INSTRUCTION MANUAL
3931
HIGH VOLTAGE
CONTACT CHECKER
Contents
Introduction.................................................................................1
Inspection ...................................................................................1
Safety Notes...............................................................................2
Usage Notes...............................................................................4
Chapter 1 Overview _________________________ 7
1.1 Product Overview..........................................................7
1.2 Principle ........................................................................8
1.3 Parts Names ...............................................................10
1.3.1 Front Panel ....................................................................10
1.3.2 Rear Panel ....................................................................12
1.3.3 H.V. TEST LEADs (9615-01, 9615-03) .........................13
i
Contents
1.4 External Dimensions ...................................................14
1.5 Measurement Flowchart..............................................15
Chapter 2 Testing Arrangements _____________ 17
2.1 Connecting the Protective Conductor Terminal ..........17
2.2 Connecting the Power Cord ........................................18
2.3 Connecting the External I/O Terminals .......................19
2.4 Connecting the H.V. TEST LEADs to the 3931...........20
2.5 Connecting the H.V. TEST LEADs to the Device to be
Tested22
2.6 Powering On and Off the 3931....................................24
2.7 Startup Inspection .......................................................25
2.7.1 Cutoff Voltage ...............................................................25
2.7.2 Analog Voltmeter ...........................................................27
Chapter 3 Testing Method ___________________ 29
3.1 Test Startup Flow ........................................................30
3.1.1 Setting the Threshold Voltage .......................................31
3.2 Starting a Test.............................................................35
3.3 PASS or FAIL Determination ......................................37
3.3.1 PASS State ...................................................................37
3.3.2 FAIL State .....................................................................40
ii
Contents
Chapter 4 External Interface__________________ 43
4.1 External I/O Terminals................................................ 43
4.1.1 Signal Line ....................................................................44
4.1.2 Timing Chart of External I/O Signals ............................45
4.1.3 Example of Input Signal Connection ............................. 46
4.1.4 Example of Output Signal Connection .......................... 47
4.1.5 Example of Connection to the WITHSTANDING
VOLTAGE HiTESTERs ................................................48
Chapter 5 Specifications ____________________55
5.1 Basic Specifications.................................................... 55
5.1.1 Interface ........................................................................57
5.2 General Specifications................................................ 58
5.3 H.V. TEST LEADs (9615-01, 9615-03)
Specifications ............................................................. 59
Chapter 6 Maintenance and Service ___________61
6.1 Cleaning and Storage................................................. 61
6.2 Repair and Servicing .................................................. 61
Introduction
Warranty
Inspection
1
Introduction
Thank you for purchasing the HIOKI “3931 HIGH VOLTAGE CONTACT CHECKER”. To obtain maximum performance from the product,
please read this manual first, and keep it handy for future reference.
HOKI cannot be responsible for losses caused either directly or indirectly by the use of the 3931 with other equipment, or if ownership is
transferred to a third party.
• When you receive the product, inspect it carefully to ensure that no damage occurred during shipping. In particular, check the accessories and connectors. If damage is evident, or if it fails to operate according to the
specifications, contact your dealer or Hioki representative.
• Use the original packing materials when reshipping the product, if possible.
Checking the contents of the package
Power cord (1)
3931 HIGH VOLTAGE CONTACT CHECKER (1)
Stopper plate (1)
(red)
9615-01 H.V. TEST LEAD
(high voltage side, 1)
(black)
9615-03 H.V. TEST LEAD
(low voltage, 1)
Instruction manual (1)
2
Safety Notes
Safety Notes
Safety Symbols
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.
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.
In the manual, the symbol indicates particularly important
information that the user should read before using the product.
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.
Indicates that dangerous voltage may be present at this terminal.
Indicates a grounding terminal.
Indicates a protective conductor terminal.
Indicates AC (Alternating Current).
Indicates the ON side of the power switch.
Indicates the OFF side of the power switch.
The following symbols in this manual indicate the relative importance
of cautions and warnings.
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.
Other Symbols
3
Safety Notes
Indicates the prohibited action.
❖
Accuracy
We define measurement tolerances in terms of f.s. (full scale) 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.
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".
Overvoltage categories (CAT)
The input section conforms to CAT I (5000 V) safety requirements, and
the power supply section conforms to CAT II (300 V) requirements.
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.
Indicates the reference.
CAT I
CAT II
CAT III
CAT IV
Secondary electrical circuits connected to an AC electrical outlet
through a transformer or similar device.
Primary electrical circuits in equipment connected to an AC electrical
outlet by a power cord (portable tools, household appliances, etc.)
Primary electrical circuits of heavy equipment (fixed installations)
connected directly to the distribution panel, and feeders from the distribution panel to outlets.
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.
4
Usage Notes
Usage Notes
Follow these precautions to ensure safe operation and to obtain the
full benefits of the various functions.
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.
• Do not touch the alligator clip while high voltage is being generated. The vinyl sheath on the alligator clip of the H.V. TEST
LEADs (9615-01, 9615-03) does not have an insulation withstand voltage.
Check the voltage.
100 to 240 V AC
• To ensure the safety of the operator first, connect the protective conductor terminal to a grounded conductor before making any other connections.
• To avoid electric shock and ensure safe operation, connect the
power cord to a grounded (3-contact) outlet.
• Before turning the product on, make sure the source voltage
matches that indicated on the product's power connector.
Connection to an improper supply voltage may damage the
product and present an electrical hazard.
• Turn off the power to all devices before plugging or unplugging any
of the external I/O terminals.
• Make sure the power is turned off before connecting or disconnecting the power cord.
• If the protective functions of the product are damaged, either
remove it from service or mark it clearly so that others do not use it
inadvertently.
Setting up the 3931
• To avoid damage to the product, do not allow the product to
Do not get wet.
get wet, and do not use it when your hands are wet.
5
Usage Notes
Corrosive or
explosive gases
Avoid the following:
Direct
sunlight
High temperature
High humidity
Electomagnetic
radiation
Dust
• Do not use the product where it may be exposed to corrosive
or combustible gases. The product may be damaged or cause
an explosion.
• 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.
• To avoid damage to the product, protect it from vibration or shock
during transport and handling, and be especially careful to avoid
dropping.
• 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.
• This product should be installed and operated indoors only,
between 0 and 40
°
C and 35 to 80% RH.
• Do not install the instrument upside-down, or stand it on its side.
6
Usage Notes
Handling the cords
• To avoid damaging the power cord, grasp the plug, not the cord,
when unplugging the cord from the power outlet.
• To avoid damaging the H.V. TEST LEADs, do not bend or pull the
test leads.
• Avoid stepping on or pinching the cable, which could damage the
cable insulation.
• For safety reasons, when taking measurements, only use the H.V.
TEST LEADs (9615-01, 9615-03) provided with the product.
Preliminary checks
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.
Before using the product, make sure that the insulation on the
H.V TEST LEADs is undamaged and that no bare conductors are
improperly exposed. Using the product under such conditions
could result in electrocution. Replace the H.V TEST LEADs with
the specified Hioki Model 9615-01, 9615-03.
1.1 Product Overview
7
Overview
1.1 Product Overview
The 3931 HIGH VOLTAGE CONTACT CHECKER is a contact
checker used for the Hioki WITHSTANDING VOLTAGE HiTESTER
with its LOW side grounded. Do not use the 3931 for any other purpose. The 3931 is not designed to serve as an isolation voltmeter.
(1) Monitoring the measurement terminal voltage
Because it monitors the voltage of the measurement terminal, the 3931 can
detect a broken wire or contact failure during a withstand voltage test. As a result, this checker does not require time only for a contact check and will improve the reliability of the test without increasing the tact time (minimum
withstand voltage test time: 1 sec). The 3931 also detects a drop in test voltage arising from fluctuations in the supply voltage.
Chapter 1
(2) Direct connection with the Hioki WITHSTANDING VOLTAGE
HiTESTER series
The 3931 is directly connectable to the Hioki WITHSTANDING VOLTAGE
HiTESTER (3158, 3173, 3159, and 3153). These HiTESTERs require no setting, except that during use of the 3153, "Do not include the TEST blinking time
in the
TEST
-signal ON output" must be selected using the optional function.
If a broken wire or contact failure is detected, the error indication LED of the
3931 lights up, the buzzer sounds to indicate the occurrence of a failure, and
the operation of the connected HiTESTER is stopped.
The 3931 is not designed for insulation resistance testing and cannot be used
with the continuous test function or the program test function of the 3159 and
3153. In addition, the 3931 is designed exclusively for AC withstand voltage
testing and cannot be used for DC withstand voltage testing.
(3) Analog voltmeter
The measurement terminal voltage is checked on the analog voltmeter (the
generated voltage is checked on the voltmeter of the WITHSTANDING VOLTAGE HiTESTER). Switch over the meter to set the criterion voltage (threshold
voltage).
(4) Warning on the application of a dangerous voltage
During the contact check (voltage monitoring), the DANGER lamp remains
ON to indicate the application of a dangerous voltage. If a dangerous voltage
is input while the contact check is not being performed, the DANGER lamp will
start blinking (50 V to 100 V).
8
1.2 Principle
1.2 Principle
WITHSTANDING VOLTAGE HiTESTER
Voltage output terminals
of the WITHSTANDING
VOLTAGE HiTESTER
a
(contact checker)
d
Voltage-monitoring
c
b
Test current
Object to be tested
Voltmete r
current
h
Terminals of the voltmeter
e
f
g
Voltage application terminals
of the object to be tested
9
1.2 Principle
The voltmeter (contact checker) shown in the diagram above is generally not used for a withstand voltage test, and the output voltage
between a and h of the WITHSTANDING VOLTAGE HiTESTER is
applied to voltage application terminals b and g of the object to be
tested. The test current flows from a → b → g → h. The WITHSTANDING VOLTAGE HiTESTER monitors this current to determine whether
the object to be tested has sufficient voltage withstand capability.
However, if no current flows, the tester considers the object to have
sufficient voltage withstand capability. Thus, if no current flows
because a wire is broken somewhere in the current path of a → b → g
→ h, the test is judged to have been passed.
To solve this problem, a voltmeter (contact checker) is connected to
the voltage application terminals of the device to be tested, as in the
WITHSTANDING VOLTAGE HiTESTER shown in the diagram. The
voltmeter (contact checker) checks to determine whether the voltage
output from the WITHSTANDING VOLTAGE HiTESTER is applied to
the voltage application terminals.
Assume that a wire is broken somewhere between a and b or g and h,
and that the correct voltage is not applied to the voltage application
terminal. In the event of a contact failure, the correct voltage is not
applied to the voltage application terminal.
The output voltage from the WITHSTANDING VOLTAGE HiTESTER
(hereinafter referred to as the "threshold voltage") is compared with
the voltage applied to the voltage application terminals. If the voltage
applied to a voltage application terminal is less than the threshold voltage, a broken wire or contact failure has occurred. If a wire is broken
in the wiring while a voltmeter (contact checker) c and d or e and f, a
failure is also detected. A broken wire between c and d or e and f does
not directly affect the test. This is detected as a failure of the testing
equipment.
An electric current also flows to the voltmeter (contact checker). Such
a current may affect the test. The threshold current during the withstand voltage test is normally approximately 0.1 mA to several tens of
mA. If the current flowing to the voltmeter (contact checker) is no more
than several tens of µA, it is considered to be low enough not to affect
the withstand voltage test. Even if the current does affect the test, the
current flowing to the voltmeter (contact checker) can always be estimated and added to the threshold current of the WITHSTANDING
VOLTAGE HiTESTER.
When the WITHSTANDING VOLTAGE HiTESTER is of the supplyvoltage boosting type, the output of which is not stabilized, the output
voltage varies with fluctuations in the commercial supply voltage. As a
voltmeter (contact checker) monitors the voltage of the voltage application terminals of the device to be tested, it detects an abnormal voltage due to these voltage fluctuations, thereby further increasing the
reliability of the test.
In addition, as the voltmeter also conducts a contact check during the
withstand voltage test, it does not require time only for a contact check
and therefore will improve the reliability of the test without increasing
the tact time on the production line.
10
1.3 Parts Names
1.3 Parts Names
1.3.1 Front Panel
RESET (STOP)
switch
COMP LEVEL
switch
To prevent electric shock, when the
touch the input-voltage terminals (HIGH and LOW), the H.V.
TEST LEADs, or the tested object.
DANGER
Analog voltmeter
lamp is lit, never
Power switch
Threshold
adjustment knob
DANGER lamp
LOW terminal
HIGH terminal
1.3 Parts Names
RESET (STOP) switch Releases the stop state of the connected WITHSTANDING VOLT-
AGE HiTESTER or the FAIL state after a failure is detected.
11
COMP LEVEL switch Changes the meter indication.
OFF (normal) : Indicates the measurement terminal voltage.
ON (depressed) : Indicates the set threshold voltage.
When this switch is ON, a
vice. As the FAIL judgment is available, if a failure is detected, the
FAIL
signal is output to the external device after the switch is turned
OFF. This switch lamp lights up in green if the test is being conducted
properly.
LOW terminal Low-voltage input terminal for measurement terminal voltage moni-
toring. Isolated from the housing.
HIGH terminal High-voltage input terminal for measurement terminal voltage moni-
toring.
DANGER lamp Lights up during a test.
Starts blinking to provide a warning if a dangerous voltage is input
while the test is not being performed.
Threshold
adjustment knob
Power switch Powers the 3931 on or off.
Sets the voltage used as a criterion for failure.
The threshold voltage is normally set to the voltage output from the
WITHSTANDING VOLTAGE HiTESTER.
The LED lights up when power is turned ON.
FAIL
signal is not output to an external de-
Analog voltmeter Indicates output-voltage when testing withstand voltage.
12
1.3 Parts Names
1.3.2 Rear Panel
Power inlet
External I/O terminals
To prevent electric shock, when the
DANGER
lamp is lit or blinking, never touch the input-voltage terminals (HIGH and LOW),
the H.V. TEST LEADs, or the tested object.
Protective conductor
terminal
Power inlet Supplies power. Connect the supplied power cord
External I/O terminals Used to connect the 3931 to a WITHSTANDING
Protective conductor
terminal
In this manual, an input signal is expressed as "signal name_IN" and an
output signal as "signal name_OUT."
(Example)
output signal
STOP
input signal
FAIL
to this inlet.
VOLTAGE HiTESTER and control the 3931.
Used to earth a protective ground wire.
Be sure to make grounding connections before
starting a test.
STOP_OUT
FAIL_ IN
1.3 Parts Names
1.3.3 H.V. TEST LEADs (9615-01, 9615-03)
To prevent electric shock, do not touch the alligator clip while
high voltage is being generated. The vinyl sheath on the alligator clip of the H.V. TEST LEADs does not have an insulation
withstand voltage.
13
Alligator clip
High-voltage
input plug
Alligator clip
Low-voltage
input plug
9615-01 (red)
9615-03 (black)
* The plugs for high voltage and low voltage are of the same size.
Alligator clip Attach to the test point on the device being mea-
sured.
High-voltage input plug
(red)
Low-voltage input plug
(black)
Connect to the HIGH terminal on the unit.
Connect to the LOW terminal on the unit.
14
1.4 External Dimensions
1.4 External Dimensions
0.08”)
±
2 mm (9.06”
±
0.08”) 230
±
2 mm (5.91”
±
150
130 ± 2 mm (5.12” ± 0.08”)
1.5 Measurement Flowchart
1.5 Measurement Flowchart
15
The flowchart below shows the flow of the test.
For detailed information, see each chapter.
Preparations for the withstand voltage test
(WITHSTANDING VOLTAGE HiTESTER)
Connecting the protective conductor terminal
Connecting the power cord
Connecting the external I/O terminals
Connecting the H.V. TEST LEADs
(WITHSTANDING VOLTAGE HiTESTER and 3931)
Powering On
(WITHSTANDING VOLTAGE HiTESTER and 3931)
NG
Startup inspection
❖2.1
❖2.2
❖2.3
❖2.4
❖2.5
❖2.6
❖2.7
NG
Correct the problem.
Check the wiring.
OK
Correct the problem.
Withstand voltage failure
NG
Check the wiring again.
OK
Setting the threshold
voltage (Test voltage)
Start the withstand
voltage test.
NG
NG
Withstand voltage
Contact check NG
Withstand voltage test
completed
OK
test NG
OK
OK
Continue the test.
Next test
❖3.1.1
❖3.2
❖3.3
OK
Malfunction
NO
Powering OFF
(WITHSTANDING VOLTAGE HiTESTER and 3931)
End the test.
16
1.5 Measurement Flowchart
Testing
17
2.1 Connecting the Protective Conductor Terminal
Arrangements
Chapter 2
2.1 Connecting the Protective Conductor
Terminal
Observe the following precautions to avoid electric shock.
• Connect the protective conductor terminal to a grounded conductor before making any other connections.
• Be sure to connect the protective conductor terminal to a
grounded conductor.
1.
Using a Phillips-head screwdriver, remove the screw of the protective
conductor terminal from the rear of the unit.
2.
3.
Connect an electric wire with a sufficient current capacity to the protective conductor terminal, and secure the wire using a Phillips-head
screwdriver.
Specified
cable
Press-fit
terminal
Ground the other end of the wire.
UL1015 AWG16
BT1.25_F4
Sumitomo Electric Industries, Ltd.'s
or equivalent
Fuji Terminal Industry Co., Ltd.'s or
equivalent
GND
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