Kikusui PLZ-4W Series User manual

Part No. Z1-002-802, IB004183
Jun. 2008
OPERATION MANUAL
ELECTRONIC LOAD PLZ-4W Series
PLZ2004WB

Use of Operation Man ual
Please read through and understand this Operation Manual before operating the product. After reading,
al w ays k eep the manual nearby so that you may refer to it as needed. When mo ving the product to another
location, be sure to bring the manual as well.
If you fi nd an y incorrectly arranged or missing pages in this manual, the y will be replaced. If the manual
gets lost or soiled, a ne w cop y can be pro vided for a fee. In either case, please contact Kikusui distrib utor/
agent, and pro vide the “Kikusui P art No. ” gi v en on the co v er .
This manual has been prepared with the utmost care; ho we v er , if you ha v e an y questions, or note an y errors
or omissions, please contact Kikusui distrib utor/agent.
Reproduction and reprinting of this operation manual, whole or partially , without our permission is prohib -
ited.
Both unit specifi cations and manual contents are subject to change without notice.
Cop yright© 2003 - 2008 Kikusui Electronics Corporation

PLZ2004WB Safety Symbols I
Indicates an imminently hazardous situation which, if ignored,
will result in death or ser ious injur y .
Indicates that a high v oltage (o v er 1 000 V) is used here . T ouch -
ing the par t causes a possib ly f atal electr ic shoc k. If ph ysical
contact is required b y y our w or k, star t w or k only after y ou mak e
sure that no v oltage is output here .
Indicates a potentially hazardous situation which, if ignored,
could result in death or ser ious injur y .
Indicates a potentially hazardous situation which, if ignored, ma y
result in damage to the product and other proper ty .
Sho ws that the act indicated is prohibited.
Is placed bef ore the sign “D ANGER, ” “W ARNING, ” or “CA U -
TION” to emphasiz e these . When this symbol is mar k ed on the
product, see the rele v ant sections in this man ual.
Indicates a protectiv e conductor ter minal.
Indicates a chassis (fr ame) ter minal.
OR
WARNING
CAUTION
D ANGER
Saf ety Symbols
For the saf e use and saf e maintenance of this pr oduct, the f ollo wing
symbols are used thr oughout this man ual and on the pr oduct. Under -
stand the meanings of the symbols and obser ve the instructions the y
indicate (the c hoice of symbols used depends on the pr oducts).

II Safety Precautions PLZ2004WB
Saf ety Precautions
The f ollo wing saf ety precautions m ust be obser ved to a v oid fi re hazard,
electrical shock, accidents, and other failures. Keep them in mind and
make sure that all of them are observed properly.
Users
•This product must be used only by qualified personnel who understand the con-
tents of this operation manual.
•If it is handled by disqualified personnel, personal injury may result. Be sure to han-
dle it under supervision of qualified personnel (those who have electrical knowl-
edge.)
• This product is not designed or manufactured for general home or consumer use.
Purposes of use
•Do not use the product for purposes other than those described in the operation
manual.
Input power
• Use the product with the specified input power voltage.
• For applying power, use the power cord provided. Note that the provided power
cord is not use with some products that can switch among different input power
voltages or use 100 V and 200 V without switching between them. In such a case,
use an appropriate power cord.
Fuse
•With products with a fuse holder on the exterior surface, the fuse can be replaced
with a new one. When replacing a fuse, use the one which has appropriate shape,
ratings, and specifications.
Cover
•There are parts inside the product which may cause physical hazards.Do not
remove the external cover.
Operation
Manual
Line
Voltage

PLZ2004WB Safety Precautions III
Installation
•When installing products be sure to observe “2.2 Precautions Concerning Instal-
lation Location” described in this manual.
• To avoid electrical shock, connect the protective ground terminal to electrical
ground (safety ground).
•When connecting the power cord to a switchboard, be sure work is performed by
a qualified and licensed electrician or is conducted under the direction of such a
person.
• When installing products with casters, be sure to lock the casters.
Relocation
• Turn off the power switch and then disconnect all cables when relocating the
product.
•Use two or more persons when relocating the product which weights more than
20 kg. The weight of the products can be found on the rear panel of the product
and/or in this operation manual.
•Use extra precautions such as using more people when relocating into or out of
present locations including inclines or steps.Also handle carefully when relocat-
ing tall products as they can fall over easily.
• Be sure the operation manual be included when the product is relocated.
Operation
• Check that the AC input voltage setting and the fuse rating are satisfied and that
there is no abnormality on the surface of the power cord. Be sure to unplug the
power cord or stop applying power before checking.
•If any abnormality or failure is detected in the products, stop using it immediately.
Unplug the power cord or disconnect the power cord from the switchboard. Be
careful not to allow the product to be used before it is completely repaired.
• For output wiring or load cables, use connection cables with larger current capac-
ity.
•Do not disassemble or modify the product. If it must be modified, contact Kikusui
distributor/agent.
Maintenance and checking
• To avoid electrical shock, be absolutely sure to unplug the power cord or stop
applying power before performing maintenance or checking.
• Do not remove the cover when performing maintenance or checking.
• To maintain performance and safe operation of the product, it is recommended
that periodic maintenance, checking, cleaning, and calibration be performed.
Service
• Internal service is to be done by Kikusui service engineers.If the product must be
adjusted or repaired, contact Kikusui distributor/agent.
Check?

IV Arrangement of this manual PLZ2004WB
Arrangement of this Manual
This Operation Manual is made up of the following sections.
Chapter 1 General Information
This chapter gives an overview and describes the features of the PLZ2004WB.
Chapter 2 Installation and Preparation
This chapter describes the procedures of unpacking and preparation of the
PLZ2004WB before use.
Chapter 3 Names and Functions of Parts
This chapter describes the names and functions of switches, displays, connectors,
and other parts of the front panel and rear panel.
Chapter 4 Maintenance
This chapter describes maintenance and calibration of the PLZ2004WB.
Chapter 5 Specifications
This chapter describes the electrical and mechanical specifications of the
PLZ2004WB.

PLZ2004W Contents V
Contents
Safety Symbols ____________________________________________ I
Safety Precautions ________________________________________ II
Arrangement of this Manual ________________________________ IV
Chapter 1 General Information 1-1
Chapter 2 Installation and Preparation 2-1
2.1 Checking the Package Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2.2 Precautions Concerning Installation Location - - - - - - - - - - - - - - - - - - - 2-2
2.3 Precautions When Moving the Unit - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
2.4 Connecting the Power Cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
2.5 Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
2.6 Parallel Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
2.6.1 Connecting the Signal Cables - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
2.6.2 Load Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
2.7 Setting the Master Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10
Chapter 3 Names and Functions of Parts 3-1
3.1 Front Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
3.2 Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
Chapter 4 Maintenance 4-1
4.1 Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4.1.1 Cleaning the Panels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4.1.2 Cleaning the Dust Filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
4.2 Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
4.3 Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Chapter 5 Specifications 5-1
5.1 Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
5.2 General Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
5.3 Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4
Index I- 1

VI Contents PLZ2004W

PLZ2004WB General Information 1-1
Chapter 1 General Information
This chapter gives an overview and describes the features of the PLZ2004WB.
About This Manual
This operation manual describes the PLZ2004WB Load Booster.
The PLZ2004WB is used in combination with the PLZ1004W Electronic Load.
This manual mainly covers the handling precautions of the PLZ2004WB and the
connection to the PLZ1004W. For the operating procedure as a electronic load, see
the PLZ1004W Operation Manual.
Product Overview
The PLZ2004WB Load Booster is used to increase the input current to the
PLZ1004W Electronic Load. One PLZ1004W is made the master unit, and load
boosters connected in parallel operate as slave units.
Features
•Up to four load boosters can be connected in parallel with a PLZ1004W master
unit, configuring a electronic load that produces up to 9 kW and 1
800 A.
• The master unit displays the total current and total wattage. The units connected
in parallel can be used as a single electronic load.
• The connection of the control cables is easy. The control cable used to connect
between the master unit and the load booster and between each load booster is
one flat cable each.
• There is no power switch. The AC input power is turned ON/OFF by the master
unit.
Options
Control flat cables
Control cable used to connect between the master unit and the load booster and
between load boosters. The following two types of cables are available.
The two types of cables only differ in their length. The 550-mm PC02-PLZ-4W is
required to connect the master unit and the load booster.
Model Code Length Application
PC01-PLZ-4W 84540 300 mm Connect between load boosters
PC02-PLZ-4W 84550 550 mm Connect between the master unit and load booster

1-2 General Information PLZ2004WB
Rack mount bracket
The following rack mounting brackets are available.
• KRB3-TOS (for inch-rack EIA standard)
• KRB150-TOS (for milli rack JIS standard)
For details, contact Kikusui distributor/agent.
Fig.1-1 Rack mount bracket installation example
5737.5
132
24.5
100
149
(465)
(460)
479
479
Unit: mm
KRB3-TOS
KRB150-TOS

PLZ2004WB Installation and Preparation 2-1
Chapter 2 Installation and Preparation
This chapter describes the procedures of unpacking and preparation of the
PLZ2004WB before use.
2.1 Checking the Package Contents
When you receive the product, check that all accessories are included and that the
product and accessories have not been damaged during transportation.
If any of the accessories are damaged or missing, contact Kikusui distributor/agent.
•It is recommended that all packing materials be saved, in case the product needs
to be transported at a later date.
Fig.2-1 Accessories
NOTE
Operation manual (1 copy)
Power cord
(1 pc.)
[Z1-002-802]
Set of screws for the load input terminal
(2 sets)
[M1-100-027]
[M5-101-009]
[M4-100-009]
J2 protection dummy plug (1 pc.)
[Attached to the J2 connector on the rear panel.]
[84-49-0071]
Load input terminal cover (2 pcs.)
[with auxiliary band]
[Q1-500-096]
[Q1-900-020]
PartNo.Z1-002-802,IB004181
Aug. 2003
OPERA
TIONMANUAL
ELECTRONIC LOAD PLZ-4W Series
PLZ2004WB
[85-AA-0003] [85-AA-0005]
Rated voltage: 125 Vac
PLUG: NEMA5-15
Rated voltage: 250 Vac
PLUG: CEE7/7
[85-10-0790]
Rated voltage: 250 Vac
PLUG: GB1002
or or
The power cord that is provided varies depending on the
destination for the product at the factory-shipment.

2-2 Installation and Preparation PLZ2004WB
2.2 Precautions Concerning Installation
Location
This section describes the precautions to be taken when installing the unit. Make
sure to observe them.
■Do not use the unit in a flammable atmosphere.
To prevent the possibility of explosion or fire, do not use the unit near alcohol, thin-
ner or other combustible materials, or in an atmosphere containing such vapors.
■Avoid locations where the unit is exposed to high temperature
or direct sunlight.
Do not place the unit near a heater or in areas subject to drastic temperature
changes.
Operating temperature range: 0 °C to 40 °C
Storage temperature range: -25 °C to +70 °C
■Avoid humid environments.
Do not place the unit in high-humidity locations--near a boiler, humidifier, or water
supply.
Operating humidity range: 20 % to 85 % RH (no condensation)
Storage humidity range: 0 % to 90 % RH (no condensation)
Condensation may occur even within the operating humidity range. In such case, do
not use the unit until the condensation dries up completely.
■Do not place the unit in a corrosive atmosphere.
Do not install the unit in a corrosive atmosphere or in environments containing sul-
furic acid mist, etc. This may cause corrosion of various conductors and bad con-
tacts of connectors inside the unit leading to malfunction and failure, or in the worst
case, a fire.
However, operation in such environments may be possible through alteration. If you
wish to use the unit in such environments, consult Kikusui distributor/agent.
■Do not place the unit in a dusty location.
Accumulation of dust can lead to electric shock or fire.
■Do not use the unit where ventilation is poor.
The unit employs a forced air cooling system. Air is taken in from intake ports
located on panels other than the rear panel and exhausted from the ports on the rear
panel. Secure adequate space around the unit to prevent the possibility of fire caused
by accumulation of heat.
■Do not place the unit on an inclined surface or location sub-
ject to vibrations.
The unit may fall or tip over causing damages and injuries.

PLZ2004WB Installation and Preparation 2-3
■Do not use the unit in a location subject to strong magnetic or
electric fields.
The unit may malfunction and cause electric shock or fire.
■Do not use the unit near highly sensitive measuring instru-
ments or transceivers.
The noise generated by the unit may affect them
■Do not stack more than two units on top of each other.
The units (load booster and master unit) can be stacked, but do not stack more than
two units on top of each other for safety reasons.
If you are using multiple load boosters, it is recommended that they be mounted on
a rack.
Fig. 2-2 Stacking of the electronic loads
2.3 Precautions When Moving the Unit
When moving the unit to the installation location or when transporting the unit, note
the following points.
■Remove all wiring.
Moving the unit with the cables connected can cause wires to break or injuries due
to the unit falling over.
■Have two or more people move the unit.
The unit weighs over 20 kg. Have two or more people move the unit. Use extra pre-
caution at inclines and steps.
■When transporting the unit, be sure to use the original pack-
ing materials.
Otherwise, damage may result from vibrations or from the unit falling during trans-
portation.
POWER
ELECTRONIC LOAD 2000W
1.5
-
150V
0
-
400A
PLZ 2004WB POWER
ELECTRONIC LOAD 2000W
1.5
-
150V
0
-
400A
PLZ 2004WB
DC INPUT
1000W
1.5
-
150V
0
-
66A
I MON
OUT
DC INPUT
1000W
1.5
-
150V
0
-
66A
I MON OUTOUT TRIG
REMOTE
POWER
Do not stack
more than
two units.

2-4 Installation and Preparation PLZ2004WB
2.4 Connecting the Power Cord
The power cord that is provided varies depending on the destination for the product
at the factory-shipment.
•This product is designed to be connected to a power supply classified as
Overvoltage Category II. Do not connect to a power supply classified as
Overvoltage Category III or IV.
• The power cord for 100-V system shown in Fig. 2-3 has a rated voltage of
125 VAC. If this power cord is used at the line voltage of a 200-V system,
replace the power cord with that satisfying that line voltage.
Have a qualified engineer select the appropriate power cord. If obtaining
the right power cord is difficult, contact Kikusui distributor/agent.
•Do not use the power cord that comes with the product as a power
cord for other equipment.
Fig. 2-3 Power cord with a three-pin plug
Follow the procedures below to connect the power cord.
•The load booster does not have a power switch. The AC input power is turned on/
off in sync with the master unit when the load booster is connected to the master
unit through the control cable.
1. Check that the AC power supply is within the input power supply range
of the product.
The allowable voltage range and frequency range of the AC input power are 90
VAC to 250 VAC and 47 Hz to 63 Hz, respectively.
2. Connect the power cord to the AC INPUT connector on the rear panel.
Use a power cord specified by Kikusui or one that has been selected by a qual-
ified engineer.
3. Insert the power plug to the outlet.
Power cord for 100-V system
Rated voltage: 125 VAC
Rated current: 10 A
Power cord for 200-V system
Rated voltage: 250 VAC
Rated current: 10 A
WARNING
[85-AA-0003]
PLUG:NEMA5-15
[85-AA-0005]
PLUG:CEE7/7
[85-10-0790]
PLUG:GB1002
NOTE

PLZ2004WB Installation and Preparation 2-5
2.5 Grounding
• Electric shock may occur, if proper grounding is not furnished.
• This product is designed as a Class I equipment (equipment furnished
with electric shock protection through protective grounding in addition to
the basic insulation). Be sure to connect the protective ground terminal to
an appropriate earth ground.
• If you do not ground the product, malfunction may occur due to external
noise, or the noise generated by the product may become large.
Make sure to ground the load booster for your safety.
Connect the power cord to a three-prong power outlet with proper grounding.
Fig. 2-4 Grounding method
WARNING
CAUTION
Three-prong outlet with
proper grounding

2-6 Installation and Preparation PLZ2004WB
2.6 Parallel Connection
To carry out parallel operation, you must connect signal wires used to connect to the
master unit and the load cable used to connect to the equipment under test.
Use the optional flat cable for the signal wire. For details, see “Control flat cables”
in chapter 1, “General Information.”
Up to four load boosters can be connected. Here, an example in which two load
boosters are connected is indicated.
•There is a danger of electric shock. Do not touch the load connector while
the power is on.
Fig. 2-5 Parallel connection of two load boosters
Table 2-1shows the relationship between the number of load boosters and the capac-
ity.
Table2-1 The number of load boosters connected in parallel and
the capacity
Number of load boosters (n) Maximum current/maximum power
PLZ1004W + (PLZ2004WB ×n)
1 600 A / 3000 W
2 1000 A / 5000 W
3 1400 A / 7000 W
4 1800 A / 9000 W
WARNING
DC INPUT
2000W
1.5
-
150V
0
-
400A
J1
J2
DC INPUT
2000W
1.5
-
150V
0
-
400A
J1
J2
J1
J2
DC IN PUT
1000W
1.5
-
150V
0
-
200A
Equipment
under test
J2
J2
J1
J1
–
+
+
–+
–
–
+
Flat cable
PC02-PLZ-4W
(Option)
Flat cable
PC01-PLZ-4W
(Option)
Master unit
Load booster 1
Load booster 2 Load wire

PLZ2004WB Installation and Preparation 2-7
•Be sure to use the load input terminals on the rear panel on the master
unit. Do not connect other equipment to the load input terminal on the front
panel.
• Improper connection of the J1 and J2 connectors can damage the
PLZ2004WB.
• Take into account the current used, and make the load cable as short as
possible with sufficient thickness.
•Separate the load cable from the flat cable as much as possible to prevent unstable
operation.
2.6.1 Connecting the Signal Cables
Use the optional cable for the connection cable.
1. Turn off the POWER switch on the master unit.
2. Unplug the power cord plug of the load booster.
3. Connect between J2 of the master unit and J1 of load booster 1 using
the optional flat cable (PC02-PLZ-4W).
4. Connect between J2 of load booster 1 and J1 of load booster 2 using
the optional flat cable (PC01-PLZ-4W).
When connecting more load boosters, make similar connections.
2.6.2 Load Wiring
•Precautions and items to be considered during load wiring when using the master
unit alone also apply to parallel operation.
Before wiring the load for parallel operation, read section 2.8, “Load Wiring” in
the PLZ1004W Operation Manual to familiarize yourself with the precautions and
items to be considered.
Electric wire used
•Use a load wire with sufficient diameter for the current as well as non-flam-
mable or flame-resistant cover.
A table indicating “nominal cross-sectional area of wires and allowable currents” is
given in section 2.8, “Load Wiring” in the PLZ1004W Operation Manual. Refer to
this table and select the thickest wire possible.
CAUTION
NOTE
NOTE
CAUTION

2-8 Installation and Preparation PLZ2004WB
Connection to the load input terminal
The load input terminal on the PLZ1004W (master unit) is not designed for large
currents as in the load input terminal of the load booster.
As shown in Fig. 2-5, separate the load wire from the equipment under test for the
master unit and the load booster.
•There is a danger of electric shock. Do not touch the load input terminal
while the power is on.
In addition, be sure to use the load input terminal cover.
• There is a danger of overcharge. Attach crimping terminal to the wire and
use the set of screws that came with the package for connection.
1. Turn off the POWER switch on the master unit.
2. Unplug the power cord plug of the load booster.
3. Check that the output of the equipment under test is off.
4. Connect the load wire to the load input terminal of the master unit.
For the connection procedure of the load wire, see section 2.8, “Load Wiring”
in the PLZ1004W Operation Manual.
5. As shown in Fig. 2-6, connect the load wire to the load input terminal of
the load booster.
Use the load input terminal cover. See Fig. 2-7 on how to use the cover.
6. Connect the master unit, load booster, and the equipment under test.
7. Check the polarity of the connections.
Fig. 2-6 Connection to the load input terminal
WARNING
CAUTION
Bolt (M12 ×25)
Spring washer (M12)
Nut (M12)
Crimp terminal
Be sure to use the set
of screws provided
with the package.

PLZ2004WB Installation and Preparation 2-9
Fig. 2-7 Attachment of the load input terminal cover
Wrap the auxiliary band between the rear panel and the
bolt.
The auxiliary band prevents the load input
terminal cover from sliding. Wrap the band
tightly to fill up the space between the panel
and the bolt.
Wrap the load input terminal cover
over the auxiliary band.
Wrap the cover leaving as little
space as possible here.
1
2
Auxiliary band
Load input terminal cover

2-10 Installation and Preparation PLZ2004WB
2.7 Setting the Master Unit
1. Turn on the power to the master unit.
The power to the load booster is in sync with the power to the master unit.
2. Select the menu setup.
Press the MENU (SHIFT+SET/VSET) key.
The menu appears.
3. Select Configuration
Press the or CURSOR key several times until Configuration is high-
lighted. When highlighted, press the ENTER key.
4. Select Master/Slave
Press the or CURSOR key several times until Master/Slave is high-
lighted. When highlighted, press the ENTER key.
5. Set the master unit.
Check to see that the cursor (blinking) is at the Operation item. If the cursor is
at some other item, press the CURSOR key several times to move the cursor
to Operation.
6. Set as a master unit.
First, turn the rotary knob to the right to select MASTER.
Press the CURSOR key twice to move the cursor (blinking) to the Booster
item.
Turn the rotary knob to set the number of load boosters.
7. Exit from the menu.
Press the MENU (SHIFT+SET/VSET) key.
On the master unit, the original screen displayed before entering menu
setup appears.
8. Power cycle the master unit.
The menu settings are confirmed.
9. Set the operation mode and value, and turn on the load.
Operate the master unit to set the master mode and value of the parallel con-
nection. The range of the rated current and rated power on the master unit is
expanded.
After entering the settings, turn off the load.
Operation : MASTER
Parallel : --
Booster : --
PREV
Master / Slave