Hioki 3550 User Manual

INSTRUCTION MANUAL

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BATTERY HiTESTER

Contents

Introduction i

Inspection i

Safety ii

Precautions v

Organization of this Manual viii

Chapter 1 Overview 1

Chapter 2 Names and Functions of Parts 3

Chapter 3 Specifications 9

3.1 General Specification 9

3.2 Measurement Range

3.2.1 Maximum Input Voltage 14

3.2.2 Floating Voltage

3.2.3 Dielectric Strength

13

15
15

Chapter 4 Standard Measurement 17

4.1 Preparing for Measurement 17

4.2 Measurement

19

Chapter 5 Advanced Measurement Functions 23

5.1 Comparator Function 23

5.1.1 What is the Comparator Function? 23

5.1.2 Comparator Settings

5.1.3 Comparator Decision Result Table

5.1.4 Switching the Comparator On and Off

5.1.5 Changing the Comparator Number

24
29
30
31

5.2 Measurement Value Memory Function 32

5.2.1 Memory 32

5.2.2 Clear

5.2.3 Readout

5.2.4 Printing

34
35
36

5.3 Beeper On/Off Function 38

5.4 Hold Function

5.5 Moving Average Function

5.6 Zero Adjust Function

5.7 Battery Low Warning

5.8 Auto Power Off

5.9 AC Four-Terminal Method

5.10 Internal Resistance of Lead-Acid Batteries

38

39

41

42

43

45

47

Chapter 6 Maintenance 49

6.1 Troubleshooting 49

6.2 Message Reference

6.3 Cleaning

51

51

___________________________________________________________________

Introduction

Thank you for purchasing the HIOKI "3550 BATTERY
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 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.

Accessories

9460 CLIP TYPE LEAD WITH TEMPERATURE SENSOR
9382 CARRYING CASE
Six LR6 alkaline batteries
Instruction Manual
Dust cover (for the printer interface)

i

Shipping

Use the original packing materials when reshipping the
product, if possible.

___________________________________________________________________

Inspection

ii

y

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Safet

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

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 symbol printed on the product indicates
that the user should refer to a corresponding
topic in the manual (marked with the
before using the relevant function.
In the manual, the symbol indicates
particularly important information that the user
should read before using the product.

symbol)

Indicates DC (Direct Current).

Indicates the ON side of the power switch.

Indicates the OFF side of the power switch.

___________________________________________________________________

Safety

___________________________________________________________________

The following symbols in this manual indicate the relative
importance of cautions and warnings.

iii

DANGER

WARNING

CAUTION

NOTE

Indicates that incorrect operation presents an
extreme hazard that could result in serious injury
or death to the user.

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.

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Safety

iv

___________________________________________________________________

Measurement categories (Overvoltage categories)

This product conforms to the safety requirements for CAT I

measurement products.

To ensure safe operation of measurement products, IEC 61010

establishes safety standards for various electrical environments,

categorized as CAT I to CAT IV, and called measurement

categories. These are defined as follows.

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).

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.

Never use a CAT I measuring product in CAT II, III, or IV

environments.

The measurement categories comply with the Overvoltage

Categories of the IEC60664 Standards.

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Safety

___________________________________________________________________

Precautions

Follow these precautions to ensure safe operation and to
obtain the full benefits of the various functions.

v

DANGER

WARNING

The floating voltage between input terminals and
ground is 450V DC/AC. Attempting to measure
voltages exceeding 450V with respect to ground
could damage the product and result in personal
injury.
When voltages higher than 30 Vrms, 42.4 Vpeak or
battery circuits with more than 60 VDC are to be
measured, be sure to establish the floating state
first. Carrying out such measurements in the
grounded state involves the risk of electric shock.
When measuring batteries, always ensure sufficient
ventilation. Sometimes sparks may occur when the
test leads are connected to batteries, which can
ignite any accumulated inflammable gases such as
hydrogen.
To avoid electric shock accidents, when measuring
batteries being charged wear proper protective gear
such as rubber gloves.

Do not allow the product to get wet, and do not take
measurements with wet hands. This may cause an
electric shock.
Do not use the product where it may be exposed to
corrosive or combustible gases. The product may be
damaged or cause an explosion.

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Precautions

vi

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WARNING

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 representative
for replacements. (Model 9460)
Be sure to connect the SOURCE and SENSE
terminals (banana plugs), and TEMP SENSOR
terminal (mini-plug) correctly. See Section 4.2,
"Measurement" for details of the connections.
To avoid injury or damage to the product, do not
attempt to measure AC voltage, or DC voltage
exceeding 50 V.

50 VDC max.

Do not apply a voltage between the SOURCE(+) and
SENSE(+) or SOURCE(-) and SENSE(-) terminals.
This could result in damage to the unit.

CAUTION

This product is not designed to be entirely water- or
dust-proof. To avoid damage, do not use it in a wet or
dusty environment.

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Precautions

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vii

CAUTION

NOTE

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.
Do not use the product near a device that generates a
strong electromagnetic field or electrostatic charge, as
these may cause erroneous measurements.

Use the specified 9460 CLIP TYPE LEAD WITH
TEMPERATURESENSORwhenthistesterisused.

Correct measurement may be impossible in the presence of
strong magnetic fields, such as near transformers and high­current conductors, or in the presence of strong
electromagnetic fields such as near radio transmitters.

Service

Before using the product the first time, verify that it
operates normally to ensure that the no damage occurred
during storage or shipping. If you find any damage,
contact your dealer or Hioki representative.

When sending the product for repair, remove the batteries
and pack carefully to prevent damage in transit. Include
cushioning material so the product cannot move within the
package. Be sure to include details of the problem. Hioki
cannot be responsible for damage that occurs during
shipment.

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Precautions

viii

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Organization of this Manual

This manual consists of the following chapters.

"Introduction", "Inspection", "Safety", "Precautions" include
some important notes which you should read before using
the unit.

Chapter 1 Overview

describes an outline of the unit, and lists its features.

Chapter 2 Names and Functions of Parts

lists the names of the parts of the unit, and the functions of
all of the indications, terminals, and switches.

Chapter 3 Specifications

lists the specifications of the unit.

Chapter 4 Standard Measurement

describes the basic operation of the unit.

Chapter 5 Advanced Measurement Functions

describes miscellaneous functions.

Chapter 6 Maintenance

gives troubleshooting information.

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Organization of this Manual

___________________________________________________________________

Chapter 1

Overview

The 3550 is designed for measuring the internal resistance,
open-circuit voltage, and terminal temperature of secondary
batteries, including lead-acid batteries, nickel-cadmium
batteries, nickel-metal hydride batteries, and lithium-ion
batteries.

Features

Since it uses the AC four-terminal method to measure the
internal resistance, it provides accurate results with the lead
resistances and contact resistances eliminated.
It is possible to display the readings for the battery internal
resistance, voltage, and terminal temperature, without
changing functions. Moreover, a composite comparator
function, which can be set on resistance and voltage values,
enables reliable detection of battery deterioration.
The unit's memory function also allows a number of sets of
readings to be stored at a touch, and later output to a
printer.
These functions make this an ideal tool for checking
batteries which are under constant trickle charging and
cannot be disconnected.

1

NOTE

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Measurements are taken by using noise reduction technology to

attenuate noise at frequencies other than the measurement

frequency (1 kHz). Incorrect measurements may result if a large

1-kHz noise component from the charger is present at the battery

terminals.

Chapter 1 Overview

2

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Chapter 1 Overview

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Chapter 2

Names and Functions of

Parts

This chapter explains the keys, input and output terminals,
display, LED indicators, and leads.

3

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Chapter 2 Names and Functions of Parts

4

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Front Panel

16

15

17

12

13

14

1 2 4 5 3 6 7 10 11 9

8

Side Panel

18 19 20

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Chapter 2 Names and Functions of Parts

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●

Keys and input/output terminals

POWER

1.

2.

300m

3.

0ADJ

4.

5.

HOLD

6.

7.

COMP

8.

30m

30

key Turns the power on or off.

Ω key

3

3

key

Ω key
Ω key

V key
V key

key

key

key

key

Selects the resistance range.

Selects the voltage range.

Zero adjustment key.

Turns the beeper on and off.

Locks out changes to the display.

Left cursor (flashing) key.

Switches the comparator on and off, and
changes display to the comparator setting
screen.

9.

10.

11.

12.

13.

14.

15.

16.

key

key

UP

DOWN

MEMO

CLEAR

READ

PRINT

SOURCE

key

key

key

key

key

Right cursor (flashing) key.

Increases the value of a numeric setting.

Decreases the value of a numeric setting.

Stores the display data in memory.

Clears data captured with the

Reads data captured with the

Prints data captured with the

MEMO

MEMO

MEMO

key.

key.

key.

Connects to the 9460 banana plug on the
SOURCE side.

17.

SENSE

Connects to the 9460 banana plug on the
SENSE side.

TEMP SENSOR

18.

EXT.MEMO

19.

Connects to the 9460 mini-plug.

Connects to an external foot switch or
similar, and stores the displayed data in
memory.

20.

PRINT

Connects to the printer.

5

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Chapter 2 Names and Functions of Parts

6

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●

LCD (view with all elements displayed)

1

2 3

●

Display

1. Measured resistance

2. Temperature measurement value [comparator resistance

lower limit setting]

3. Temperature measurement value [comparator resistance
lower limit setting]

mΩ

V

HOLD

COMP

Indicates the unit of resistance.

Indicates the unit of voltage.

Indicates the unit of temperature.

Appears when the display is locked.

Appears when the comparator function is on.

Appears when the beeper is turned on.

DATA

No.

Indicates that data captured data with the

MEMO

key is present.

Indicates the number of data points captured

with the

MEMO

key.

Usually, this is the number of the last data

point captured.

[The comparator table number.]

[]: Appears in on the comparator setting screen.

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Chapter 2 Names and Functions of Parts

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7

MEMO

Flashes once when the

MEMO

pressed.

Appears when the battery voltage of the

tester is low, to prompt the user to replace

the battery.

COMP.SET

Appears during display of the comparator

setting screen.

OHM

Appears during display of the screen for

setting the comparator resistance upper and

lower limit values.

VOLT

Appears during display of the screen for

setting the comparator voltage threshold

value.

●

LEDs

PASS

Indicates that the tested battery is

satisfactory for operation.

key is

WARNING

Indicates that the tested battery is

beginning to deteriorate.

FAIL

Indicates that the tested battery has

deteriorated.

These indications appear when the upper and lower
comparator limits for internal resistance and the
comparator threshold value for voltage are all set.

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Chapter 2 Names and Functions of Parts

8

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●

9460 CLIP TYPE LEAD WITH TEMPERATURE SENSOR

Clip (red)

Temperature
sensor

Mini-plug
(TEMP.SENSOR)

Clip (black)

Banana plug (black)

Banana plug (red)

SOURCE SENSE

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Chapter 2 Names and Functions of Parts

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Chapter 3

Specifications

3.1 General Specification

9

Measurement method

A/D conversion

Display

Panel abbreviations

and symbols

Sampling rate

Open-circuit terminal

voltage

Input overflow

Battery low detection

Constant current fault

detection

Moving average

function

Resistance: AC four-terminal method.
Temperature: platinum temperature
sensor.

Double inte

gration method.

LCD and LEDs (comparator output)

HOLD,COMP

MEMO

COMP.SET,OHM,VOLT,V

,

No.

, ,

,m,Ω, ,

DATA

,

o

C

,

0.83 sets (resistance, voltage, and
temperature measurements)/second.

5Vmax.

"OF" indication

" " indication (indicates at 6.4 V
with LR6 X 6)

"----" indication.

measurement (can be set to on or off)

Zero adjustment

function

Hold function

___________________________________________________________________

Circuit offset voltage is displayed as
0V.

Display is held.

Chapter 3 Specifications

10

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Beeper function

Auto power off

Comparator settings

Number of

comparator settings

Comparator output

Resistance

Voltage

LO

HI

Audible output for warning and fail
results.
Canbeturnedonandoff.

Power off automatically after about
30 minutes.

Resistance upper and lower limits
and voltage lower limit.

Ten sets.

LEDs for
(amber), and
Audible tone for

PASS

FAIL

(green),

(red) results.

WARNING

WARNING

results.

LO IN HI

WARNING

(Amber)*1

PASS

(Green)

WARNING

(Amber)

WARNING

(Amber)

and

FAIL

(Red)

FAIL

(Red)

FAIL

*1 Voltage low and internal resistance low: amber flashing

Data save

Save measurement value in memory
when

EXT.MEMO

MEMO

key pressed or

terminals shorted.
Memory holds 260 sets of resistance,
voltage, and temperature values, and
comparator result.
The LED for warning flashing is
stored in memory as a WARNING
result.

Data readout

Data in memory is read out to
display.

Data clear

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Chapter 3 Specifications

Clear the data in memory.

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11

Printer interface

Operating
temperature and
humidity range

Storage temperature
and humidity range

Power source

Rated supply voltage

Location for use

Maximum power
consumption

Continuous operating
time

Dimensions

Centronics (can be connected to the
9203 DIGITAL PRINTER)

o

Cto40

0

o

C(32。F to 104。F)

80 %RH (no condensation)

-10

o

Cto50

o

C(14。F to 122。F)

80 %RH (no condensation)

Six LR6 alkaline batteries or six R6P
manganese batteries

1.5 VDC X 6 (Voltage fluctuations of
10% from the rated supply voltage
are taken into account.)

Altitude up to 2000 m (6562-ft.)

1.8 VA

Approx. 7 hours (at 30 mΩ range,
comparator ON, beeper ON, with
LR6 batteries)

Approx. 196W X 130H X 50D mm
(7.72"W X 5.12"H X 1.97"D)

Mass

Approx. 710 g (25.0 oz.)
(Including batteries)

Effect of radiated
radio-frequency
electromagnetic field

at 3V/m
Resistance measurement

3.0% f.s.

Voltage measurement

3.0%f.s.

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Chapter 3 Specifications

12

___________________________________________________________________

Standards applying

EMC

EN61326:1997+A1:1998+A2:2001
+A3:2003

Safety

EN61010-1:2001
Pollution Degree 1,
Measurement Category I
(anticipated transient overvoltage
2500 V)

Accessories

9460 CLIP TYPE LEAD WITH
TEMPERATURE SENSOR
9382 CARRYING CASE
Instruction Manual
Dust cover (for the printer interface)
Six LR6 alkaline batteries

Options

9203 DIGITAL PRINTER
9425 CONNECTION CABLE
(2-meter long for connecting to the

9203)
9233 RECORDING PAPER
(ten 10-meter rolls for the 9203)

Accuracy

We define measurement tolerances in terms of f.s. (full
scale), rdg. (reading) and dgt. (digit) values, with the
following meanings:

f.s. (maximum display value or scale length)

The maximum displayable value or the full length of the
scale. This is usually the maximum value of the currently
selected range.

rdg. (reading or displayed value)

The value currently being measured and indicated on the
measuring product.

dgt. (resolution)

The smallest displayable unit on a digital measuring product,
i.e., the input value that causes the digital display to show a
"1".

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Chapter 3 Specifications

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13

3.2 Measurement Range

Conditions to guarantee accuracy:

o

Temperature :23
Humidity :80 %RH or less (no condensation)
Zero adjustment :After zero adjustment for each range
Warminguptime :Atleast10minutes
Period of guaranteed accuracy :1 year

(1) Resistance Measurement

Temperature coefficient: ( 0.01% rdg. 0.5 dgt.)/
Measurement current frequency: 1 kHz

Range

30 mΩ 30.00 mΩ 10 µΩ 50 mA

300 mΩ 300.0 mΩ 100 µΩ 5mA

3 Ω 3.000 Ω 1mΩ 500 µA

Maximum
indication

Resolution

Measurement

current

o

C 5

C

Six months
1 year

Six months
1 year

Six months
1 year

o

C

30 Hz

Accuracy

0.8% rdg. 6 dgt.

1.2% rdg. 6 dgt.

0.8% rdg. 6 dgt.

1.2% rdg. 6 dgt.

0.8% rdg. 6 dgt.

1.2% rdg. 6 dgt.

(2) Voltage Measurement

o

Temperature coefficient: ( 0.005% rdg. 0.5dgt.)/

Range

3V 3.000 V 1mV

30 V 30.00 V 10 mV

Maximum
indication

Resolution Accuracy

Six months
1 year

Six months
1 year

C

0.1% rdg. 6 dgt.

0.15% rdg. 6 dgt.

0.1% rdg. 6 dgt.

0.15% rdg. 6 dgt.

(3) Temperature Measurement

Measurement range Resolution Accuracy

-10oCto60oC 0.1oC

___________________________________________________________________

Six months
1 year

0.5% rdg. 10 dgt.

0.75% rdg. 15 dgt.

Chapter 3 Specifications

14

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3.2.1 Maximum Input Voltage

DANGER

The maximum input voltage is 50 VDC. Attempting
to measure voltage in excess of the maximum input
could destroy the product and result in personal
injury or death.
To avoid electrical hazards and damage to the
product, do not apply voltage exceeding the
maximum input to the measurement terminals.

50 VDC max.

50 VDC maximum
No AC voltage input

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Chapter 3 Specifications

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15

3.2.2 FloatingVoltage

Between input terminals and ground, 450 VDC/AC
maximum.

DANGER

Do not input voltage in excess of this floating
voltage to the measurement terminal. This could
result in injury or damage to the unit.
When voltages higher than 30 Vrms, 42.4 Vpeak or
battery circuits with more than 60 VDC are to be
measured, be sure to establish the floating state
first. Carrying out such measurements in the
grounded state involves the risk of electric shock.

3.2.3 Dielectric Strength

Between input terminals and output terminals (including the

EXT.MEMO

DANGER

terminal): 1350 Vrms maximum for 1 minute.

1350 Vrms max.
for 1 minute

PRINT

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Chapter 3 Specifications

16

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Chapter 3 Specifications

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17

Chapter 4

Standard Measurement

4.1 Preparingfor Measurement

To avoid electric shock when replacing the batteries,

WARNING

first disconnect the leads from the object to be
measured.
Do not mix old and new batteries, or different types
of batteries. Also, be careful to observe battery
polarity during installation. Otherwise, poor
performance or damage from battery leakage could
result.
After replacing the batteries, replace the cover
before using the product.

1. Remove the battery cover.

2. Insert the batteries into the battery compartment as shown in
the figure below.

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Chapter 4 Standard Measurement

18

___________________________________________________________________

To avoid the possibility of explosion, do not short

WARNING

circuit, disassemble or incinerate batteries.
Handle and dispose of batteries in accordance with
local regulations.

NOTE

The " " indicator appears when battery voltage becomes low.

Replace the batteries as soon as possible.

Removing the batteries clears all measurement data from

memory. (See Section 5.2, "Measurement Value Memory

Function.")

After replacing the batteries, the auto power off function is set

to 30 minutes, with the beeper on.

Be sure to press the

POWER

key to power the unit off before

removing the batteries. If the batteries are removed while the

unit is powered on, the previous comparator number may not be

recovered.

To avoid problems with battery operation, remove the batteries

from the product if it is to be stored for a week or more.

Even when the power to the main unit is switched off, a very

small current (approximately 0.7 mA) is drawn from the

batteries to back up internal data. Therefore if the unit is left

switched off with new batteries installed, they will become fully

drained within 2 to 2.5 months.

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Chapter 4 Standard Measurement

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19

4.2 Measurement

WARNING

CAUTION

To prevent electric shock, before using this tester,
fit the supplied dust cover for the printer interface
over the PRINT terminal.
To avoid injury or damage to the product, do not
attempt to measure AC voltage, or DC voltage
exceeding 50 V.

Do not attempt to measure the voltage of a generator.
This would result in an AC voltage being applied to the
voltage-generating output terminals, which is
dangerous.
After measuring a high-voltage battery, before
continuing to measure a low-voltage battery first short
the measurement leads together. This will discharge
the DC-elimination capacitor which is connected across
the leads. Otherwise an excess voltage may be
applied to the low-voltage battery, which is dangerous.

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Chapter 4 Standard Measurement

20

___________________________________________________________________

1. Connect the 9460 leads as shown in the figure below.
Connect leads to all five terminals; SOURCE +/-, SENSE
+/-, and TEMP SENSOR.

Mini-plug

TEMP SENSOR
terminal

2. Press the

SOURCE and SENSE terminals

POWER

keytoturnonthepowerandstart

Banana plugs

Black Red

measurement.
After pressing the

POWER

key to power on, it is necessary to
wait for ten minutes of warming-up time, to allow the unit to
stabilize.

3. Connect the red clip to the positive (+) side of the battery to
be tested and connect the black clip to the negative (-) side.

Make the connections so that the temperature sensor is
firmly in contact with the battery terminal.

Battery

Black

Red

4. Using the range keys, select the voltage and resistance

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Chapter 4 Standard Measurement

___________________________________________________________________

21

measurement ranges.

5. When the measurement is completed, disconnect the leads
from the tested battery and press the

POWER

key to turn off

the power.

NOTE

When measuring the contact resistance of a relay or connector,

be careful of the open-circuit voltage across the test leads. It

may not always be possible to destroy an oxide layer on the

terminals of the object being measured in order to obtain an

accurate reading.
When the indication for a measurement value is "OF", this

indicates that the measured voltage, resistance, or temperature

value is outside the measurement range.

A resistance indication "----" means that the measurement could

not be made because there is a break in the test lead circuit.

The "----" indication may also appear if the leads are not

making good contact with the object to be measured, or if its

resistance is extremely large compared with the measurement

range.

The "----" indication may also appear immediately after

changing the resistance or voltage measurement range.

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Chapter 4 Standard Measurement

22

___________________________________________________________________

A temperature indication "---" means that the temperature sensor

is not connected. The "---" indication may also appear if there

is a break in the test lead circuit.

Except for setting the auto power off mode and the moving

average function, do not press the

POWER

key in combination

with other keys. (For details of the moving average settings, see

Section 5.5, "Moving Average Function", and for details of the

auto power off settings, see Section 5.8, "Auto Power Off".)

If you do press a combination of the

keys, and an "

press the

POWER

"or"

INSP

key to power off and on again. Otherwise,

" indication appears, immediately

Adju

POWER

key and other

continuing with key operations may destroy the calibration data

for the unit, and correct measurement will no longer be possible.

If the leads are open-circuit, a spurious voltage indication may

sometimes be given. This is not a malfunction.

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Chapter 4 Standard Measurement

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23

Chapter 5

Advanced Measurement

Functions

5.1 Comparator Function

5.1.1 What is the Comparator Function?

The comparator function compares the measurement values
with preset lower and upper limit values for internal
resistance and voltage level, and determines which range the
measurement falls into, based on the preset conditions. It
then lights the corresponding LED, and sounds a beeper for
the WARNING and FAIL cases. (See Section 5.3 Beeper
On/Off Function)

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Chapter 5 Advanced Measurement Functions

24

___________________________________________________________________

5.1.2 Comparator Settings

(1) Before changing the settings

To set the comparator (upper and lower resistance limits and
voltage comparison value), do the following:

1. Press and hold the
upper and lower resistance limit settings appear.

COMP

key for at least 3 seconds. The

2. "

Resistance
range

COMP.SET

","

" appears at the lower left of the screen,

OHM

showing that you are ready to change the comparator
settings.

Comparator
number

Lower resistance limit Upper resistance limit

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Chapter 5 Advanced Measurement Functions

___________________________________________________________________

(2) Setting the comparator number

Change the comparator number with the

UP

and

DOWN

25

keys. You can select any comparator number up to 10.

(3) Setting the resistance range

Press the resistance range key (Ω

) corresponding to the resistance to be measured.

3

RANGE:30m,300m

,

The currently selected resistance range is displayed at the
center on the screen.

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

26

___________________________________________________________________

(4) Setting the resistance limits

1. Using the key, move the flashing number to the most
significant digit of the lower resistance limit setting at the
lower left of the screen.

Lower resistance limit Upper resistance limit

2. Set the lower and upper resistance limits with the

DOWN

keys.

UP

Both the upper and lower resistance limits can be set to any
value in the range 0 to 3000.

and

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Chapter 5 Advanced Measurement Functions

___________________________________________________________________

(5) Setting the voltage range

27

1. Using the key, move the flashing number to the least
significant digit of the upper resistance limit setting at the
lower right of the screen.

2. Press the

key again to display the voltage comparison
value setting screen will appear.
"

COMP.SET

"and"

" appear while setting the voltage

VOLT

comparison value.

Voltage range

3. Press the voltage range key (

VRANGE:3

corresponding to the voltage to be measured.

The position of the decimal point corresponds to the
currently selected voltage range.

,

30

)

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

28

___________________________________________________________________

(6) Setting the voltage comparison value

1. Using the key and the

UP

and

DOWN

keys, set the
voltage comparison value at the lower left of the screen.
The allowable range of settings for the voltage comparison
value is -3000 to 3000.

Voltage range

2. Move the flashing number to the least significant digit with
the

key.

3. Press the

key again to display the upper and lower

resistance limit settings.

4. Go on to set the next comparator number. You can make
voltage comparison values for up to 10 comparator numbers.

(7) Ending setup

When done with comparator selection, press the

COMP

key.

Display returns to the previous measurement screen.

NOTE

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Chapter 5 Advanced Measurement Functions

When the settings are made by setting a comparator number,

they are saved in memory at the point at which the comparator

setting screen is exited.

Comparator setting is not possible while the display is locked or

while reading out measurement values from memory.

___________________________________________________________________

29

5.1.3 Comparator Decision Result Table

The decision result is indicated by the LEDs and by the
beeper, as shown in the following table.

Resistance

Voltage

Voltage
comparison
value

*1 Voltage low and resistance low: amber flashing

Beeper sounds when the comparator result is WARNING or FAIL. (Refer to
Section 5.3, "Beeper On/Off Function")

Lower resistance limit Upper resistance limit

LO IN HI

LO

HI

WARNING

Amber *1

PASS

Green

WARNING

Amber

WARNING

Amber

A"PASS" result is shown by the green LED, a
"WARNING" by the amber LED, and a "FAIL" by the red
LED.
The boundary conditions are as follows.

Resistance LO ≦ Lower resistance limit ＜ Resistance IN

＜ Resistance HI

＜ Voltage HI

Example 1

Resistance IN ≦ Upper resistance limit
Voltage LO ≦ Voltage comparison value

Interpreting the comparator output table

●

When the measured resistance is at or below the lower

resistance limit, and the measured voltage is greater than the
voltage comparison value (that is, resistance: LO and
voltage: HI), the LED for

(green) lights. The beeper

PASS

does not sound.

Example 2

When the measured resistance is greater than the lower

resistance limit and lower than the upper resistance limit
value, and the measured voltage is greater than the voltage
comparison value (that is, resistance: IN, voltage: HI) the
LED for

WARNING

(amber) lights and the beeper sounds.

FAIL

Red

FAIL

Red

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

30

___________________________________________________________________

5.1.4 Switchingthe Comparator On and Off

Pressing the

and off. When the comparator is on, the "

COMP

key toggles the comparator function on

COMP

"
indication appears in the display, and the comparator
operates as measurements are taken. When the comparator
is off, the "

COMP

" indication disappears from the display,

and the comparator does not operate.

When one of the range keys (

Ω,

3

3

V,

30

V) is pressed and the range is

30m

Ω,

300m

Ω,

changed, comparator operation stops even if the comparator
function is being used. To use comparator function again,
press the

COMP

key. The range reverts to the setting extant

prior to the change.

When you turn on the power, the comparator is always set

to ON.

NOTE

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Chapter 5 Advanced Measurement Functions

If there is no measurement value, "----" is displayed and

comparator operation is not enabled.

___________________________________________________________________

31

5.1.5 Changingthe Comparator Number

To change the comparator number, do the following
procedure.

1. Press and hold the

COMP

key for at least 3 seconds. The

resistance comparator setting screen appears.

"

COMP.SET

" appears at lower left of the screen.

2. Select the comparator number with the
You can select any number up to 10.

UP

and

DOWN

keys.

3. When the setting is completed, press the

NOTE

___________________________________________________________________

The selected comparator number remains in memory even when

the power is turned off.

Chapter 5 Advanced Measurement Functions

COMP

key.

32

y

___________________________________________________________________

5.2 Measurement Value MemoryFunction

WARNING

To avoid damage to the product, do not apply voltage

to the EXT.MEMO terminals.

The currently measured values (resistance value, voltage
value, temperature, and comparator result), taken as a set can
be stored: up to 260 such sets of values can be held, and
later displayed and printed as required.

5.2.1 Memor

Store the current settings as follows.

Press the

"

MEMO

measurement value and comparator result are stored.

MEMO

key.

" appears at the upper right of the screen and the

MEMO Screen

"

" is displayed at the upper right of the screen and the

DATA

number of data points stored in memory is displayed.

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Chapter 5 Advanced Measurement Functions

___________________________________________________________________

33

Using the

MEMO

EXT. MEMO

key can be obtained.

terminals, the same effect as the

1. Using a blade screwdriver or a similar tool, insert the
individual leads into the terminal apertures. (Leads are not
supplied.)
When inserting or removing the leads, push in the terminal
button with a screwdriver as shown in the figure below.

Recommended wire
size

(AWG #18)

Usable limits

Single strand: 0.4 to 1.0 mm dia.

Single strand: 1.0 mm dia.

multi-strand: 0.75 mm

2

(AWG #26 to #18)
multi-strand: 0.3 to 0.75 mm
(AWG #22 to #20)
minimum strand diameter: 0.18 mm

Standard insulation
stripping length

Button pressing tool

10 mm

Blade screw driver

(tip width 2.6 mm)

2

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

34

___________________________________________________________________

2. Contact the leads together for at least 100 ms (use a switch)
to obtain the effect of pressing the
The "

MEMO

" indication appears in the display, and one set

MEMO

key.

of measurement values and comparator results are saved in
memory.

Contact for at least 100 ms

At least 2 s

Wait for at least 2 seconds until the next storing.

"

" is displayed at the upper right of the screen along

DATA

with the number of data points in memory.

NOTE

If while the

key is pressed, then the values may be saved twice.

Even when the unit is powered off the values are preserved in

memory.

If the batteries are removed, the values in memory are cleared.

5.2.2 Clear

Clear the latest value in memory as follows.

1. Press the
data point from memory.

2. To clear all data, press and hold the
seconds.

NOTE

Removing the batteries clears all data.

EXT.MEMO

CLEAR

terminals are shorted together another

key. This clears the most recently stored

CLEAR

key for five

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Chapter 5 Advanced Measurement Functions

___________________________________________________________________

35

5.2.3 Readout

Redisplay a measurement value from memory as follows.

1. Press the

READ

key.

NOTE

The "

MEMO

number of "

MEMO

" indication appears in the upper right and the

No.   

" indication flashes.

means that the currently displayed readings are
values recalled from memory.
The flashing number is the number of the set of values
currently displayed.

2. Pressing the

UP

key or

DOWN

key increments or
decrements this number, to display whichever set of data
values is required.

The comparator result for previous data values read out from
memory is also shown, but a "WARNING" result does not flash.

In the case of a "WARNING" the display is permanently on.

Data cannot be redisplayed when "

upper right of the screen (when there is no data in memory).

" does not appear at the

DATA

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Chapter 5 Advanced Measurement Functions

36

g

___________________________________________________________________

5.2.4 Printin

WARNING

For safety, never connect the 3550 to the printer
during measurement.
To prevent electric shock, before using this tester,
fit the supplied dust cover for the printer interface
over the PRINT terminal.
To avoid damage to the product, do not apply
voltage to the PRINT terminal.

Print the measurement value stored in memory as follows.

1. Disconnect the lead from the tested battery.

2. Connect this tester to the 9203 DIGITAL PRINTER with the
9425 CONNECTION CABLE (2 m). (Refer to the printer
instruction manual for how to make printer settings.)

3. Press the

PRINT

key. "Prnt" appears on the screen and the

data is printed.

4. To stop the printing, press the

PRINT

key.

NOTE

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Chapter 5 Advanced Measurement Functions

Use the HIOKI 9203 DIGITAL PRINTER.

It is also possible to connect a general-purpose printer with a

Centronics interface. The connector used for this unit is a 20-

pin half-pitch D-subminiature connector, DHA-RC20-R132N

(Daiichi Electronics) or equivalent.

It is not possible to print data while measurement is taking

place.
When printing comparator results, both a flashing "WARNING"
and a constant "WARNING"areprintedas"Warn."

When "

(there is no data in memory), printing is not possible.

" does not appear at the upper right of the screen

DATA

___________________________________________________________________

37

Output Example of the 9203

Output Example of the General-purpose Printer

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

38

___________________________________________________________________

5.3 Beeper On/Off Function

Pressing the key toggles the beeper on and off.
When the beeper is on, the "

" indication appears in the
display, and the beeper sounds when there is a "Warning" or
"Fail" result. When the beeper is off, the
"

" indication disappears from the display, and the beeper

does not operate.

5.4 Hold Function

This suspends measurement, with the display values held the
same.
Press the

HOLD

and the display is locked to prevent it from changing.

key. "

" is displayed on the screen

HOLD

NOTE

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Chapter 5 Advanced Measurement Functions

While the display is locked, the resistance and voltage range keys

(

0ADJ

effective.

30m

Ω,

,

300m

COMP

Ω,

,

, ,

Ω,

3

UP

3

,and

V,

DOWN

30

V), and the

keys are not

___________________________________________________________________

39

5.5 MovingAverage Function

If the resistance measurement value is unstable, this can be
corrected with the moving average function. This takes the
average of four samples of the resistance value and displays
the result.
The moving average takes the sum of the current value and
the previous three sampled values, and divides by four.
To take the moving average, use the following procedure.

1. Power the unit off.

2. Hold down the key while pressing the

3. Hold down the

key until a screen for setting the moving

average appears.

POWER

key.

4. Press the

___________________________________________________________________

key once more.

Chapter 5 Advanced Measurement Functions

40

___________________________________________________________________

NOTE

5. When the above screen appears, press the

POWER

key to

power the unit off.

6. Press the

POWER

key again to power the unit on.

7. To cancel the moving average function, in the moving
average setting screen, press the

key to cancel the moving

average function.

If you hold down a key other than the key while powering
on, an "INSP"or"Adju" indication may appear. In this case,

press the

again. Continuing with other key operations will result in the

calibration data being lost, as a result of which correct

measurement will no longer be possible.

It is not possible to change the number of samples (i.e. four)

used for calculating the moving average.

When using the moving average function, the time taken for the

measurement value to stabilize is increased.

POWER

key once more, and to power on the unit

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Chapter 5 Advanced Measurement Functions

___________________________________________________________________

41

5.6 Zero Adjust Function

The zero adjustment function adjusts the zero position of the
resistance and voltage ranges of this unit.
The value read during zero adjustment is taken as zero, and
used to calibrate subsequent measurements.

1. Short the SOURCE and SENSE of the 9460 CLIP TYPE
LEAD WITH TEMPERATURE SENSOR together as shown in
the figure below.

2. Press the

0ADJ

key. During zero adjustment, "0Adj"is

displayed in the resistance measurement display position.

3. When "0Adj" disappears and measurement starts, connect the
leads to the battery to be tested.

NOTE

___________________________________________________________________

Keep the leads shorted together throughout the zero adjustment

process.

The zero adjustment is valid for the currently selected range

only, as long as the power remains on. Powering on the unit

resets all zero adjustment values.

When the resistance or voltage value is displayed as "----", or
whenthereadingismorethan"200", "FAIL" is displayed. The

zero adjustment is not carried out.

Chapter 5 Advanced Measurement Functions

42

g

___________________________________________________________________

Shorting only the

Always make sure that both the

are shorted together.

If the leads are shorted but their ends are brought close to metal

parts, the measured value may fluctuate as a result of

electromagnetic induction. In this case, move the ends of the

leads away from the metal parts.

SENSE

terminals will not display 0 V.

5.7 BatteryLow Warnin

When the remaining battery capacity is low, the " "
indicator appears at the right of the display.
After printing out any held data values, replace the battery,
referring to Section 4.1, "Preparing for Measurement."

SENSE

and

SOURCE

terminals

NOTE

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

If the batteries are exhausted, you may be able to turn on the

power, but soon the "

off. (Momentary operation is possible because the battery partially

regains its former voltage after resting, but soon declines to the

exhausted state.) When the batteries wear out, replace them in

accordance with the specified procedure.

" mark will appear and the power will go

___________________________________________________________________

43

5.8 Auto Power Off

In the following states, if there is no switch operation for 30
minutes the unit automatically powers off.

When the resistance value is "----" indication.
During hold
On the comparator setting screen
During the printing output
During reading the memory data

For continuous measurement, in some cases it may be
necessary to disable the auto power off function. Do this as
follows.

1. Turn the power off.

2. Press the

HOLD

POWER

key simultaneously. Press the

while. The auto-power off setting screen will appear.

key on the unit while holding down the

HOLD

key for a

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

44

___________________________________________________________________

NOTE

3. Press the

HOLD

4. When the above screen appears, press the

key again.

POWER

off the power.

5. Press the

POWER

6. To set to the auto-power off, press the

key again to turn the power on.

HOLD

key in the auto
power off setting screen and set the auto power off to 30
minutes.

If the

EXT.MEMO

the auto power off function does not operate.

If the

POWER

HOLD

key, is held down, and an "INSP"or"Adju"indication

appears, immediately press the

again. Otherwise, continuing with key operations may destroy

the calibration data for the unit, and correct measurement will

no longer be possible.

After the batteries are replaced, the auto power off is set to 30

minutes.

The set time of auto power off cannot be changed.

terminals are continuously shorted together,

key is pressed while another key, other than the

POWER

key to power off and on

key to turn

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

___________________________________________________________________

45

5.9 AC Four-Terminal Method

The 3550 uses the AC four-terminal method, so that
resistance measurement can be carried out with the resistance
of the leads, and the contact resistance between the object to
be measured and the leads canceled out. The following
figure shows the principle of the AC four-terminal
measurement method.

Constant current
source

Is

Voltmeter

DC-elimination
capacitor

R

1

R

2

Resistance R

Resistance measurement circuit

V

IS

R

3

Values R1 to R4 are the resistances of the test leads plus
contact resistances.

An AC current (Is) is supplied from the

SOURCE

terminals of

the 3550 across the tested battery.

The voltage drop across the internal impedance of the battery

) is measured by the

(V

IS

since the

SENSE

SENSE

terminals are connected to an internal

terminals. At this point,

voltmeter with a high impedance, almost no current flows
through the resistances R2 and R3 which represent the lead
resistances and contact resistances.

As a result, there is almost no voltage drop across the
resistances R2 and R3. Thus the voltage drop due to the
lead resistances and contact resistances is very small, and
these can be canceled out.

R

4

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

46

___________________________________________________________________

NOTE

In the 3550, a synchronized wave detection system is used,

whereby the internal impedance is separated into effective

resistance and reactance, and the resistive component only

displayed.

Reactance

Impedance

Effective resistance

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

___________________________________________________________________

）

47

5.10 Internal Resistance of Lead-Acid
Batteries

This shows the relationship between the capacity for lead­acid batteries and the initial value for internal resistance.
(Quote: Text from battery fitters qualification lecture notes,
Battery Industry Association) The terms CS, HS, and MSE
appearing in the figure are battery types defined by JIS
(Japanese Industrial Standards).

Temperature of battery：25

)

Ω

m
(

e
c
n
a

t
s

i
s
e

r
l
a
n

r
e

t
n

I

CS

HS

MSE

Capacityof lead-acid battery（Ah

CS : Clad type stationary lead-acid battery
HS : High rate discharge paste type stationary lead-acid

battery

MSE : Seal type stationary lead-acid battery

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

48

___________________________________________________________________

From the figure, MSE internal resistance can be read as
approximately 1 mΩ (at 100Ah), or approximately 0.13 mΩ
(at 1000 Ah).
When the battery deteriorates, internal resistance rises to 1.5
to 2 times the initial value (reference value).
With an MSE (seal type stationary lead-acid battery), battery
condition is regarded as marginal when internal resistance
reaches 1.5 times the initial value, and complete
deterioration is assumed when internal resistance reaches 2
times the initial value.

NOTE

Even if different batteries have the same capacity, initial internal

resistance may vary according to battery type and maker. The

figure is only for reference.The internal resistance warning

(WARN) and fail (FAIL) values vary according to maker.

___________________________________________________________________

Chapter 5 Advanced Measurement Functions

___________________________________________________________________

g

49

Chapter 6

Maintenance

If damage is suspected, check the "Troubleshooting" section
before contacting your dealer or Hioki representative.

6.1 Troubleshootin

Symptom Cause Follow-up

Nothing appears on
the screen when the

POWER

pressed.

Measurement values
are wrong.

"---" is displayed.
"OF" is displayed.

Comparator result is
not correct.

key is

Batteries are exhausted, or
not inserted.

Leads are not correctly
connected.

There is an electrical
discontinuity in the leads.

Zero adjustment is not
correct.

The measurement range is
not appropriate.

The comparator setting is
not correct.

Replace the batteries or reinsert
them correctly.
See Section 4.1, "Preparing for
Measurement."

Connect leads correctly.
See Section 4.1, "Preparing for
Measurement."

Replace with a new lead.

Perform correctly zero
adjustment.
See Section 5.6, "Zero Adjust
Function."

Select the appropriate range
with the range key.
See Section 4.2,
"Measurement."

Set the comparator correctly.
See Section 5.1, "Comparator
Function."

___________________________________________________________________

Chapter 6 Maintenance

50

___________________________________________________________________

Symptom Cause Follow-up

Data in memory is not
displayed when the

READ

pressed.

Printing is not
possible.

key is

Thereisnodatain
memory.

Thereisnodatain
memory.

Storedatainmemory.
See Section 5.2, "Measurement
Value Memory Function."

Storedatainmemory.
See Section 5.2, "Measurement
Value Memory Function."

NOTE

The comparator setting
screen appears.

The connecting cable is
not correctly connected.

The printer is not ready. Turn the printer power on and

Exit the comparator setting
screen, to return to the
measurement screen.
See Section 5.1, "Comparator
Function."

Correctly connect the
connecting cable.

set correctly.

To avoid problems with battery operation, remove the
batteries from the product if it is to be stored for a week
or more.

When sending the product for repair, remove the batteries
and pack carefully to prevent damage in transit. Include
cushioning material so the instrument cannot move within
the package. Be sure to include details of the problem.
Hioki cannot be responsible for damage that occurs during
shipment.

Never modify the product. Only a Hioki service engineer
can disassemble or repair the product. Failure to observe
these precautions may result in fire, electric shock, or
injury.

___________________________________________________________________

Chapter 6 Maintenance

___________________________________________________________________

g

51

6.2 Message Reference

Message Meaning Follow-up

FAIL

Prnt

0Adj

INI

INSP

Adju

Er10
Er11
Er12
Er20
Er21
Er22
Er23
Er24

Zero adjustment cannot be
carried out.

Data is being sent to the
printer.

Zero adjustment is being
carried out.

Initialization after battery
replacement.

Inspection and adjustment
modes for factory use.

Internal variable error. Servicing is required.

Connect correctly the lead and
execute the zero adjustment.
See Section 5.6, "Zero Adjust
Function."

Disappears when data output to the
printer is completed.

Disappears when zero adjustment is
completed.

This is not a malfunction.

Press the
power on.

POWER

key to turn the

6.3 Cleanin

To clean the product, wipe it gently with a soft cloth
moistened with water or mild detergent. Never use solvents
such as benzene, alcohol, acetone, ether, ketones, thinners or
gasoline, as they can deform and discolor the case.

When cleaning the LCD, gently wipe with a soft dry cloth.

___________________________________________________________________

Chapter 6 Maintenance

52

___________________________________________________________________

___________________________________________________________________

Chapter 6 Maintenance

HIOKI 3550 BATTERY HiTESTER

Instruction Manual

Publication date: September 2006 Revised edition 10

Edited and published by HIOKI E.E. CORPORATION

Technical Support Section

All inquiries to International Sales and Marketing Department

81 Koizumi, Ueda, Nagano, 386-1192, Japan

TEL: [phone] / FAX: [phone]

E-mail: [e-mail]

URL http://www.hioki.co.jp/

Printed in Japan 3550A981-10

All reasonable care has been taken in the production of this manual,
but if you find any points which are unclear or in error, please
contact your supplier or the International Sales and Marketing
Department at HIOKI headquarters.
In the interests of product development, the contents of this manual
are subject to revision without prior notice.
Unauthorized reproduction or copying of this manual is prohibited.

2003-01 改訂  枠消す

HEAD OFFICE

81 Koizumi, Ueda, Nagano 386-1192, Japan
TEL [phone] / FAX [phone]
E-mail: [e-mail] / URL http://www.hioki.co.jp/

HIOKI USA CORPORATION

6 Corporate Drive, Cranbury, NJ 08512, USA
TEL [phone] / FAX [phone]

3550A981-10 06 -09H

Printed on recycled paper