 RS-232C terminal
Used for remote control with RS-232C.
4 Protective ground terminal
Used to earth a protective ground wire. Be sure to make grounding connections
before starting a test.
5 Buzzer adjustment knob
Used for buzzer sound adjustment. Two knobs are provided: one for PASS
screening and one for FAIL screening.
6 External I/O terminal
For output of 3158 state and input of start and stop signals.

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1.2 Names and Functions of Parts
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2
1
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Hi
g
h-volta
g
e side
(
red
)
Low-volta
g
e side
(
black
)
9614 REMOTE CONTROL BOX (DUAL)
9613 REMOTE CONTROL BOX (SINGLE)
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2
9615 H.V. TEST LEAD
1 Alligator clip
Connect to a test point on the tested object.
Vinyl shield on 9615 H.V. TEST LEAD alligator clip is not high voltage
insulated. DO NOT touch when high voltage is applied.
2 High-voltage output plug
Connect to the HIGH terminal on the unit.
3 Low-voltage output plug
Connect to the LOW terminal on the unit.
REMOTE CONTROL BOX
1OPERATEswitch
Used to enable remote-control operation. When this switch is ON, the START and
STOP keys for remote control are active. Changing this switch during testing will
forcibly terminate the test.
2 START key
Works in the same manner as the START key on the unit. With the 9614
REMOTE CONTROL BOX (DUAL), 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.
4 Switch signal-line plug
Connect to the external switch terminal on the unit.

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2.1 Connecting the Protective Ground Terminal
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WARNING ･To avoid electric shock, be sure to connect the protective ground
terminal to a grounded conductor.
･To avoid electric shock, connect the protective ground terminal to a
grounded conductor before making any other connections.
Chapter 2
Testing Arrangements
2.1 Connecting the Protective Ground Terminal
(1) Using a Phillips-head screwdriver, remove the protective ground terminal from
the rear of the unit.
(2) Connect an electric wire with a sufficient current capacity to the protective
ground terminal, and secure the wire using a Phillips-head screwdriver.
(3) Ground the other end of the wire.

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2.2 Wearing rubber gloves
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DANGER To avoid any life-threatening electric shock accidents, ensure that the
following rules are observed.
･The AC Withstanding HiTester is a dangerous product which
discharges high voltages. To prevent getting electrocuted, always
wear high-voltage protective rubber gloves when carrying out any
operation.
･Be careful when using the product and ensure that you do not touch
this product, any tested object that is connected or any H.V. Test
Lead, etc.
2.2 Wearing rubber gloves
1. To avoid electrocution, always wear high-voltage protective rubber gloves when using
this product.
2. Contact your dealer or Hioki representative to help you look for high-voltage protective
rubber gloves.