Kikusui OT03-PCR-WEA User manual

OT03-PCR-WEA
User’s Manual
High Voltage Test System for Avionics
6kVA Single/Three-phase output transformer
Table of Contents 5
Component Names 6
Preparation 8
Operation 28
Maintenance 30
Specifications 33
Appendix 40
Part No. Z1-010-063, I0051102
Sep 2022

2User’s Manual OT03-PCR-WEA
This manual includes descriptions of the overview,
preparation, operation, and usage precautions of the
product. Read this manual thoroughly before use, and use
the product properly.
Intended readers
These manuals are intended for users of this product and
their instructors. The manuals assume that the reader has
knowledge about power supplies.
Manual construction
• User’s Manual (this manual)
This document is intended for those who use this
product for the first time and provides information on the
product including the overview, connecting procedures,
operating procedures, usage precautions, and
specifications of the product.
• Safety Information
This document contains general safety precautions.
Keep them in mind and make sure to observe them.
Trademarks
Company names and product names in this document are
generally trademarks or registered trademarks of the
respective companies.
Copyright
Reproduction and reprinting of these manuals, whole or
partially, without our permission is prohibited.
Both unit specifications and manual contents are subject to
change without notice.
© 2022 Kikusui Electronics Corporation
Dispose of this product in accordance with your local
regulations.
• In this manual, the 6 kVA single-phase / three-phase
output transformer OT03-PCR-WEA is referred to as
“output transformer” or “OT03-PCR-WEA”.
• In this manual, the PCR-WEA and PCR-WEA2(R)
Series are referred to as “PCR-WEA Series” or “PCR-
WEA”.
• In this manual, the Avionics Test Software SD012-PCR-
WE is referred to as “application software” or “SD012-
PCR-WE”.
• “PC” in this manual is a generic term for personal
computers and workstations.
• The term “EUT” is used to refer generally to an
equipment under test.
• The screen captures and illustrations used in this
manual may differ from the actual items.
• The following markings are used in this manual.
Indicates a potentially hazardous situation which, if ignored,
could result in death or serious injury.
Indicates a potentially hazardous situation which, if ignored,
may result in slight injury or damage to the product and
other property.
Indicates information that you should know.
>
Indicates the hierarchy of items you need to select. The item
to the left of this symbol indicates a higher level item.
When using this product, be sure to observe the
precautions in the Safety Information Manual. Items
specific to this product are given below.
• This equipment is not intended for use in residential
environments and may not provide adequate protection
to radio reception in such environments.
• Do not use the product where ventilation is poor. Heat is
discharged from the vents on the rear panel. To prevent
the heat from building up and causing a fire, keep the
vents at least 50 cm away from walls. Also, do not place
objects within 50 cm of the rear panel.
About Manuals
Disposal
Notations Used in This Manual
WARNING
CAUTION
Safety Precautions
CAUTION

OT03-PCR-WEA User’s Manual 3
• When installing this product, be sure to observe the
temperature and humidity ranges. For environmental
conditions, see General Specifications (p.37).
• How to lock the casters
This product has casters on its bottom side, so it is easy
to move the product. To ensure that the product is not
moved accidentally while it is being operated, lock the
casters.
This product is a unit for conducting high-voltage tests of
avionics systems using our PCR-WEA Series.
The built-in step-up transformer allows testing at high
voltages, which was not supported by the PCR-WEA
Series.
Features
Equipped with two output modes
It is possible to switch between the “transformer
connection mode” in which the PCR-WEA Series is
connected via the step-up transformer of this product
when performing tests requiring high voltages, and the
“bypass mode” in which the PCR-WEA Series voltage is
output as it is without going through the transformer of
this product when performing tests where high voltage is
not required.
No need to connect wiring from PC to this product
Since this product is connected to the PCR-WEA Series
with a DIGITAL I/O connector, wiring from the PC to this
product is not necessary.
The output mode can be switched via the PCR-WEA
Series.
Operation using a dedicated application software
Combining the Avionics Test Software SD012-PCR-WE
with the PCR-WEA makes it easy to perform tests for
avionics.
Output mode can be switched by the software.
For the test items that can be performed, see the
SD012-PCR-WE User’s Manual.
Applicable models
Notes on Usage
free
lock
Accessories
Power cord (1 pc., length: approx. 2.5 m)
Safety Information (1 copy)
China RoHS sheet (1 sheet)
Userʼs Manual (this manual, 1 copy)
Plug: NEMA5-15,
Rating: 125 Vac/10 A
[85-AA-0004]
Plug: CEE7/7,
Rating: 250 Vac/10 A
[85-10-1070]
Plug: GB1002,
Rating: 250 Vac/10 A
[85-10-0791]
or or
Theattachedpowercordvariesdependingontheshipmentdestination.
PCR6000WEA2(R) connection
cable (M5 terminal - M5 terminal)
(7 pcs., approx. 1.5 m) [91-94-3321]
Sensing cable between PCR-WEA
and output transformer
(4 pcs., approx. 1.5 m)
[91-94-3331]
12 kVA Plastic plate for
parallel connection
(1 sheet) [91-51-0023]
Heavy object warning label (1 sheet)
If necessary, attach to the product.
DIGITAL I/O connection cable
(1 pc., approx. 1 m)
[91-94-3071]
Cable tie (4 pcs.)
[P4-200-006]
Model name Output method Notes
PCR3000WEA2 Single-phase
output
Single-phase
three-wire
output1
Three-phase
output
1. Output available only when bypass mode is
selected
PCR6000WEA2
PCR6000WEA2R
Single-phase
output
Single-phase
three-wire
output1
Three-phase
output
PCR12000WEA2
PCR12000WEA2R
Single-phase
output
Single-phase
three-wire
output1
Three-phase
output
Output is available
by connecting two
units of this product
(6 kVA x 2 units) in
parallel
Product Overview

4User’s Manual OT03-PCR-WEA
System Configuration
R
S
T
NNNWVU
NWVU
OT03-PCR-WEA NWVU NNNWVU
NWVU NNNWVU
GNWVU
EUT
PCR-WEA IN
DIGITAL I/O
PC
DIGITAL I/O
PCR-WEA1Series
(PCR6000WEA2)
Example: When this product is connected to the PCR6000WEA2 and three-phase output is used
Power cord
Power cord2
Switchboard
Outlet
1. This product supports only PCR-WEA / PCR-WEA2 (R) Series. It does not support PCR-WE.
2. Included with this product.
3. Included with the PCR-WEA.
4. When three-phase 200 V input model.
200 Vacrms
to 240 Vacrms4
ij
External control
connector3
(DIGITAL I/O)
DIGITAL I/O
connection cable2
(DSUB 25-pin)
Output cable2
Output cable
100 Vac
to 240 Vac
ij
Avionics test
software
SD012-PCR-WE
AC INPUT
Transformer
connection
mode
Transformer
connection
mode
Bypass
mode
Bypass
mode
Attenuator
Step-up
transformer
Sensing cable2
Interface
- RS232C, USB, LAN
- GPIB
(option board required)
Sensing cable

OT03-PCR-WEA User’s Manual 5
Table of Contents
About Manuals ...................................................2
Disposal..............................................................2
Notations Used in This Manual...........................2
Safety Precautions .............................................2
Notes on Usage..................................................3
Accessories ........................................................3
Product Overview ...............................................3
System Configuration .........................................4
Component Names ............................................6
Preparation
Connecting the Power Cord ...............................8
Connecting to the PCR-WEA .............................9
Selecting Cables..................................................... 9
Connecting the Output Cable (between PCR-WEA
and OT03-PCR-WEA) .......................................... 10
Connecting the DIGITAL I/O Connectors ............. 12
Turning the Power On ......................................13
Releasing the Shutdown Function from Activating13
Turning the POWER Switch On ........................... 13
Turning the POWER Switch Off ........................... 14
Connecting to the EUT .....................................15
Using the Compensation (Voltage compensation)
Function............................................................17
Connecting the Sensing Cables ........................... 17
Using in Parallel Connection ............................22
Connecting to the PCR12000WEA2(R)................ 23
Operation
Starting a Test ..................................................28
Finishing a Test ................................................29
Maintenance
Cleaning the Dust Filter....................................30
Calibration ........................................................31
Replacing the Fuse ..........................................32
Specifications
Functions and Performance ................................. 33
Outline Drawing.................................................... 39
Appendix
Options.............................................................40
Rack Mount Brackets ........................................... 40
3 kVA Connection Cable Kit ................................. 42
3 kVA Mount Kit.................................................... 42
DIGITAL I/O Connector....................................43
DIGITAL I/O Connector Pin Arrangement ............ 43
Mapping Settings.................................................. 45
External Control.................................................... 47

6User’s Manual OT03-PCR-WEA
Component Names
Front panel
Number Name Description See
1POWER indicator Lights when the POWER switch is on. (green) -
2OUTPUT indicator Lights when the output of the connected PCR-WEA is turned on. (green) -
3HIGH RANGE indicator
Lights when the output voltage range of the connected PCR-WEA is in the H
range. (green)
-
4TRANSFORMER indicator Displays the connection mode.
When off: Bypass mode
(The voltage of the PCR-WEA is output as it is)
When lit green: Transformer connection mode
(The voltage of the PCR-WEA is stepped-up by the transformer of this
product and output)
-
5ALARM indicator Lights when an alarm occurs inside the product or through an external
connection. (red)
-
6Air inlet Air inlet for internal cooling -
7POWER switch Turns the power on and off. Flip the switch to the I side to turn the power
on. Flip it to the  side to turn the power off.
POWER indicator lights when the power is on.
p.13
8Casters 4 locations p.40
32:(5
27

3&5

:($
6kVA OUTPUT TRANSFORMER 67$786
32:(5 287387 $/$50
+,*+
5$1*(
75$16
)250(5
6
8
7
1 2345

OT03-PCR-WEA User’s Manual 7
Rear panel
Number Name Function See
1DIGITAL I/O
(PARALLEL OUT)
Digital control connector
Used when releasing the shutdown function or connecting in parallel.
p.13
p.22
2PCR-WEA IN
(PARALLEL IN)
Digital control connector
Connects to the PCR-WEA Series DIGITAL I/O.
p.12
3Air outlet Air outlet for internal cooling -
4SENSING terminal block
(OUTPUT)
Connects the sensing cables.
Connects to the EUT.
A cover is attached when the product is shipped from the factory.
p.17
5SENSING terminal block
(INPUT)
Connects the sensing cables.
Connects to the SENSING terminal block of the PCR-WEA Series.
A cover is attached when the product is shipped from the factory.
p.17
6The serial number — -
7OUTPUT terminal block Output terminal block
Connects to the EUT.
A cover is attached when the product is shipped from the factory.
p.15
8INPUT terminal block Input terminal block
Connects to the OUTPUT terminal block of the PCR-WEA Series.
A cover is attached when the product is shipped from the factory.
p.10
9AC INPUT This connector is used to connect the power cord. p.8
10 Fuse holder AC INPUT fuse holder p.32

8User’s Manual OT03-PCR-WEA
Preparation
Connecting the Power Cord
This product is designed as an equipment of IEC Overvoltage Category II (energy-consuming equipment
supplied from a fixed installation).
Nominal input rating
1With the POWER switch off, connect the power cord between the AC INPUT and the
power outlet.
WARNING
Risk of electric shock.
• This product is IEC Safety Class I equipment (equipment with a protective conduc-
tor terminal). Be sure to ground the product to prevent electric shock.
• The product is grounded through the power cord ground wire. Connect the protec-
tive conductor terminal to earth ground.
• Use the included power cord to connect to the AC power line. If the included power cord
cannot be used because the rated voltage or the plug shape is incompatible, have a quali-
fied engineer replace it with an appropriate power cord that is 3 m or less in length. If
obtaining a power cord is difficult, contact your Kikusui agent or distributor.
• The power cord with a plug can be used to disconnect the product from the AC power line
in an emergency. Connect the plug to an easily accessible power outlet so that the plug
can be removed from the outlet at any time. Be sure to provide adequate clearance around
the power outlet.
• Do not use the included power cord with other instruments.
• Voltage Any of the nominal supply voltages within the range from 100 Vac to 240 Vac
• Frequency 50 Hz / 60 Hz

OT03-PCR-WEA User’s Manual 9
Preparation
Connecting to the PCR-WEA
Selecting Cables
Select the cable to be used for the connection between the PCR-WEA and this product by considering the
following items.
Cable current capacity
Cables will not be damaged even if the EUT is short-circuited when you use the ones having a capacity
that meets or exceeds the rated output current of PCR-WEA. The cables to be used must have sufficient
current capacities for the rated output current of the PCR-WEA.
Allowable current of power cables
A cable’s temperature is determined by the resistive loss based on the current, the ambient temperature,
and the cable’s external thermal resistance. The following table shows the current capacity of heat-resis-
tant vinyl cables that have a maximum allowable temperature of 60 °C when one of the cables is
separated and stretched out horizontally in air in an ambient temperature of 30 °C. The current must be
reduced under certain conditions, such as when vinyl cables that have a low heat resistance are used,
when the ambient temperature is 30 °C or greater, or when cables are bundled together and little heat is
radiated.
For PCR6000WEA2(R) and PCR12000WEA2(R), use the connection cable included with
this product.
When connecting to this product with PCR3000WEA2, purchase the option for 3 kVA (3 kVA
connection cable kit) separately, or use the appropriate cable from “Selecting Cables” (p.9).
WARNING
Risk of fire. Use cables with sufficient current capacities for the rated output current of the
PCR-WEA.
Risk of electric shock. Use cables with a rated voltage that meets or exceeds the isolation
voltage of the PCR-WEA.
CAUTION
Use cables having a diameter that can be used for the terminal blocks and being insulated
with flame-resistant, tough material.
Nominal cross-sec-
tional area [mm2]
AWG (Reference cross-sec-
tional area) [mm2]
Allowable current1
[A] (Ta = 30 °C)
1. Excerpt from Japanese laws related to electrical equipment.
Kikusui-recom-
mended current [A]
2 14 (2.08) 27 10
3.5 12 (3.31) 37 -
5.5 10 (5.26) 49 20
8 8 (8.37) 61 30
14 6 (13.3) 88 50
22 4 (21.15) 115 80

10 User’s Manual OT03-PCR-WEA
Preparation | Connecting to the PCR-WEA
Connecting the Output Cable (between PCR-WEA and
OT03-PCR-WEA)
Connection on the PCR-WEA side
See “Connecting the Load” in the PCR-WEA Series User’s Manual to connect the cable to the OUTPUT
terminal.
Connection on the OT03-PCR-WEA side
1Turn off all devices that you will connect.
2Unfasten the two M3 screws from the INPUT terminal cover, and remove the cover.
When connecting the PCR3000WEA2 and this product with the output cable, remove the
short bar attached to the OUTPUT terminal block of the PCR3000WEA2 before connecting.
WARNING
Risk of electric shock. Be sure to attach the terminal cover.
If you use cables with unnecessarily high current capacity, it may become impossible
to attach the terminal cover.
M3

OT03-PCR-WEA User’s Manual 11
Preparation | Connecting to the PCR-WEA
3Securely connect the cable to the INPUT terminal block of this product.
Tightening torque: 2.0 N•m
Connecting to the PCR3000WEA2
Connecting to the PCR6000WEA2(R)
Connecting to the PCR12000WEA2(R)
Use two units of this product and connect them in parallel. For details, see Connecting Connecting to the
PCR12000WEA2(R)（p.23）.
4Fasten the INPUT terminal cover you removed in step 2 with the two screws.
PCR3000WEA2
OT03-PCR-WEA
OUTPUT
U
V
W
N
N1P
1P3W
3P
NVU
VUNW
LLL
INPUT
N WVU
M5
OT03-PCR-WEA
INPUT terminal block
U
V
W
N
M5
OT03-PCR-WEA
INPUT terminal block
PCR6000WEA2(R)
OUTPUT
N1P
1P3W
3P
NVU
VUN
N
N
N
N
N
NW
LLL
OT03-PCR-WEA
INPUT
NNNWVU

12 User’s Manual OT03-PCR-WEA
Preparation | Connecting to the PCR-WEA
Connecting the DIGITAL I/O Connectors
OT03-PCR-WEA is controlled by the PCR-WEA with DIGITAL I/O connection.
Connect the DIGITAL I/O connector on the PCR-WEA to the PCR-WEA IN connector on the OT03-PCR-
WEA using the connection cable (D-sub 25-pin, male-male, 1 m) included with this product.
For DIGITAL I/O settings, see DIGITAL I/O Connector（p.43）.
DIGITAL I /O
OUT
SLAVE No. SLAVE No.
IN
SLOT 1 SLOT 2
SLOT 3 USB
LAN
ANALOG IN
PARALLEL
NL
USBLAN
SLOT DIGITAL I
/
O
ANALOG IN
DIGITAL I /O (PARALLEL OUT) PCR-WEA IN (PARALLEL IN)
DIGITAL I/O
connector pin
no.
DIGITAL I/O
connector pin no.
PCR1000WEA/ PCR2000WEA/ PCR3000WEA2
PCR6000WEA2/ PCR12000WEA2
OT03-PCR-WEA (PCR-WEA IN)
D-sub 25-pin (female)
D-sub 25-pin (female)
14
25
1
13
1425
113
DIGITAL I/O
connector pin no.
D-sub 25-pin (female)
1425
113

OT03-PCR-WEA User’s Manual 13
Preparation
Turning the Power On
When you turn on the POWER switch for the first time after purchase, do it without any EUT connected in
order to check the status of the product.
Releasing the Shutdown Function from Activating
Connect the external control (DIGITAL I/O) connector included with the PCR-WEA to the DIGITAL I/O of
this product to release the shutdown function.
If you turn on the POWER switch of PCR-WEA without connecting the connector, you will not be able to
turn the output on because the shutdown function will be activated.
For details, see “Preventing the Shutdown Function from Activating” in the PCR-WEA Series User’s
Manual.
Turning the POWER Switch On
1Check that nothing is connected to the OUTPUT terminal block of this product.
2Check that the power cord and PCR-WEA are connected correctly.
3Connect the external control (DIGITAL I/O) connector included with the PCR-WEA
to the DIGITAL I/O of this product.
4Turn on the POWER switch of PCR-WEA.
For details, see “Turning the Power Switch On” in the PCR-WEA Series User’s Manual.
5Turn on the POWER switch of this product.
The POWER indicator lights up in green.

14 User’s Manual OT03-PCR-WEA
Preparation | Turning the Power On
Turning the POWER Switch Off
1Turns off the PCR-WEA output.
2Turn the POWER switch off.
3Turn off the POWER switch of the PCR-WEA.
CAUTION
Do not turn off the power of this product with the PCR-WEA output.
Arc voltage generated in the built-in relay may shorten the life of the component or cause
welding of relays.

OT03-PCR-WEA User’s Manual 15
Preparation
Connecting to the EUT
It is recommended to check that normal voltage is output before connecting to the EUT.
Use appropriate cables from “Selecting Cables” (p.9) between this product and the EUT.
Use cables with a rated voltage of 600 V or higher.
1Turn off all devices that you will connect.
2Unfasten the two M3 screws from the OUTPUT terminal cover, and remove the
cover.
WARNING
Risk of electric shock. Be sure to attach the terminal cover. If you use cables with
unnecessarily high current capacity, it may become impossible to attach the terminal
cover.
M3

16 User’s Manual OT03-PCR-WEA
Preparation | Connecting to the EUT
3Securely connect the EUT cables to the OUTPUT terminal block.
If the EUT has a ground (GND) terminal, be sure to connect it to the (ground) terminal of the
product’s OUTPUT terminal block. Be sure to use a wire whose diameter is greater than or equal to
the diameter of the wires used to connect the EUT.
Tightening torque: 2.0 N•m
4Connect the cables to the EUT.
5Fasten the OUTPUT terminal cover you removed in step 2 with the two screws.
Three-phase outputSingle-phase three-wire outputSingle-phase output
U
V
W
N
U
V
N
Connect three L terminals and bundle them together.
L
N
EUT
LNG
OT03-PCR-WEA OT03-PCR-WEA OT03-PCR-WEA
EUT
L1L2GN
EUT
VUNWG
OUTPUT
NNNLLL
OUTPUT
N VU
OUTPUT
N WVU
M5M5 M5
OT03-PCR-WEA
OUTPUT terminal block
OT03-PCR-WEA
OUTPUT terminal block
OT03-PCR-WEA
OUTPUT terminal block

OT03-PCR-WEA User’s Manual 17
Preparation
Using the Compensation (Voltage compensation) Function
The output voltage from OT03-PCR-WEA is subject to voltage drop and voltage attenuation due to load
conditions, output frequency, etc. The output voltage can be corrected using the “Voltage correction func-
tion” of the dedicated application software SD012-PCR-WE. In addition to the “voltage correction function”
of the application software, the PCR-WEA compensation function (hard sensing) can also be used.
Connecting the Sensing Cables
Between PCR-WEA and OT03-PCR-WEA
Connect between the sensing terminals of OT03-PCR-WEA and PCR-WEA using the sensing cables included
with this product.
1Turn off all devices that you will connect.
2Connect the sensing cable to the PCR-WEA side.
For details, see “Wiring the Hard Sensing and Soft Sensing” in the PCR-WEA Series User’s
Manual.
3Connect the sensing cable to the SENSING (INPUT) terminal of this product.
WARNING
Risk of electric shock.
• Turn off all the POWER switches to be connected and disconnect the power supply
from the switchboard.
• Be sure to attach the terminal cover.
Soft sensing is not available for SD012-PCR-WE. Use hard sensing.
SENSINGterminalblock
(exampleofsingle-phaseconnectionwithPCR3000WEA2)
PCR-WEA
OT03-PCR-WEA
SENSINGterminalblock(INPUT)
Forsensingcables,
usetheshortestcables,
andtwistorrunthem
alongsideeachother
10mm
Theshapesoftheterminalblocksvary
dependingonthemodel.
Whilepressingherewithascrewdriver,
insertthewire.
Correct Incorrect Incorrect
Thestrippedwireis
touchingthechassis.
Thewirestrands
aretouchingthe
chassis.
SENSING
VUNW
LN
1P3W
( )
3P
( )
1P
( )
VUN
VUNW
SENSING (INPUT)
The sensing cable can be connected without removing the sensing cover on the OT03-PCR-
WEA side.

18 User’s Manual OT03-PCR-WEA
Preparation | Using the Compensation (Voltage compensation) Function
4Use the included cable tie to gently tie the cables as shown below.
The cable tie can be reused. Do not cut the extraneous portion of the tie.
5Attach the tip of the cable tie to the product as shown below.
6Firmly tighten the cable tie so that the sensing cables do not come loose.
Youcanpullouttheband
byholdingherewitha
pairoftweezers.
Sensingcable

OT03-PCR-WEA User’s Manual 19
Preparation | Using the Compensation (Voltage compensation) Function
Between OT03-PCR-WEA and EUT
Hard sensing can compensate up to approximately 1.5 V for a single line. Select a load cable that has suf-
ficient current capacity to prevent the voltage drop in the cable from exceeding the compensation voltage.
Use AWG22 to AWG16 cables when connecting to the sensing terminals. Use cables with a rated voltage
of 600 V or higher. Strip approximately 10 mm of coating from the end of the cables.
1Turn off all devices that you will connect.
2Refer to the figure below, and connect the sensing cable from the SENSING (OUT-
PUT) terminal of this product.
3Use the included cable tie to gently tie the cables as shown below.
The cable tie can be reused. Do not cut the extraneous portion of the tie.
EUT
OT03-PCR-WEA OT03-PCR-WEA
Single-phase output Single-phase three-wire output
OUTPUT
N N N L L L
SENSING
OUTPUT
N L
LNG
EUT
L1L2GN
OUTPUT
N V U
SENSING
OUTPUT
N V U
OT03-PCR-WEA
Three-phase output
EUT
VUNWG
OUTPUT
N W V U
SENSING
OUTPUT
N W V U
Youcanpullouttheband
byholdingherewitha
pairoftweezers.
Sensingcable

20 User’s Manual OT03-PCR-WEA
Preparation | Using the Compensation (Voltage compensation) Function
4Attach the tip of the cable tie to the product as shown below.
5Firmly tighten the cable tie so that the sensing cables do not come loose.