New End Jack For Pomona/Fluke Test Leads ?

[SgtRock]

Greetings EEVBees:

--I want some plugs on hand to replace the worn out ones on my Pomona/Fluke test leads, see picture. I want to maintain the 10 Amp Cat 3 1000V, Cat 4 600V ratings. Can I safely repair these leads or should I buy new ones? I sometimes sell my used equipment on down the road, so I want to be sure to maintain the safety ratings as much as possible. I do not want to put anyone at risk just to save a few pennies. Your advice is humbly solicited.

"I wear suspenders and a belt. I am a security man all the way"
Justin Wilson (The Cajun Cook) 1914 - 2001
 
Best Regards
Clear Ether

[ProBang]

Hello.

I have no doubt, you can replace the shrouded plug and the test leads are reaching their origin specs.

The point is: The specs for the Cat- Ratings have changed.
To be "up-to-date" needs new leads.
Differences to the "old" Cat- Ratings:

1. For the Cat IV Rating it is necessary, that the tip of the probe is insulated (except the first 2 mm).
For the Cat III Rating there is no need for that, the well known 16 mm tip is enough.
2. The lead must indicate, if the insulation is damaged, e.g. the lead has an inner hull of white silicone,
the outer hull is red. You can immediately see, if the red insulation is damaged.
3. The contact in the shrouded plug must have an insulation at his top. To avoid under every circumstances
to have contact with a part under current/voltage.
(Who figures that out? Is there really anyone, who sticks the probe into the mains and poke with his finger,
just for fun, into the plug of the test lead?? A volunteer candidate and uprising hero of the Darwin-Award?)

Question: Why don't you make it simple and sell the multimeter without probes? (It is not unusual.)

Greetings,


Hartmut

[SgtRock]

Dear Hartmut:

--Thanks for the current information. I am assuming that the older Pomona/Fluke leads are grandfathered, so to speak, and may be sold on with out any exceptional liability. However, I will keep what you said in mind, and make sure any new acquisitions, adhere to the recent standards. I did find a couple of DIY plug ends which are safe enough, but one is not a right angle and the other is multi-stacking, see below links and pics. I am going to get a few of each for future use. If I can find the straight shrouded plug in black, I might just sacrifice one of my old beat up sets, in order to make a set of shorty test leads, I get tired of having all that extra wire in my way, and some silicone jumpers of various terminations. I am still hoping to fine some DIY Pomona/Fluke plug ends. Fat chance!

http://www.ebay.com/itm/150746930198?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

http://www.ebay.com/itm/261132636139?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

"An expert is a man who has made all the mistakes which can be made in a very narrow field."
Niels Bohr 1885 - 1962

Best Regards
Clear Ether

[ModemHead]

Pomona 6729 are shrouded right-angle DIY plugs.  Rated 20A, 1000V Cat III according to the datasheet.  About $6 per pair at Mouser, etc.

Pomona 6383 are shrouded straight DIY plugs.  I've used these to repair damaged test leads, they have a nice 'factory' look, but are only rated 5A, 300V Cat II according to their datasheet.

[SgtRock]

Dear ModemHead:

--Thanks for the good info, as per usual. Exactly what I needed. I plan on ordering some of these from Mouser in the new year. And do not forget Boys & Girls to go to Mouser from the EEVblog page so that Sagan can get some new shoes.

"Get ready, little lady. Hell is coming to breakfast."
Chief Dan George 1899 1981

Best Regards
Clear Ether

[alm]

Note that these plugs are not CAT IV rated. I wonder if this requires molded plugs or special assembly techniques.

[SgtRock]

Dear Alm:

--Good point. I had not noticed. I guess I will add a couple of layers of shrink tubing of the appropriate color when assembling, if that sounds right to everybody.

"Measure twice. Cut once"
Norm Abram 1950 -

Best Regards
Clear Ether

[Monkeh]

Heatshrink does not make a Cat IV rating.

Do you even need such a rating? Don't worry about selling them, if you want to include probes, include a set of new ones. I for one don't want old, mangled probes when I buy a meter.

[alm]

Agree on the heat shrink not magically making it CAT IV. I would tape a label over the CAT IV rating on the probes to indicate the downgrade to CAT III.

[SgtRock]

Greetings EEVBees:

--Agree wholeheartedly about magic not being involved. I will melt away the Cat 4 designation, since with the broken shroud the lead is already out of specification and cannot be easily repaired to spec. But I will still double heat shrink around the repair, to make the repair as safe a possible. I am still planning to make some Cat 3 shorties for my own use, when next I buy some of the most recent Cat 4 leads. Thanks for all of the good comments and advice.

"An expert is a man who has made all the mistakes which can be made in a very narrow field."
Niels Bohr 1885 - 1962

Best Regards
Clear Ether