KUST Elektronik PT5020 Bedienungsanleitung

PT5020 & PT5030 Operation Manual

Operation Manual

KUST Elektronik GmbH

PT5020 & PT5030

Impulse Winding Tester

KUST Elektronik GmbH

Friedenstraße 26

D-35578 Wetzlar

Germany

E: info@kust-elektronik.com

P: +49 (0) 64414471223

PT5020 & PT5030 Operation Manual

Contents

Chapter 1 Overview......................................................................................................................... 1-1!

1.1 Production introduction .................................................................................................... 1-2!

1.2 Operation environment ..................................................................................................... 1-3!

1.2.1 Power supply .......................................................................................................... 1-3!

1.2.2 Environment temperature and humidity................................................................. 1-3!

1.2.3 Warm-up................................................................................................................. 1-3!

1.3 Dimensions and weight..................................................................................................... 1-3!

Chapter 2 General specifications..................................................................................................... 2-1!

2.1 Specifications.................................................................................................................... 2-1!

2.2 Comparison methods ........................................................................................................ 2-2!

2.2.1 Area size comparison ............................................................................................. 2-2!

2.2.2 Differential area comparison .................................................................................. 2-2!

2.2.3 Corona discharge comparison ................................................................................ 2-3!

2.2.4 Differential phase comparison................................................................................ 2-4!

Chapter 3 : Panels and display ........................................................................................................ 3-1!

3.1 Front panel ........................................................................................................................ 3-1!

3.2 Rear panel ......................................................................................................................... 3-3!

3.3 Introduction to display area .............................................................................................. 3-4!

Chapter 4 Introduction to [DISP] .................................................................................................... 4-1!

4.1 Measurement display page................................................................................................ 4-1!

4.2 Introduction to symbols in measurement display page..................................................... 4-1!

4.3 Introduction to soft keys in measurement display page.................................................... 4-1!

4.3.1 Standard sampling .................................................................................................. 4-2!

4.3.2 Compare ................................................................................................................. 4-3!

4.3.3 Measure .................................................................................................................. 4-4!

4.3.4 Utility...................................................................................................................... 4-5!

4.3.5 Statistics.................................................................................................................. 4-5!

4.3.6 Modify .................................................................................................................... 4-5!

Chapter 5 Introduction to [SETUP]................................................................................................. 5-1!

5.1 Introduction to icons of soft keys ..................................................................................... 5-1!

5.2 Measurement setup page................................................................................................... 5-1!

5.2.1 Imp Volt ................................................................................................................. 5-2!

5.2.2 Sample .................................................................................................................... 5-2!

5.2.3 Test Imp.................................................................................................................. 5-2!

5.2.4 Erase Imp................................................................................................................ 5-3!

PT5020 & PT5030 Operation Manual

5.2.5 Volt ADJ................................................................................................................. 5-3!

5.2.6 Wave Disp .............................................................................................................. 5-3!

5.2.7 Trig Mode............................................................................................................... 5-4!

5.2.8 Delay Time ............................................................................................................. 5-4!

5.2.9 BDV Test................................................................................................................ 5-4!

5.2.10 Start Volt .............................................................................................................. 5-5!

5.2.11 End Volt ............................................................................................................... 5-5!

5.2.12 Volt Step............................................................................................................... 5-5!

5.2.13 Comparator........................................................................................................... 5-5!

5.2.14 Position (AREA SIZE, DIFF ZONE, PHASE DIFF) .......................................... 5-5!

5.2.15 Position（PHASE DIFF）................................................................................... 5-6!

5.2.16 DIFF（Limit）（ AREA SIZE, DIFF ZONE, PHASE DIFF）........................... 5-6!

5.2.17 DIFF（Limit）（ CORONA）.............................................................................. 5-6!

5.3 Int. File.............................................................................................................................. 5-6!

5.4 Ext. File............................................................................................................................. 5-8!

Chapter 6 Introduction to [SYSTEM] ........................................................................................... 6-10!

6.1 System............................................................................................................................. 6-10!

6.1.1 Brightness............................................................................................................. 6-11!

6.1.2 Pass/Fail................................................................................................................ 6-11!

6.1.3 Pass Alarm............................................................................................................ 6-11!

6.1.4 Fail Alarm............................................................................................................. 6-11!

6.1.5 Key Sound ............................................................................................................ 6-11!

6.1.6 Hard Copy ............................................................................................................ 6-11!

6.1.7 Password............................................................................................................... 6-11!

6.1.8 Language .............................................................................................................. 6-12!

6.1.9 Theme................................................................................................................... 6-12!

6.1.10 Date .................................................................................................................... 6-12!

6.1.11 Time.................................................................................................................... 6-12!

6.2 I/O Interface .................................................................................................................... 6-12!

6.2.1 I/O......................................................................................................................... 6-13!

6.2.2 PT50xx RS232C interface................................................................................. 6-13!

6.2.3 USB interface ....................................................................................................... 6-15!

6.3 About .............................................................................................................................. 6-17!

Chapter 7 User guide....................................................................................................................... 7-1!

7.1 Use of keys........................................................................................................................ 7-1!

7.1.1 Switch the display page.......................................................................................... 7-1!

7.2 Basic measurement ........................................................................................................... 7-1!

7.2.1 Non-standard test.................................................................................................... 7-1!

PT5020 & PT5030 Operation Manual

7.2.2 Sample test for standard wave................................................................................ 7-1!

7.3 BDV test ........................................................................................................................... 7-2!

7.4 Technology application..................................................................................................... 7-2!

7.4.1 Test objects............................................................................................................. 7-2!

7.4.2 Select comparison method...................................................................................... 7-3!

7.4.3 Settings of comparison method .............................................................................. 7-3!

7.4.4 Select standards ...................................................................................................... 7-4!

7.4.5 Chart for differential area ....................................................................................... 7-4!

Chapter 8 Command reference........................................................................................................ 8-1!

8.1 Command structure........................................................................................................... 8-1!

8.2 Data format ....................................................................................................................... 8-3!

8.3 Notation conventions and definitions ............................................................................... 8-3!

8.4 Command reference.......................................................................................................... 8-4!

8.4.1 DISPlay subsystem commands .............................................................................. 8-4!

8.4.2 Measure Function subsystem commands ............................................................... 8-7!

8.4.3 COMParator subsystem commands ....................................................................... 8-8!

8.4.4 Impulse VOLTage subsystem commands............................................................ 8-13!

8.4.5 Sample RATE subsystem commands................................................................... 8-15!

8.4.6 Standard WAVE subsystem commands............................................................... 8-17!

8.4.7 Wave Adjust subsystem commands ..................................................................... 8-18!

8.4.8 STATistic subsystem commands ......................................................................... 8-19!

8.4.9 TRIGger subsystem commands............................................................................ 8-20!

8.4.10 FETCh？subsystem commands ......................................................................... 8-21!

8.4.11 MEASure subsystem commands........................................................................ 8-23!

8.4.12 ABORt subsystem command ............................................................................. 8-24!

8.4.13 Mass MEMory subsystem commands................................................................ 8-24!

8.4.14 Local Control subsystem commands.................................................................. 8-25!

8.4.15 Common commands........................................................................................... 8-26!

8.5 Error and warning message............................................................................................. 8-26!

Chapter 9 Handler interface............................................................................................................. 9-2!

9.1 Basic information.............................................................................................................. 9-2!

9.2 Electrical characteristics ................................................................................................... 9-3!

9.2.1 DC isolated output.................................................................................................. 9-3!

9.2.2 Isolated input .......................................................................................................... 9-4!

9.3 Jumper setup on HANDLER interface ............................................................................. 9-5!

Chapter 10 Package contents and warranty................................................................................... 10-1!

10.1 Package contents........................................................................................................... 10-1!

PT5020 & PT5030 Operation Manual

10.2 Warranty ....................................................................................................................... 10-1!

PT5020 & PT5030 Operation Manual

1-1

Chapter 1 Overview

Thank you for your Choosing one of our products. Before the use of it, please locate the items

listed in this manual to ensure nothing is missing. If in the case that any item is missing, please

It is necessary to read this manual carefully before your proper use of PT50xx series impulse

winding tester.

Warning!

1) Operation

Do not put heavy objects on the tester.

There is a cooling fan on the rear side of this instrument, so any block of the air inlet is

prohibited.

2) Rigid power input

The stability of high voltage depends on stable power input. Be sure to provide rated AC

power or corrected power.

3) Grounding

For the safety of personnel and instrument, ensure the grounding terminal, designed in

power cord, be grounded correctly.

4) Test cable

To avoid electrical shock hazard, do not touch test terminals and test samples. The reason

is that a high voltage test cable is connected to the rear panel of this instrument, thus when

testing, the cable and test samples connected will carry a high voltage.

5) DO NOT open case unauthorized!

To avoid the injury to personnel and damage to the instrument, do not open the case

unauthorized due to the existence of high voltage in instrument.

6) Carry or move

Before moving the instrument, unplug the AC power sockets and remove high voltage test

line or external control line.

7) Maintenance

In non-use state, the instrument should be covered with a plastic or cloth cover. To clean

the tester, wipe the dirty parts with a soft cloth socked with diluted neutral detergent. Do

not use the following chemicals to clean the instrument: diluent, benzene or organic

solvent with similar chemical property with above materials.

8) Location

Do not locate the instrument in the environment of high temperature, direct sunlight or

PT5020 & PT5030 Operation Manual

1-2

1 2 3 4

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Number RevisionSize

Date: 26-Aug-2004 Sheet of

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poor ventilation. In addition, the instrument will generate high voltage, so it must be used

at room temperature and in the absence of much dust.

1.1 Production introduction

Due to the influence of wire material, magnetic material, framework and manufacture technics,

winding products such as transformers, motor windings may have defects of low insulation

between winding layers, circles and leads. PT50xx series impulse winding tester, adopting

high-speed sampling techniques, is a new test instrument for insulation performance of winding

products.

PT50xx series compares the standard waveform stored in the non-volatile memory with the

current tested waveform. PT50xx series provides the PASS or FAIL comparison result according

to AREA SIZE, DIFFERENTIAL AREA, CORONA DISCHARGE or DIFFERENTIAL

PHASE. With its strong functions, accurate comparison methods, easy operation and various

interfaces, PT50xx can provide a perfect test solution for most winding products.

Principles of impulse winding test

The impulse winding tester tests the electrical characteristics of coil winding without damaging the

DUT. The prerequisite condition is to test the quality of a coil at just a glance. The detection is

carried out when the same electric impulse, as used in the standard coil and here discharged by a

capacitor, is applied to the DUT. The voltage attenuation wave is generated in response to the

impulse, related to the Q-factor and inductance of the coil. In this sense, the tester can detect turn

and layer short, the differences in the number of turns and the material of the core. If high impulse

voltage is applied, the poor insulation will appear as a corona or layer discharge.

Figure 1-1 Simplified diagram for principles of impulse winding test

In figure 1-2, the self-oscillation attenuation wave has a close relation with the inductance L and

quality factor Q, while L and Q depend on the number of turn, manufacture technology,

properties of iron core material and whether it has air-coils. What’s more, the applied voltage is a

high impulse voltage, thus, it is easy to observe the short circuit, partial short turns and lays or

turns discharge phenomenon caused by insulation damage.

PT5020 & PT5030 Operation Manual

1-3

Figure 1-2 Typical self-attenuation oscillation wave

1.2 Operation environment

1.2.1 Power supply

Voltage: 198V-242V AC, 99V-121V AC

Power frequency: 47.5Hz-63Hz

Consumption: ≤50VA

1.2.2 Environment temperature and humidity

Normal working temperature: 0°~40°, Humidity: ≤90%RH

Referential working temperature: 20°±8°, Humidity: ≤80%RH

Transferring environment temperature: 0°~50°, Humidity: ≤93%RH

1.2.3 Warm-up

The warm-up time should not be less than 15 minutes.

1.3 Dimensions and weight

Dimensions (W*H*D): 398mm×129mm×370mm

Weight: Approx. 6kg

PT5020 & PT5030 Operation Manual Chapter 2 General specifications

2-1

Chapter 2 General specifications

2.1 Specifications

Specifications

PT5020

PT5030

Output for impulse voltage

100V~3000V

10V steps

5%±10V

100V~5000V

10V steps

5%±20V

Inductance test range

>10µH

Impulse energy

Max 250milli-Joules

Max 250 milli-Joules

Contents in waveform

display area on LCD

800×480 dot-matrix LCD

256×650 dot-matrix

Setup parameters, standard wave and test wave, comparison result, file

information, etc.

Sample wave

Sampling rate: 200MSPS 100MSPS, 50MSPS, 20MSPS, 10MSPS,

5MSPS, 2MSPS, 1MSPS, 500kMSPS, 200kMSPS,100kMSPS

Resolution: 8bits

Sampling point: 6500bytes

Standard wave sample

Sequential cycle, single cycle, one sample (up to 32 times of sample

averaging)

Input impedance

10MΩ

Test speed

6 times/sec

Averaging rate

Number of test impulse

1 to 32 averaging rate

programmable

Number of demagnetizing impulse

0 to 16 averaging rate

programmable

Measurement function

Voltage, time and frequency

Trigger mode

Internal, Manual (Foot), External and Bus

Comparison method

AreaSize Comparison

DiffZone Comparison

Corona Comparison

PhaseDiff Comparison

Area size measurement

accuracy

±1%

Area difference

measurement accuracy

±1%

Comparison output

OK/NG display

PT5020 & PT5030 Operation Manual Chapter 2 General specifications

2-2

Beeper alarm

Beep mode

ON (adjust for high and low tone), OFF

Memory

Built-in memory: 100 files

USB disk memory

Interface

HANDLER (START, STOP, PASS, NG, BUSY, EOC, etc.)

RS232C USB Device USB Host LAN

2.2 Comparison methods

2.2.1 Area size comparison

As shown in figure 2-1, when comparison method is set to AREA SIZE, the area sizes of both

standard waveform and the tested waveform are calculated (integration method) between A and

B. The percent deviation is the ratio of the area size difference to the area size of the standard

waveform between A and B, expressed as a percentage.

Figure 2-1 Area Size Comparison

The area size of the waveform is nearly proportional to the energy loss in the winding. When a

sample winding has a short circuit between layers, the short circuit area is reflected as an

increase of energy loss.

2.2.2 Differential area comparison

When comparison method is set to Differential Area, PT50xx calculates the area size of

differential portion between the standard waveform and the tested waveform from A to B. (The

differential portion area size is indicated as the shaded part in Figure 2-2.) The percent deviation

is the ratio of the differential portion area size to the area size of the standard waveform between

A and B, expressed as a percentage.

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