KUST Elektronik PT5020 User manual

PT5020 & PT5030 Operation Manual
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Operation Manual
KUST Elektronik GmbH
PT5020 & PT5030
Impulse Winding Tester
KUST Elektronik GmbH
Friedenstraße 26
D-35578 Wetzlar
Germany
E: [e-mail]
P: [phone]

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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!

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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!

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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!

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

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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
contact us immediately.
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

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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.

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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

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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
>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

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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.