Kikusui PFX2000 Series User manual

OPERATION MANUAL
Charge/Discharge Battery Test System
PFX2000 Series
Part No. Z1-002-582, IB003122
Aug. 2004
PFX2011
PFX2021
PFX2121
PFX2331
PFX2332
5V-5A 2-ch Charge/Discharge
Power Supply Unit
20V-10A Charge/Discharge
Power Supply Unit
120-ch
Control Unit
5-Unit
Frame
5-Unit
Large Capacity Frame

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 it
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© 2004 Kikusui Electronics Corporation
Printed in Japan.

PFX2000 I
P o wer Requirements of this Pr oduct
Po wer requirements of this product have been changed and the relevant sections of the Operation
Manual should be revised accordingly.
(Revision should be applied to items indicated by a check mark .)
Input v oltage
The input v oltage of this product is VAC ,
and the voltage range is to VAC. Use the product within this range only.
Input fuse
The rating of this product's input fuse is A, VAC, and .
• To avoid electrical shock, always disconnect the AC power cord or turn off
the switch on the switchboard before attempting to check or replace the
fuse.
• Use a fuse element having a shape, rating, and characteristics suitable
for this product. The use of a fuse with a different rating or one that short
circuits the fuse holder may result in fire, electric shock, or irreparable
damage.
A C power cord
The product is pro vided with AC power cords described below. If the cord has no power plug,
attach a power plug or crimp-style terminals to the cord in accordance with the wire colors
specified in the drawing.
• The attachment of a power plug or crimp-style terminals must be carried
out b y qualified personnel.
WARNING
WARNING
Blue (NEUTRAL )
Brown (LIVE)
Green/Yellow (GND)
White (NEUTRAL)
Black (LIVE)
Green or Green/Yellow (GND)
Kikusui distributor/agent can provide you with suitable AC power cord.
For further information, contact Kikusui distributor/agent.
Without a power plug Without a power plug
Plugs for Europe
Plugs for USA
Provided by Kikusui distributor/agent
✔

II PFX2000

PFX2000 Safety Symbols III
For the saf e use and saf e maintenance of this pr oduct, the f ollo wing sym -
bols 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).
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

IV Safety Precautions PFX2000
Saf ety Precautions
The f ollo wing saf ety precautions m ust be obser ved to a v oid fi re hazar d,
electrical shoc k, accidents, and other failures. K eep them in mind and
make sure that all of them are obser ved pr operl y .
User s
• This product m ust be used only b y qualifi ed personnel who understand the con -
tents of this oper ation 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 AC 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

PFX2000 Safety Precautions V
Installation
•When installing products be sure to observe “Installation” described in this man-
ual.
• To avoid electrical shock, connect the protective ground terminal to electrical
ground (safety ground).
•When connecting the AC 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 AC power cord. Be sure to unplug
the AC power cord or stop applying power before checking.
•If any abnormality or failure is detected in the products, stop using it immediately.
Unplug the AC power cord or disconnect the AC power cord from the switch-
board. 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 AC 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?

VI Arrangement of this manual PFX2000
Arrangement of this manual
This Operation Manual is made up of the following sections.
Preface
Provides a brief descriptions of the product and specifies its features.
Chapter 1 Setup
This chapter describes the steps taken before actually using the product such as
unpacking, installation, etc.
Chapter 2 Operating Procedure
This chapter describes the power-up procedure, the connection to the DUTs, and the
trip connector.
Chapter 3 Names and Functions of Parts
This chapter describes the names and functions of switches, displays, connectors,
and other parts of the panels.
Read this chapter to learn about the details of the (alert) marks indicated
on the panel.
Chapter 4 Maintenance
This chapter describes maintenance and calibration of the product.
Chapter 5 Specifications
This chapter describes the electrical and mechanical specifications of this product.
Appendix
Describes the method and the characteristics of voltage and current measurement on
the PFX2011/PFX2021.

PFX2000 Contents VII
Power Requirements of this Product ____________________________ I
Safety Symbols ____________________________________________ III
Safety Precautions _________________________________________ IV
Preface _________________________________________________ P-1
Chapter 1 Setup__________________________________________ 1-1
1.1 Checking the Package Contents 1-2
1.2 Installation 1-4
1.2.1 Precautions Concerning Installation Location 1-4
1.2.2 Rack Mounting 1-5
1.3 Precautions When Moving the Product 1-7
1.4 Connecting the Power Cord 1-7
1.5 Grounding 1-10
1.6 Installing and Removing Charge/Discharge Power Supply Units 1-11
1.6.1 Combinations of Unit Frames and Charge/Discharge
Power Supply Units 1-11
1.6.2 Installation Procedure 1-12
1.6.3 Removal Procedure 1-14
1.7 Setting the Frame Address 1-16
1.8 Connecting the TP-BUS 1-19
1.8.1 Connecting TP-BUS Cables 1-19
1.8.2 Setting the TERMN Switch 1-23
1.9 Connecting the USB 1-24
1.9.1 Connecting the USB Cable 1-24
1.9.2 USB Driver 1-25
1.9.3 Instrument ID 1-25
2.1 Turning On the Power 2-2
2.2 Connecting the Output Cables 2-3
2.3 Using the Trip Connector 2-8
Chapter 3 Names and Functions of Parts ______________________ 3-1
3.1 Names and Functions of Parts 3-2
3.1.1 Unit Frame 3-2
3.1.2 Charge/Discharge Power Supply Unit 3-5
3.1.3 Control Unit 3-7
Chapter 4 Maintenance ____________________________________ 4-1
4.1 Cleaning 4-2
4.1.1 Cleaning the Panels 4-2
4.1.2 Cleaning the Dust Filter 4-2
4.2 Inspection 4-4
4.3 Calibration 4-4
4.4 Malfunctions and Causes 4-5
Chapter 5 Specifications ___________________________________ 5-1
Contents

VIII Contents PFX2000
5.1 Charge/Discharge Power Supply Unit Specifications 5-2
5.1.1 Functional Specifications 5-2
5.1.2 Electrical Specifications 5-7
5.1.3 General Specifications 5-14
5.2 Unit Frame Specifications 5-15
5.2.1 Functional Specifications 5-15
5.2.2 Electrical Specifications 5-15
5.2.3 General Specifications 5-17
5.2.4 Outline Drawing 5-18
5.3 Control Unit Specifications 5-19
5.3.1 Electrical Specifications 5-19
5.3.2 General Specifications 5-20
5.3.3 Outline Drawing 5-20
Appendix _______________________________________________ A-1
A.1 Measurement Function of the Charge/Discharge Power Supply Unit A-1
A.1.1 Overview A-1
A.1.2 Measurements during Normal Operation A-1
A.2 Power Regeneration Function A-10
A.3 Reference Data A-12
A.3.1 Pulse Current Waveform A-12
Index ___________________________________________________ I- 1

PFX2000 Preface P-1
Preface
About This Manual
This operation manual covers information about the hardware of the following mod-
els in the PFX2000 Series Charge/Discharge Battery Test System.
• PFX2011 5-V/5-A 2-ch Charge/Discharge Power Supply Unit
• PFX2021 20-V/10-A Charge/Discharge Power Supply Unit
• PFX2121 120-ch Control Unit
• PFX2331 5-Unit Frame
• PFX2332 5-Unit Large Capacity Frame
The PFX2000 Series Charge/Discharge Battery Test System is controlled using
BPChecker2000, an application software. For a description of the operation of the
system, see the BPChecker2000 User’s Manual.
Product Overview
This battery charge/discharge test system is capable of meeting various needs of the
user by allowing the user to select the required units from different types of units
grouped by functionality and combine the required number of those units.
The basic system consists of charge/discharge power supply units installed in unit
frames, a control unit, a PC, and an application software.
Consideration has been given to the expandability of the charge/discharge power
supply unit, the unit frame, and the control unit. Additionally, a functional expan-
sion unit that enables impedance measurement is provided.
Each unit excluding the control unit is designed on the assumption that it be
installed in a rack. This allows support for large-scale systems.
The USB is used to connect between the PC and the control unit. The TP-BUS is
used to connect between each unit. All units can be controlled from
BPChecker2000.
•The PC that is used in this system must be running Windows 2000 Professional
(Intel) (SP2 or later) or Windows XP Professional (Intel). For details on the mini-
mum PC requirements, see the BPChecker2000 User's Manual.
NOTE

P-2 Preface PFX2000
Features
Charge/discharge power supply unit
•Pulse charge function
Provides pulse charge mode that allows sophisticated charger simulation and
research and development of various charge methods.
•Temperature measurement function
Equipped with a simplified temperature measurement function using a ther-
mistor as a temperature sensing element. This enables temperature measurement
on each channel. In addition, you can set OTP (overtemperature protection) as a
protection function as well as specify dT/dt (temperature increase per unit time)
and MaxTemp (maximum temperature) as charge cutoff conditions.
•Charge/discharge power supply units replaceable without shutting
down the power to the frame
When in STANDBY status, you can switch charge/discharge power supply units
without having to shut down the power to the unit frame.
•Battery voltage detection terminals of high input resistance
The battery voltage detection terminals have high input resistance achieving
extremely small leakage currents. This prevents batteries from being discharged
during rest.
•Reliability for long continuous operation
MOSFET is used for switching between charge, discharge, and rest securing
reliability for long continuous operations.
•Versatile charge/discharge cut off conditions
Allows you to specify voltage, time, temperature, and other parameters for the
charge cutoff and/or discharge cutoff conditions.
•Improved system reliability
Provides a variety of protection functions, including OVP (overvoltage (over-
charge) protection), UVP (undervoltage (overdischarge) protection), and OHP
(overheat protection), and a watchdog timer (for system monitoring) to improve
system reliability. Especially for OVP and UVP, double protection through soft-
ware protection and hardware protection is provided.
•High precision measurements
Adopts the 24-bit A/D converter for measuring voltage and current enabling
high-precision measurements. In addition, the built-in reference voltage circuit
with temperature control secures high stability.
In pulse charge/discharge, generation of complicated current waveforms, volt-
age measurement at arbitrary points, and measurement of pulse current are pos-
sible by exploiting the use of the 16-bit D/A converter and high-speed A/D
converter.
•Two independent channels on a single unit (PFX2011 only)
The two channels are completely independent. You can set different test condi-
tions to each channel.
•Power regeneration function (PFX2021 only)
Equipped with a regeneration function that uses the power obtained from an
internal loss for operation, if the internal loss reaches a certain level during the
discharge test. Contributes to the downsizing of the system, saving of power,
and reduction of waste heat.
•Faithfully measures the average pulse current (PFX2021 only)
Equipped a V/F converter dedicated to measuring average current. The transient

PFX2000 Preface P-3
state of pulse current can be faithfully measured. The current measurement error
caused by the imbalance of rising and falling edges is suppressed to its mini-
mum.
•20-value CP pulse discharge function (PFX2021 only)
Equipped with a 20-value CP pulse discharge function through high-speed com-
putation (software) control.
•20-value CC pulse discharge function (PFX2021 only)
Pulse settings can be assigned up to 20 different values, which enables the sup-
port for discharge simulations of packed batteries.
Unit frame
•TP-BUS connection
Uses the TP-BUS for connecting between unit frames for easy connection.
When removing a frame from the TP-BUS, you do not have to shut down other
frames.
•Large capacity support (PFX2332 only)
Equipped with a large capacity AC line filter and a power bus for sharing the
regenerated power between charge/discharge power supply units.
Control unit
•Multichannel support
A single control unit supports up to 120 channels (when using the PFX2011
Charge/Discharge Power Supply Unit).
•USB connection
The USB is used to connect with the PC. Thus, other interface boards are not
needed if your PC has USB ports.
Up to two units can be connected to a single PC.
System Configuration
Fig. P-1 and Fig. P-2 show system configuration examples.

P-4 Preface PFX2000
Fig. P-1 120-channel system configuration example
In the example of Fig. P-1, a 120-channel system is configured using one control
unit, 12 PFX2331 unit frames, and 60 PFX2011 charge/discharge power supply
units. In addition, one PFX2211 Impedance Measurement Unit is included enabling
impedance measurements of all batteries connected to the 120 channels. Moreover,
Fig. P-1 shows that synchronized testing with a temperature chamber is possible by
adding a GPIB interface board.
Since up to two control units can be connected to a single PC, a system consisting of
up to 240 channels can be constructed.
TP-BUS 2 (60 channels)
PFX2121 120-ch Control Unit
PFX2211 Impedance
Measurement Unit
PFX2011 5-V/5-A 2-ch
Charge/Discharge Power
Supply Unit
PFX2331
5-Unit Frame
Application software
BPC2000
Protocol converter
EIA standard rack
Temperature chamber
GPIB
GPIB
PC
USB
TP-BUS 1
(60 channels + impedance measurement)

PFX2000 Preface P-5
Fig. P-2 60-channel system configuration example
In the example of Fig. P-2, a system similar to Fig. P-1 is configured using
PFX2332 unit frames and PFX2021 charge/discharge power supply units. However,
because two channels on the PFX2021 are equivalent to one channel on the
PFX2011, this is a 60-channel configuration.
TP-BUS 2 (30channels)
PFX2121 120-ch Control Unit
PFX2211 Impedance
Measurement Unit
PFX2021 20-V/10-A
Charge/Discharge Power
Supply Unit
PFX2332 5-Unit
Large Capacity Frame
Application software
BPC2000
Protocol converter
EIA standard rack
Temperature chamber
GPIB
PC
USB
TP-BUS 1
(30 channels + impedance measurement)
GPIB

P-6 Preface PFX2000

PFX2000 Setup 1-1
Chapter 1 Setup
This chapter describes the steps taken before actually using the product such as
unpacking, installation, etc.

1-2 Setup PFX2000
1.1 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 your Kikusui agent or dis-
tributor.
•It is recommend that all packing materials be saved, in case the product needs to
be transported at a later date.
Table1-1 Control Unit Accessories
Table 1-2 Charge/Discharge Power Supply Unit Accessories
PFX2121 Product Quantity Figure Note
USB cable 2 m 1 piece 91-80-9300
PFX2000 Series
Battery Test System
Operation Manual
(This manual)
1 piece Z1-002-582
TP-BUS connector 2 pieces 84-61-5102
TP-BUS core 2 pieces 67-90-0080
PFX2011 PFX2021 Product Quantity Figure Note
Handling of the Prod-
uct 1 sheet Z9-000-053
NOTE

PFX2000 Setup 1-3
Table 1-3 Unit Frame Accessories
PFX2331 PFX2332 Product Quantity Figure Note
Rack mount oval head
screw M5x14 4 pieces M2-002-091
Rack mount cup
washer 4 pieces M5-003-031
Unit attachment screw
M3x8 10 pieces*1
*1. Includes spares.
M3-002-031
TP-BUS connector 1 piece 84-61-5102
TP-BUS core 1 piece 67-90-0080
Output connector*2
*2. PFX2332 comes with a large current connector. The connector is marked “HC” for distinction.
10 pieces
84-61-5107
84-61-5207
(HC)
Screwdriver 1 piece Y2-000-002
Thermistor 10 pieces 38-00-0160
Power cord 2.5 m*3
*3. The PFX2332 power cord is attached to the unit.
1 piece 85-AA-0005
Handling of the Prod-
uct 1 sheet Z9-000-054

1-4 Setup PFX2000
1.2 Installation
This section describes precautions concerning installation location of the PFX2000
system and rack mounting of the unit frame.
1.2.1 Precautions Concerning Installation Location
This section describes the precautions to be taken when installing the product. Make
sure to observe them.
■Do not use the product in a flammable atmosphere.
To prevent the possibility of explosion or fire, do not use the product near alcohol or
thinner or in an atmosphere containing such vapors.
■Avoid locations where the product is exposed to high temper-
ature or direct sunlight.
Do not place the product near a heater or in areas subject to drastic temperature changes.
Operating temperature range: 0 °C to +40 °C
Storage temperature range: -10 °C to +60 °C
■Avoid locations of high humidity.
Do not place the product in high-humidity locations, i.e., near a boiler, humidifier,
water supply, etc.
Operating humidity range: 30 % to 80 % RH (no condensation)
Storage humidity range: 20 % to 80 % RH (no condensation)
Condensation may occur even in the operation humidity range. In such case, do not
use the product until the condensation dries up completely.
■Do not place the product in a corrosive atmosphere.
Do not install the product in a corrosive atmosphere or in environments containing sulfuric
acid mist, etc. This may cause corrosion of various conductors and bad contacts of connec-
tors inside the product leading to malfunction and failure, or in the worst case, a fire.
■Do not place the product in a dusty location.
Accumulation of dust can lead to electric shock or fire.
■Do not use the product where ventilation is poor.
The charge/discharge power supply unit is cooled by forced-air cooling. Secure ade-
quate space around the unit frame to prevent the intake and exhaust ports from
being obstructed. Obstruction of the ports can lead to fire or malfunction caused by
accumulation of heat.
■Do not place objects on top of the product.
Placing objects on top of the product can cause failures (especially heavy objects).