Instruction Manual
3540
mΩ HiTESTER
May 2012 Revised edition 18 3540A981-18 12-05H
Contents
Introduction i
Inspection i
Safety ii
Precautions v
Chapter 1 Outline 1
1.1 Four-terminal Method 1
1.2 Temperature Correction Function
1.3 Effects of Thermoelectromotive Force
Chapter 2 Name and Functions 7
2.1 Front Panel 7
2.2 Rear Panel
2.2.1 3540 11
2.2.2 3540-01
2.2.3 3540-02
2.2.4 3540-03
2.3 Top Case 13
11
11
11
12
3
5
Chapter 3 Specifications 15
3.1 General Specifications 15
3.2 Measurement Range
18
Chapter 4 Operating Procedure 21
4.1 Preparing Measurement 21
4.1.1 Measurement Leads 22
4.1.2 About the Temperature Probe
4.1.3 Instrument Handle
4.2 Resistance Measurement 24
4.2.1 Setting the Power Supply Frequency 25
4.2.2 Changing the Measurement Range
4.2.3 Zero Adjust Function
23
23
26
27
4.2.4 Switching the Sampling Speed 28
4.2.5 Hold Function
4.2.6 Overload Indicator
4.2.7 Current Abnormality (CCERR) Detection
Function
28
29
29
4.3 Comparator Function 30
4.3.1 Using the Comparator 31
4.3.2 Selecting the Comparator Table
4.3.3 Selecting the Comparator Mode
4.3.4 Selecting the Buzzer Mode
4.3.5 Configuring the Comparison Values
4.3.6 Outputting Comparator Results
31
31
32
33
34
4.4 Temperature Correction Function (TC) 35
4.5 Temperature Measurement
36
Chapter 5 External Control Features 37
5.1 Connectors 38
5.1.1 The External Terminal 39
5.1.2 The External Connectors
5.2 Connections to Terminals 41
5.2.1 The External Terminal 41
5.2.2 External Connectors
5.3 Electrical Specification 43
5.3.1 Power Supply Rating 43
5.3.2 Input/output Ratings
5.3.3 Internal Circuit
5.4 Using the Signals 46
5.4.1 Measurement Control 47
5.4.2 Outputting Measurement Results
40
42
44
45
50
Chapter 6 RS-232C Interface 53
6.1 Specifications 53
6.1.1 RS-232C Settings 53
6.1.2 Electrical Characteristics
6.1.3 Connector
6.1.4 Connection Method
53
54
54
6.2 Communication Method 55
6.2.1 Connection to Computer 55
6.2.2 Command Transfer Method
6.2.3 Command Format
6.2.4 Response Format
6.2.5 Delimiter
55
56
57
57
6.3 Command 58
6.3.1 Explanation of Command References 58
6.3.2 Command References
6.3.3 Received Data
59
70
Chapter 7 Printers 73
7.1 Making Connections 73
7.2 Printing
75
Chapter 8 Maintenance and Service 77
8.1 Battery Replacement Procedure 77
8.2 Fuse Replacement Procedure
8.3 Troubleshooting
8.4 Error Code Table
8.5 Service
8.6 Cleaning
79
80
82
83
83
Appendix Zero Adjustment 85
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Introduction
Thank you for purchasing the HIOKI "3540 mΩ HiTESTER." To
obtain maximum performance from the product, please read this
manual first, and keep it handy for future reference.
Inspection
When you receive the product, inspect it carefully to ensure that
no damage occurred during shipp ing. 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.
Accessories
9287-10 CLIP TYPE LEAD 1
9451 TEMPERATURE PROBE
Instruction Manual
R6P manganese batteries (monitor batteries)
Spare fuse to protect the circuit
(F1.0 AH/250 V)
Ferrite clamp
External connector socket (Ver.-01 only)
1
1
6
1
1
1
i
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Inspection
ii
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Safety
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
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
user should refer to a corresponding topic in the
manual (marked with the
relevant function.
･ In the manual, the
important information that the user should read before
symbol printed on the product indicates that the
symbol) before using the
symbol indicates particularly
Indicates DC (Direct Current).
Indicates the ON side of the power switch.
Indicates the OFF side of the power switch.
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Safety
___________________________________________________________________
The following symbols in this manual indicate the relative
importance of cautions and warnings.
iii
WARNING
CAUTION
NOTE
Indicates that incorrect operation presents a
significant hazard that could result in serious injury or
death to the user.
Indicates that incorrect operation presents a
possibility of injury to the user or damage to the
product.
Advisory items related to performance or correct
operation of the product.
Measurement categories
To ensure safe operation of measurement instruments, IEC 61010
establishes safety standards for various electrical environments,
categorized as CAT II to CAT IV, and called measurement
categories. These are defined as follows.
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).
Using a measurement instrument in an environment designated
with a higher-numbered category than tha t for which the
instrument is rated could result in a severe accident, and must be
carefully avoided.
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Safety
iv
___________________________________________________________________
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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Safety
___________________________________________________________________
Precautions
Follow these precautions to ensure safe operation and to obtain the
full benefits of the various functions.
v
WARNING
CAUTION
Use either the specified Hioki model 9445-02/03 AC
ADAPTER.
･ Never apply an external voltage to the SENSE and
SOURCE terminals of the instrument.
･ To properly suppress noise, this product must be set to
match the power supply frequency. Before using the
product, make sure the power supply frequency selector
is set correctly, to avoid erroneous readings.
(Refer to 4.2.1 Setting the Power Supply Frequency.)
･ Do not store or use the product where it could be
exposed to direct sunlight, high temperature or humidity,
or condensation. Under such conditions, the product
may be damaged and insulation may deteriorate so that
it no longer meets specifications.
･ To avoid damage to the product, protect it from
vibration or shock during transport and handling, and be
especially careful to avoid dropping.
･ The sensor used in the temperature probe is a thin,
precision platinum film.
Please note that excessive voltage pulses or static
discharges can destroy the film.
To avoid damage or malfunction, avoid hitting the tip of
the temperature probe and overly bending the leads.
When measuring high temperatures, do not let the
handle of the temperature probe or the compensation
lead wire exceed the temperature range.
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Precautions
vi
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NOTE
The battery indicator lights up when the remaining battery
capacity is low. In this case, the instrument's reliability is not
guaranteed. Replace the battery immediately.
(Refer to "8.1 Battery Replacement Procedure.")
Be sure to turn the power switch OFF ( ) when not using the
instrument.
Warm up the instrument for at least 30 minutes prior to use, to
attain proper measurement accuracy.
This product should be installed and operated indoors only,
between 0 and 40
and 80 %RH or less.
A fuse is provided in the current source (SOURCE) to protect the
circuit. If the fuse burns out, measurements cannot be made.
Refer to "8.2 Fuse Replacement procedure" on how to check for a
burned-out fuse.
This instrument should not be used with relays or other devices
that handle small signals, since it may damage their contact
coating.
Do not measure points which have a voltage across them. The
main unit of the 3540 will be damaged by an induced voltage if a
measurement is made immediately after a temperature rise test or
dielectric test of a motor or transformer.
Accurate measurement may be difficult to obtain if the instrument
is used near equipment that generates noise.
Also, the indicator may sometimes fluctuate if the device-undertest picks u p noise. Therefore, do not use the instrument in
environments with excessive electrical noise.
The measurement indication may sometimes fluctuate due to
noise pick-up if the temperature probe is touched or held with
bare fingers.
Temperature correction is not possible when the temperature
probe is in contact with the surface of the device to be measured.
Note that the temperature probe is only designed to measure
ambient air temperature.
Significant measurement error will result if the device to be
temperature corrected and the temperature probe are not at the
same ambient air temperature.
Large measurement error will result if the temperature probe is
not inserted fully into the tc sensor jack.
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Precautions
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vii
Make sure the power is turned off before connecting or
disconnecting the AC adapter.
The AC adapter may pick up noise which will affect the
measurement. In such a case, operate the instrument from battery
power.
Measurement range , comparator settings and all settings of the
3540 (except for the measured value) are backed up internally,
but this backup occurs only after a certain amount of time has
elapsed without any operation. Therefore, after changing the
settings, wait a few moments (about 5 seconds) before turning off
the power.
Because the 3540 uses direct current to make measurements,
thermoelectromotive effects can result in measurement errors.
Refer to "1.3 Effects of T hermoelectromotive Force" for details.
When the one that includes the L component such as the
transformer for the power supply a lot is measured a measured
value may not stabilize.
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Precautions
viii
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Precautions
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Chapter 1
Outline
The 3540 mΩ HiTESTER is an four-terminal method tester
designed to accurately measure the coil resistance in motors and
transformers, the contact resistance of relays, switches a nd
connectors, and the trace resistance on printed circuit boards.
In addition, a temperature correction function, comparator function
and data output function are provided, making the 3540 mΩ
HiTESTER ideal for use in production and inspection lines and
systems.
1.1 Four-terminal Method
1
To obtain accurate results when measuring resistance values that
are very small, the Four-terminal method must be used. As shown
in figure 1, in the Two-terminal method, the resistance of the test
leads adds to the resistance of the device being measured, resulting
in an erroneous measurement. However, in the Four-terminal
method shown in the Figure 2, the input consists of two current
terminals to which a constant current is supplied, and two voltage
terminals measured the voltage drop. The voltmeter has a high
input impedance so that essentially no current flows through the
leads connected between the device-under-test and the voltage
terminals. As a result, there is almost no voltage drop across the
resistances r
resistances and contact resistances is very small, and these can be
canceled out.
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3
. Thus the voltage drop due to the lead
and r
4
1.1 Four-terminal Method
2
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Ohmmeter
Constant current
source
Voltmeter Voltmeter
I
E
r
2
Resistance
r
1
R
0
The current I flows to the measured
resistance R
resistance r
and the wiring
0
and r2.
1
Therefore, the measuring voltage E
canbeobtainedbyE=I(r1+R0+r2),
and it would include the wiring
resistance r1and r2.
Figure 1
Measurement Using the 2-terminal
Method
Ohmmeter
Constant current
source
I
E
r
2
r
4
Resistance
r
3
E
0
R
0
All of the current I flows to the
measured resistance R
.
0
Therefore, the voltage drop of r
r
become 0, and voltage E and the
4
voltage drop E
measured resistance R
of each end of the
0
become
0
equal. Accordingly, the resistance
measurement without influence of r
to r4becomes possible.
Figure 2
Measurement Using the 4-terminal
Method
3
r
1
and
1
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1.1 Four-terminal Method
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1.2 Temperature Correction Function
The temperature sensor used in the 3540's temperature probe is a
thin platinum film whose resistance changes according to
temperature. The resistance of the film is detected and converted to
a temperature value by the CPU.
This section explains use of the 3540's temperature coefficient
correction function.
Since the resistance of copper wire is relatively susceptible to
changes in temperature, that fact must be kept in mind when
measuring its resistance. Using the temperature probe, the
resistance value of copper wire can easily be converted to its 20
equivalent for display.
In general, the relationship between the resistance of copper wire
and temperature is as indicated by the following expression.
=Rt0x {1 + α
R
t
Here, α
is referred to as the temperature coefficient, which is
t0
expressed as follows.
= 1 / [{1 / (0.00393 x α }+(t0- 20)] (2)
α
t0
Here, σ is the conductivity of copper wire. From expressions (1)
and (2), the temperature coefficients of various types of wire with
various conductivities can be calculated, and their resistance values
at a particular temperature obtained. Table 1 shows the
conductivity of various types of copper wire.
x (t - t0)} (1)
t0
3
Diameter (mm) Soft copper
0.10 to 0.26
0.26 to 0.29
0.29 to 0.50
0.50 to 2.00
2.00 to 8.00
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0.98 0.93 ---
0.98 0.94 ---
0.993 0.94 ---
1.00 0.96 0.96
1.00 0.97 0.97
Table 1 Conductivity
1.2 Temperature Correction Function
Tin-plated
soft copper
σ
Hard copper
4
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For 3540 temperature correction, conductivity σ is calculated as
1. Accordingly, when the resistance value R
the time of temperature correction is taken as R
that is displayed at
20
, the measured
t
resistance at the current ambient temperature is expressed by the
following expression. (Temperature coefficient: α
-6
ppm = x 10
R
)
=Rt/{1+α
20
x (t - 20)} (3)
20
=3930ppm,
20
Error occurs during temperature correction because the temperature
coefficient calculated according to expression (2) differs when the
conductivity σ is other than 1.
For example, when the tin-plated soft copper wire (diameter 0.10
to 0.26) of Table 1 is measured, σ = 0.93 gives α
of 3650 ppm,
t0
so that the 3540 temperature value contains error.
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1.2 Temperature Correction Function
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1.3 Effects of Thermoelectromotive Force
Thermoelectromotive force is the potential difference at the
junction of two dissimilar metals. If this emf is large, measurement
errors can result. As the 3540 uses constant direct current flowing
through the object being measured, readings can be affected by
even slight thermoelectromotive force.
Furthermore, the quantity of thermoelectromotive force is
dependent upon the temperature of the measurement environment,
with the force generally being greater at higher temperature.
Thermoelectromotive force occurs at the junction of dissimilar
metals and between the probes of the 3540 and the contacts on the
object being measured. The following figure illustrates
thermoelectromotive force. The battery symbols represent a
junction of dissimilar metals, and the probe symbols represent the
thermoelectromotive force.
Metal A Thermoelectromotive force
Metal:B
5
3540
As an example of the error effects of thermoelectromotive force, if
the force is 10 μV and the measured resistance is 3 Ω, the current
is 1 mA in the 3 Ω range, so the measured value displayed on the
3540 is actually
(3 Ω x 1mA+10μV) / 1 mA = 3.010 Ω. In t hi s s ituation,
changing the probe direction to HI-LO leaves the polarity of the
thermoelectromotive force unaffected, so the measured value is
now (3 Ω
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x 1mA-10μV) / 1 mA = 2.990 Ω.
1.3 Effects of Thermoelectromotive Force
6
___________________________________________________________________
If the measurement error is large due to the effect of
thermoelectromotive force, the following countermeasures can be
employed.
(1) Reverse the probes and use the average measured value.
(2) As the thermoelectromotive force is temperature dependent,
maintain a constant temperature in the measurement environment.
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1.3 Effects of Thermoelectromotive Force
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4
Chapter 2
Name and Functions
2.1 Front Panel
7
Handle LCD Comparator display
15.HI/REF key
14.TABLE key
1.Power switch
10.FAST mark
16.Comparator configuration keys
5.HOLD mark
4.AUTO mark
2.Measurement display area
3. keys 7.TC key(8.TEMP key)
.AUTO key
17.Buzzer key
5.HOLD key (6.0ADJ key)
13.COMP key
12.SHIFT key
10. SAMPL key (11. 50/60Hz key)
9.LOCK mark
7.TC mark
Input terminal
9.LOCK key
(UNLOCK key)
12. SHIFT mark
18.Battery
mark
14. Table No display
13. Comparator display
15. Comparator mode display
16. Comparator configuration display
17. Buzzer mode display
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2.1 Front Panel
8
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1. POWER switch
On power-up, the LCD and LED's light and the instrument
performs an internal check and init ialization of internal analog
circuits. An error code is displayed if an internal error is detected
during the check. (Refer to "8.4 Error Code Table".)
Upon completion of the internal check, the LCD displays the
instruments power supply frequency setting and the 3540 version
number.
2. Measurement display area
Displays the measurement count, decimal point, unit of
measurement, and the measurement range.
3.
The
keys Page 26
(up) and (down) keys are used to select the
resistance measurement range.
4. AUTO
Pressing the AUTO
key, AUTO mark Page 26
key turns on automatic range selection,
lighting the AUTO mark on the LCD. The measurement range for
resistance is then automatically selected according to the resistance
of the resistor being measured.
5. HOLD
Pressing the HOLD
key, HOLD mark Page 28
key turns on the hold mode, lighting the
HOLD mark on the LCD and fixing the currently displayed
measurement value.
6. 0ADJ
key Page 27
To zero-adjust the instrument, short the test leads and press
SHIFT
+ 0ADJ . (Zero adjustment is only possible with a
reading of 100 counts or less.)
7. TC
key, TC mark Page 35
When the temperature probe is connected, pressing the TC
key
converts the measured resistance value of copper wire to its 20
equivalent resistance value and displays it.
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2.1 Front Panel
___________________________________________________________________
8. TEMP key Page 36
Pressing SHIFT
selects the temperature measurement mode. Pressing SHIFT
TEMP
a second time returns measurement to the resistance
+ TEMP with the temperature probe connected
+
mode.
9. LOCK
Pressing the LOCK
/ UNLOCK key, LOCK mark
key lights the LOCK mark on the LCD and
locks out key input. With key input locked, all of the keys on the
instrument are disabled except for the POWER
SHIFT
10. SAMPL
key. To unlock the keys, press SHIFT + UNLOCK .
key, FAST mark Page 28
Sampling speed is switched using the SAMPL
switch and the
key. With fast
sampling, FAST is displayed on the LCD and sampling takes place
at the rate 16 samples per second. When slow sampling is selected,
sampling takes place at the rate of 4 samples per second.
11. 50/60Hz key Page 25
Power supply frequency is selected by pressing SHIFT
50/60Hz
. Select the frequency that matches that of your power
supply.
12. SHIFT
Pressing the SHIFT
key, SHIFT mark
key lights the SHIFT mark on the LCD and
puts the keys in the shift mode. In the shift mode, pressing any
key activates the function whose name is printed in blue below
that key. To cancel the shift mode, press the SHIFT
time.
13. COMP
Pressing the COMP
key, comparator display Page 31
key turns on the comparator, lighting the
comparator display on the LCD and enabling comparison
measurement. To end comparison measurement, press the COMP
key a second time.
14. TABLE
Pressing the TABLE
key, Table No. display Page 31
key switches the internal comparator table
number. With the 3540, up to seven different comparator
configurations can be saved.
+
key a second
9
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2.1 Front Panel
10
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15. HI/REF key, comparator mode dis play Page 31
The comparator mode is selected with the HI/REF
key. When the
HIGH or LOW mark is lit on the LCD, the comparator is in the
Hi-Lo mode. When the REF or % mark is lit, it is in the REF-%
mode.
16. Comparator configuration keys, comparator configuration
display
Page 33
Upper (HIGH) and lower (LOW) comparator limits and the
comparator reference value (REF) and range (%) can be set by
pressing keys corresponding to the various digits of the comparator
configuration display on the LCD
17. Buzzer key and buzzer mode display
Page 32
Pressing the buzzer key switches the buzzer mode that is set
dependent upon comparator results. When the
buzzer mark is
lit on the LCD, the buzzer is in the HL mode, and sounds when
the comparator result is HIGH or LOW. When the
buzzer
mark is lit on the LCD, the buzzer is in the IN mode, and sounds
when the comparator result is IN. When no buzzer mark is lit on
the LCD, the buzzer is in the OFF mode, and does not sound.
18. Battery mark
Page 77
The battery indicator appears when battery voltage becomes low.
Replace the batteries as soon as possible.
(Refer to "8.1 Battery Replacement Procedure".)
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2.1 Front Panel
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11
2.2 Rear Panel
2.2.1 3540
TC sensor jack (Page 36) 2. AC adapter jack
2.2.2 3540-01
External connector (Page 40)
1. AUTO/MANU selection switch
External terminal (Page 39)
TC sensor jack (Page 36) 2. AC adapter jack
2.2.3 3540-02
Printer connector (Page 73)
1. AUTO/MANU selection switch
TC sensor jack (Page 36) 2. AC adapter jack
___________________________________________________________________
External terminal (Page 39)
2.2 Rear Panel
12
___________________________________________________________________
2.2.4 3540-03
RS-232C connector (Page 54)
1. AUTO/MANU selection switch
TC sensor jack (Page 36) 2. AC adapter jack
External terminal (Page 39)
1. AUTO/MANU selection switch Page 34
Selects the AUTO mode, for continuous comparator output
operation("normal" mode), or the MANU mode for comparator
output only when the MANU and GND terminals of the external
connector on the rear panel are shorted.
2. AC adapter jack
The 3540 can be operated from an AC power source by connecting
an AC adapter.
When using an AC adapter, use only the specified HIOKI model
9445-02, 9445-03 AC ADAPTER.
An AC adapter rated at 9 VDC and 1.4 A to the AC adapter
socket. The polarity of socket is center-plus.
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2.2 Rear Panel
___________________________________________________________________
13
2.3 Top Case
Battery cover (Page 78)
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2.3 Top Case
14
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___________________________________________________________________
2.3 Top Case
___________________________________________________________________
15
Chapter 3
Specifications
3.1 General Specifications
Measurement method
Operating method
Display
Auto range
Input overflow
Current abnormality
Sampling speed
Response time
Comparator
Temperature correction
function
External control
*1
*2
Four-terminal method
Dual integrator circuit
LCD display
Resistance measurement 3500 counts
Temperature measurement 999 counts
Provided (disabled when comparator is on)
"OF" display
"----" displayed (CCERR: external output*2)
Resistance measurement
"SLOW" 4 samples/sec
"FAST" 16 samples/sec
Temperature sampling 1 sample/sec
Resistance measurement
"SLOW" 300 msec
"FAST" 80 msec
Table storage of up to 7 configurations (table
externally selectable
Comparator results displayed by LED and
externally output (open collector*2)
Comparator modes (Hi-Lo/REF-%), Buzzer mode
(HL/IN/OFF)
Reference temperature 20oC (68 ), copper wire
(temperature coefficient: 3930 ppm)
TTL output
BCD
Open collector output
EOC, Hi, IN, Lo, CCERR
TTL input
TRIG, MANU, 0 ADJ, PRINT
comparator control
*3
)
*4
*3
, range control*3,
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3.1 General Specifications
16
___________________________________________________________________
Interface
Printer
Power supply frequency
Overvoltage protection
Operating
temperature/humidity
Storage temperature/humidity
Operating Environment
Power source
AC adapter (option)
Maximum rated power
Continuous operating time
Dimensions
Mass
RS-232C interface
Centronics interface
*5
*4
50/60 Hz, switchable
30 VDC or ACpeak (circuit protection by fuse)
0to40oC (32 to 104 ), 80 %RH or less
(No condensing)
-10 to 50oC (14 to 122 ), 80 %RH or less
(No condensing)
Indoor < 2000 m ASL (6566 feet)
Six LR6 alkaline batteries or six R6P manganese
Batteries
Rated supply voltage 1.5 VDC x 6
9445-02 AC ADAPTER
9445-03 AC ADAPTER
Rated supply voltage of the AC adapter is 100 to
240 VAC. (Voltage fluctuations of 10% from the
rated supply voltage are taken into account.)
Rated supply frequency is 50/60 Hz.
5VA
LR6 Alkaline Batteries
Approx.7 hours
(30 m, 300 mΩ range, LED and buzzer: ON)
Approx.18 hours
(other ranges, LED and buzzer: ON)
R6P manganese Batteries
Approx.1.5 hours
(30 m, 300 mΩ range, LED and buzzer: ON)
Approx.6 hours
(other ranges, LED and buzzer: ON)
Approx. 215W x 61H x 213D mm
(8.46"W x 2.40"H x 8.39"D)
3540
Approx. 900 g (31.7 oz.)
3540-01, 3540-02, 3540-03
Approx. 1,000 g (35.3 oz.)
(Except for batteries)
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3.1 General Specifications
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