Hioki 3159 User manual

INSTRUCTION MANUAL
3159
INSULATION/
WITHSTANDING
HiTESTER

Contents
Introduction i
Inspection i
Safety Notes ii
Notes on Use v
Chapter Summary vi
Chapter 1 Overview 1
1.1 Product Introduction 2
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 10
2.2 Connecting the External I/O Connector 11
2.3 Power Cord Connection 12
2.4 Powering On and Off the Unit 13
2.5 Connecting the 9615 H.V. TEST LEAD 14
2.6 Connecting the REMOTE CONTROL BOX 15
2.7 Installation of the Unit 16
2.8 Connection to the Measured Equipment 17
2.9 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 Comparative 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 the Output Voltage range 28
3.3.5 Examples of Settings 29

3.4 Starting a Test 32
3.4.1 Setting the Output Voltage 33
3.4.2 Executing a Test 34
3.4.3 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 39
3.5.3 "FAIL" State 40
3.5.4 Screening in "FAIL" State 44
Chapter 4 Insulation Resistance Mode Testing
Method 45
4.1 Insulation Resistance Mode Display 46
4.2 Displaying the READY State 48
4.2.1 Key-lock Function 49
4.3 "SETTING" State 50
4.3.1 Setting the Test Voltage Value 51
4.3.2 Setting the Lower (Upper) Limit Value 52
4.3.3 Setting the Test Time 54
4.3.4 Examples of Settings 55
4.4 Starting a Test 58
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 About the Auto Discharge Function 66
Chapter 5 Auto Test Mode Testing Method 67
5.1 Withstand Voltage 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 Auto Discharge Function for insulation resistance
Tests 82
Chapter 6 Optional Functions 83
6.1 PASS Hold Function 85
6.2 FAIL Hold Function 86
6.3 Hold Function 87
6.4 Momentary Out 89
6.5 Double Action 90
6.6 FAIL Mode 91
6.7 RS Command [START] 92
6.8 Inter-lock Function 93
6.9 Voltage Comparator Position 94
6.10 Insulation Resistance Test Measurement Range 95
6.11 Insulation Resistance Test Termination Mode
Settings 96
6.12 Example of Optional Functions Use 98
Chapter 7 Saving/loading Preset Values 99
7.1 Saving Preset Values 99
7.1.1 Procedure for Saving Data 99
7.1.2 Example of Saving 102
7.2 Loading Preset Values 104
7.2.1 Procedure for Loading Data 104
7.2.2 Example of Loading 106
Chapter 8 External Interface 109
8.1 External I/O Terminal 109
8.1.1 Signal Line 110
8.1.2 Example of Input Signal Connection 112
8.1.3 Example of Output Signal Connection 113
8.1.4 Inter-lock Function 115
8.1.5 Timing Chart of External I/O Terminal 117
8.2 Status Out 122
8.3 Buzzer 124

Chapter 9 RS-232C Interface 125
9.1 Specifications 125
9.2 Connection Method 126
9.3 Command Transfer Methods 127
9.4 Command 129
9.4.1 Common Command Messages 130
9.4.2 Specific Command Messages 131
9.5 Response Formats 152
Chapter 10 Specifications 155
10.1 Basic Specifications 155
10.1.1 Withstand Voltage test portion 155
10.1.2 Insulation resistance test portion 157
10.1.3 Timer Section 157
10.1.4 Interface 158
10.2 General Specifications 160
Chapter 11 Maintenance and Inspection 161
11.1 Maintenance and Service 162
11.2 Fuse Replacement 163
11.3 Troubleshooting 164
11.4 Displaying Errors 165
11.5 Resetting the System 166
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

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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 3159 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 ) 2
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 3159 with other equipment, or if ownership is transferred to a
third party.

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DANGER
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 DC (Direct Current).
Indicates a protective conductor 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 I Secondary electrical circuits connected to an
AC electrical outlet through a transformer or
similar device.
CAT II Primary electrical circuits in equipment connected to
an AC electrical outlet by a power cord (portable
tools, household appliances, etc.)
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).
Overvoltage Categories
This product conforms to the safety requirements for CAT II measurement
products.
To ensure safe operation of measurement products, IEC 60664 establishes
safety standards for various electrical environments, categorized as CAT I to
CAT IV, and called overvoltage categories. These are defined as follows.
Higher-numbered categories correspond to electrical environments with
greater momentary energy, so a measurement product designed for CAT III
environments can endure greater momentary energy than one designed for
CAT II. 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.

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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.
Avoid stepping on or pinching the cable, which could damage the
cable insulation.
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: 250VT8AL (3159, 3159-01), 250VT4AL (3159-02 to 3159-04)
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 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.
NOTE Do not use the product near a device that generates a strong electromagnetic field or
electrostatic charge, as these may cause erroneous measurements.
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 procedures for setting, testing, and test results judgment.
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 Optional Functions
Describes procedures for setting optional functions.
Chapter 7 Saving/Loading Preset Values
Describes procedure for saving and loading test values.
Chapter 8 External Interface
Describes use of the external I/O, status out and buzzer.
Chapter 9 RS-232C Interface
Describes communication procedures and commands for an RS-232C
interface.
Chapter 10 Specifications
Contains the unit specifications such as the general specifications,
measurement accuracy, etc. of the unit.
Chapter 11 Maintenance and Inspection
Covers the maintenance and inspection, fuse replacement, and ultimate
disposal.
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
With the unit insulation resistance and withstand voltage tests based on a
wide variety of standards can be performed. The timer and comparative
screening functions using the upper- and lower-limit values provide accurate
test results. When testing withstand voltage, the unit does not operate until
the output-voltage preset using the voltage adjustment knob is within 5%
(output-voltage 1 kV: 50 V) of the comparative-voltage value, thus
ensuring more accurate readings.
(2) Automatic insulation resistance testing and withstand voltage
testing
The Auto 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. (withstand voltage test only)
(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
testing mode.
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 3159 start/stop control.
(7) External I/O
The external I/O terminal generates signals according to the state of the
3159. 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.
(9) Status Out
Relay contact signals are output from the terminal on the rear panel
according to the state of the 3159. The DANGER lamp can be connected to
ensure safer testing.

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1.2 Names and Functions of Parts
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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.
1Analog voltmeter Indicates output-voltage when testing withstand voltage.
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.
A high voltage is generated between this terminal and the LOW
terminal.WhentheDANGER lamp is lit, never touch this terminal.
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 signal line for the REMOTE CONTROL BOX.
6Output voltage knob Sets the output-voltage.
7Rubber keys The 10 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.
8VFD (vacuum
fluorescent display) Displays various information, such as the test state and test results.
9START key Used to start a test. This key functions only when the READY lamp
is lit.
10 STOP key Normally used to terminate a test.
11 Main power switch Powers the 3159 on or off.
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
1/key Moves the flashing cursor.
The switching range is preset before shipment:
Withstand voltage test:
Comparative voltage value Upper limit Value Lower limit Value
Test time Output voltage range
Insulation resistance test:
Test voltage value Lower limit Value Upper limit Value
Test time
To display the flashing cursor, press the /keys. The cursor appears,
displaying the preset comparative voltage value or test voltage value.
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:
Upper limit Value (Withstand voltage test)
Output voltage range (Withstand voltage test)
Test voltage value (Insulation resistance test)
Lower limit Value (Insulation resistance test)
4LOCK key Used to lock the keys.
When pressed, the LOCK key disables all keys except the START
key, STOP key, and UNLOCK key (LOCK +SHIFT key).
(See Section 3.3.2)
5SHIFT key Used in combination with other keys.
(1) SHIFT +key
Displaying the Preset-data loading screen. (See Chapter 7)
(2) SHIFT +key
Displaying the Preset-data saving screen. (See Chapter 7)
(3) SHIFT +UNLOCK key
Disabling the key lock function.
(4) SHIFT +/key
Changing the increment size of setting values.
6Wkey
(withstand-voltage test) Performs withstand voltage tests and settings.
7Ikey
(insulation-resistance test) Performs insulation resistance tests and settings.
8W I key Tests for voltage, then insulation resistance.
9I W key Tests for insulation resistance, then withstand voltage.

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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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1 Fuse holder Contains a power fuse.
2Power inlet Connect the grounded three-core power cord supplied here.
Integrated with a fuse holder.
3RS-232C terminal Used for remote control with RS-232C.
4Protective ground
terminal Used to earth a protective ground wire. Be sure to make grounding
connections before starting a test.
5Buzzer adjustment
knob Used for buzzer sound adjustment. Two knobs are provided: one
for PASS screening and one for FAIL screening.
6STATUS OUT dip
switch Used to set the output conditions for relay contacts when using the
status out function.
7STATUS OUT relay
terminal Switches on the relay contacts if the conditions set with the
STATUS OUT dip switch are met.
8 External I/O
terminal For output of 3159 state and input of start and stop signals.
9HIGH terminal A high-voltage terminal for voltage output. Connected to the HIGH
terminal on the front panel.
10 LOW terminal A low-voltage terminal for voltage output. Contains the same
electrical potential as this units casing.

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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.
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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)
1 OPERATE 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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1.3 External Dimensions
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1.3 External Dimensions