Instruction Manual for HIOKI models including: DT4261, FT3701, DT4261 Digital Multimeter Solar Kit, Digital Multimeter Solar Kit, Multimeter Solar Kit, Solar Kit, Kit
DIGITAL MULTIMETER DT4261 SOLAR KIT
2024-01-18 — After performing a zero-voltage measurement (see below), disconnect the high- voltage (HV) cable and wait at least 10 minutes for the HV system to discharge ...
Hioki EV HV SYSTEM ADVANCED TEST KIT EV HV System Advanced Test Kit
A Guide on Electrical Safety for EV Maintenance and Service Stay safe during EV maintenance High voltages make safety for EV maintenance essential. This guide outlines correct procedures and reliable electrical tests to ensure safe operations. Motor, inverter, etc. HV system Chassis Battery Zero-voltage Temperature Equipotential bonding Insulation resistance When Z3210 is installed DT4261 and IR4059 2 Shutting down the HV system of the vehicle Visual inspection For safety, be sure to carry out a visual inspection and look out for motor faults by performing a DTC (Digital Trouble Codes) scan. DTC scan Disconnect the HV bus Temperature measurement of the HV batteries Before proceeding to electrical testing and measurement, make sure to shut down*1 the vehicle's HV (High-voltage) system by disconnecting the service plug or using the switch. *1 The removal of high-voltage components is hazardous work. Ensure that the work is performed by qualified personnel with professional training, following applicable laws and regulations. For details, please follow the operation manual of each vehicle manufacturer. Measure the surface temperature of the HV battery with a non-contact thermometer. In this inspection, check for variations in temperature as well as areas of high temperature. These may indicate issues that need further investigation. INFRARED THERMOMETER FT3701 The FT3701 is an infrared thermometer with a two-point laser marker that measures the average surface temperature inside a circle formed by the two points. Zero-voltage measurement This measurement is conducted to prevent electric shock and to make sure that the vehicle is shut down. Safety from electrocution is ensured by measuring the voltage on surfaces that are likely to be touched when unplugging the HV connector. In this test, voltage should be measured between specific points and the chassis ground of the vehicle. It should show up as zero volts (0 V). DIGITAL MULTIMETER DT4261 The DT4261's terminal shutters make it physically impossible to insert the wrong test lead. They prevent overvoltage and electrical shock accidents. The LoZ (low input impedance) mode gets rid of the effects of ghost voltages caused by the measurement target's stray capacitance and the multimeter's high input impedance. This lets you get accurate readings. Disconnect the HV battery cable Discharge After performing a zero-voltage measurement (see below), disconnect the highvoltage (HV) cable and wait at least 10 minutes for the HV system to discharge. To avoid a serious accident, it is necessary to wait for a certain period of time. Take note that the discharge time may vary, so make sure to check with the vehicle manufacturer. Zero-voltage measurement After unplugging the HV battery's connector, make sure that the HV system is shut down. Complete shutting down the HV system 3 Flow after repair and inspection Repair and inspection of vehicle Equipotential bonding test This test is conducted after high-voltage (HV) components have been installed or replaced. By checking the ability for electricity to flow (conductance/ resistance) between all parts and the chassis, this test ensures that the chassis properly functions as a ground to capture stray voltages during and between operation. For this, the resistance is measured at the points where the chassis of the vehicle and the HV components are connected. If the resistance value is high or differs significantly from the value measured before the service work was performed, the connection of the HV component may have been installed incorrectly. RESISTANCE METER RM3548 RM3548 is a four-terminal (four-wire Kelvin) DC milliohm meter The current applied during testing (500 nA to 1 A) enables accurate measurement of tens of . This meets the ECE-R100*2 standard's requirement *2 Safety standard for electric powertrains of road vehicles including rechargeable battery systems. Insulation resistance test In this test, we verify that there are no flaws in the insulation between the HV system and the ground to prevent electrocution. The insulation test is performed on both the connector of the HV battery (battery side) and the connector of the inverter (inverter side). The insulation resistance is measured between each of the sides (battery and inverter) and the chassis ground of the vehicle. The voltage applied during measurement (test voltage) must be greater than the vehicle's battery voltage. Please keep in mind that the test voltage may vary based on the vehicle model. INSULATION TESTER IR4059 For the HV range (500 V or 1000 V), the IR4059 has a safety feature that requires the technician to unlock in addition to choosing the voltage to prevent unintentional HV accidents Stable measurement under capacitive loads The test lead with remote switch is equipped with an LED The green/red light makes pass/fail judgments instantaneous and easy Zero-voltage measurement When the repair or inspection is finished, take a zero-voltage measurement on the inverter side and the battery side before safely reconnecting the HV system. After zero-voltage testing, install the high-voltage cable, service plug (a.k.a. switch), and return the vehicle's HV system to energized status. Restoring the high voltage 4 RESISTANCE METER RM3548 Resistance range 3 m (0.1 µ resolution) to 3 M range (100 resolution) Testing current 500 nA DC to 1 A DC Open-terminal voltage 5.5 V DC max. Temperature measurement -10.0°C to 99.9°C More information about RM3548 INSULATION TESTER IR4059 Rated output voltage Overload protection Response time 50 V DC, 125 V DC, 250 V DC, 500 V DC, 1000 V DC 600 V AC (10 s) Approx. 0.3 second for PASS/FAIL judgement (based on in-house testing) More information about IR4059 PIN TYPE LEAD 9465-11 PROTECTER Z5041 Protects main unit from shocks MAGNETIC STRAP Z5020 Fixed to the chassis with magnets WIRELESS ADAPTER Z3210 Transfers measurement data to a mobile device MAGNETIC STRAP Z5020 Fixed to the chassis with magnets 2 pieces required DIGITAL MULTIMETER DT4261 DC voltage range AC voltage range 600.0 mV to 1000 V 6.000 V to 1000 V (true RMS, crest factor 3 or less) LoZ V 600.0 V (true RMS, crest factor 3 or less) DC + AC voltage, DC current, AC current, Other measurement AC current with clamp-on probe, frequen- functions cy, resistance, continuity, capacitance, diode test WIRELESS ADAPTER Z3210 Transfers measurement data to a mobile device More information about DT4261 MAGNETIC STRAP Z5020 Fixed to the chassis with magnets 2 pieces required INFRARED THERMOMETER FT3701 Measurement temperature range Measurement wavelength Thermal emissivity compensation () Measurement field diameter -60.0 to 760.0 (-76°F to 1400°F) 8 to 14 µm 0.10 to 1.00 100 mm at 3000 mm (3.94 in. at 9.84 ft.) (distance : spot = 30 : 1) More information about FT3701 CARRYING CASE C0213 It can accommodate all measuring instruments. EV maintenance manual included. HEADQUARTERS 81 Koizumi, Ueda, Nagano 386-1192 Japan https://www.hioki.com/ *The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by HIOKI E.E. CORPORATION is under license. Note: Company names and product names appearing in this brochure are trademarks or registered trademarks of various companies. DISTRIBUTED BY All information correct as of Dec. 4, 2023. Contents are subject to change without notice. series_EV_maintenance_tools_E1-3ZB