KUST Elektronik PT5040 User manual

PT5040 Operation Manual
Operation Manual
KUST Elektronik GmbH
PT5040
Impulse Winding Tester
KUST Elektronik GmbH
Am Weinberg 2
D-35619 Braunfels
Germany
[e-mail]
P: [phone]
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Me as ure ................................
PT5040 Operation Manual
Contents
C hapt er 1 O v er v i ew ................................................................................................ ........................ 1 - 1
P r o duct i on i nt r oduct i on ................................................................................................ .......... 1 - 2
Oper at i on e nv ir onment ................................................................................................ ........... 1 - 3
Pow er suppl y ................................................................................................ ................... 1 - 3
Env ir onment t em per ature and hum i di t y ................................................................ ......... 1 - 3
W arm - up ................................................................................................ ......................... 1 - 3
D i m ens i ons a nd wei ght ................................................................................................ ........... 1 - 3
C hapt er 2 G e ner al spe ci fi cat i ons ................................................................................................ .... 2 - 1
Speci fi cat i ons ................................................................................................ .......................... 2 - 1
Compar i son met hods ................................................................................................ .............. 2 - 2
A r ea s i ze c ompar i son ................................................................................................ ...... 2 - 2
D i f f er ent i al ar e a com par i son ........................................................................................... 2 - 2
C or ona di sc harge com par i son ................................................................ ......................... 2 - 3
D i f f er ent i al phas e com par i son ................................................................ ........................ 2 - 4
C hapt er 3 : Panel s and di spl ay ................................................................................................ ........ 3 - 1
F r ont panel .............................................................................................................................. 3 - 1
R ear pa nel ................................................................................................ ............................... 3 - 4
I nt r oduct i on t o di spl a y ar ea ................................................................................................ .... 3 - 5
C hapt er 4 I nt r oduct i on t o [ D I SP ] ................................................................................................ .... 4 - 1
Me as ur em ent di spl a y page ................................................................................................ ...... 4 - 1
I nt r oduct i on t o s y m bol s i n m eas ur em ent di spl a y page ........................................................... 4 - 1
I nt r oduct i on t o sof t ke y s i n m eas urem ent di spl a y page ................................ .......................... 4 - 1
S t andar d sa mpl i ng ................................................................................................ ........... 4 - 2
Compar e ................................................................................................ .......................... 4 - 3
........................................................................................... 4 - 4
U tili t y .............................................................................................................................. 4 - 5
S t at i st i cs ................................................................................................ .......................... 4 - 5
Modi f y ................................................................................................ ............................ 4 - 5
Chapt er 5 I nt r oduct i on t o [ S ET U P ] ................................................................................................ 5 - 1
I nt r oduct i on t o i cons of sof t key s ................................................................ ............................ 5 - 1
Me as ur em ent se t up page ................................................................................................ ......... 5 - 1
W i nding T y pe ( onl y f or Mul t i - channel i nst r um ent ) ................................ ........................ 5 - 2
W orki ng M ode ( onl y f or Mul t i - channel i nst r um ent ) ................................ ...................... 5 - 2
S t d Mode ( onl y f or Mul t i - ch annel i nst r um ent ) ................................ ............................... 5 - 3
Test Wi nding ( o nl y f or Mul t i - channel i nst r um ent ) ................................ ......................... 5 - 3
C ur r W i nding ( onl y f or Mul t i - channel i nst r um ent ) ................................ ........................ 5 - 3
I m p V ol t ................................................................................................ .......................... 5 - 4
Sam ple ................................................................................................ ............................ 5 - 4
T es t I m p ................................................................................................ .......................... 5 - 4
Eras e I mp ................................................................................................ ........................ 5 - 4
V ol t ADJ ................................................................................................ .......................... 5 - 4
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PT5040 Operation Manual
W av e D i sp ................................................................................................ ....................... 5 - 5
T ri g Mode ................................................................................................ ....................... 5 - 5
D el ay T i me ................................................................................................ ...................... 5 - 6
B DV T es t ................................................................................................ ........................ 5 - 6
S t ar t V ol t ................................................................................................ ......................... 5 - 6
End V ol t ................................................................................................ .......................... 5 - 6
V ol t S t ep ................................................................................................ .......................... 5 - 7
Compar ator ................................................................................................ ..................... 5 - 7
Posi ti on ( A R EA SI Z E, D I FF Z O N E, PHA S E D I FF ) ................................ ..................... 5 - 7
Posi ti on （ PHA SE D I F F ） ................................................................ ............................. 5 - 7
D I FF （ L i m i t ）（ A R EA SI Z E, D I FF Z ONE, PHA S E D I F F ） ................................ ....... 5 - 7
D I FF （ L i m i t ）（ COR ONA ） ................................................................ ........................ 5 - 8
I nt . F il e 5 - 8
Ext. F i l e 5 - 10
C hapt er 6 I nt r oduct i on t o [ S Y S TE M] ........................................................................................... 6 - 12
6 - 12
B ri ght nes s ................................................................................................ ..................... 6 - 13
P as s/ F ai l ................................................................................................ ........................ 6 - 13
P as s A l arm ................................................................................................ .................... 6 - 13
F ai l A l arm ................................................................................................ ..................... 6 - 13
Ke y Sound................................................................................................ ..................... 6 - 13
H ar d Copy ................................................................................................ ..................... 6 - 13
P assw ord ................................................................................................ ....................... 6 - 13
L anguage ................................................................................................ ....................... 6 - 14
Them e ........................................................................................................................... 6 - 14
D at e ................................................................................................ ............................... 6 - 14
T i me .............................................................................................................................. 6 - 14
I / O I nter f ace ................................................................................................ .......................... 6 - 14
I / O ................................................................................................................................ . 6 - 15
PT 50xx R S 232 C i nter f ace ................................................................ ......................... 6 - 15
U S B i nter f ace ................................................................................................ ................ 6 - 17
L AN i nter f ace ................................................................................................ ............... 6 - 20
6 - 22
C hapt er 7 U se r guide ................................................................................................ ...................... 7 - 1
U se of key s ................................................................................................ ............................. 7 - 1
Sw it ch t he di spl a y page ................................................................................................ .. 7 - 1
B as i c m eas ur em ent ................................................................................................ ................. 7 - 1
Non - st andar d t es t ................................................................................................ ............ 7 - 1
Sam ple t es t f or st andar d w ave ................................................................ ........................ 7 - 1
B DV t es t 7 - 2
T echn ol ogy appl i cat i on ................................................................................................ ........... 7 - 2
T es t obj ect s ................................................................................................ ..................... 7 - 2
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Sel ect st andards................................
PT5040 Operation Manual
Sel ect com par i son met hod .............................................................................................. 7 - 3
Set ti ngs of com par i s on meth od ................................................................ ....................... 7 - 3
................................................................ ............... 7 - 4
Char t f or di f f er ent i al ar ea ................................................................................................ 7 - 4
C hapt er 8 Com m and r efer ence ................................................................................................ ....... 8 - 1
Com m and s tr uct ure ................................................................................................ ................. 8 - 1
D ata f ormat ................................................................................................ ............................. 8 - 3
N otat i on conv ent i ons a nd de fi ni ti ons ................................................................ ..................... 8 - 3
Com m and r efer ence ................................................................................................ ................ 8 - 4
D I SP l ay subs y st em co mm ands ................................................................ ....................... 8 - 4
Me as ure F unct i on subs y st em com m ands ................................................................ ........ 8 - 7
C O MP arator su bsy s t em com m ands ................................................................ ................ 8 - 8
I m pul se VO L T age subs y st em co mm ands ................................................................ ..... 8 - 13
Sam ple RA T E subsy st em com m ands ................................................................ ............ 8 - 16
S t andar d W A V E subsy st em com m ands ................................................................ ......... 8 - 17
W av e A dj ust subs y st em com m ands ................................................................ .............. 8 - 19
ST A T i st i c s ubsy st em co mma nds ................................................................ ................... 8 - 20
MW I N di ng subs y st em com m ands ................................................................ ................ 8 - 21
TR I Gger su bsy st em co mma nds ................................................................ .................... 8 - 24
F ET C h ？ subs y st em com ma nds ................................................................ .................... 8 - 25
ME A Sure su bsy st em co mma nds ................................................................ .................. 8 - 27
AB O R t subs y st em com m and ................................................................ ........................ 8 - 28
Mass MEM or y subs y st em com m ands ................................................................ .......... 8 - 28
L ocal Cont r ol subs y st em com m ands ................................................................ ............ 8 - 29
Com m on com m ands ................................................................................................ ..... 8 - 29
Error and warni ng m essa ge ................................................................................................ ... 8 - 31
C hapt er 9 H a ndl er i nter f ace ................................................................................................ ............ 9 - 2
B as i c i nformat i on ................................................................................................ .................... 9 - 2
Ele ct ri cal charact er i st i cs ................................................................................................ ......... 9 - 3
DC i sol at ed output ................................................................................................ .......... 9 - 3
I sol at ed i nput................................................................................................ ................... 9 - 4
Jumper se t up on HAN D L ER i nter f ace ................................................................ ................... 9 - 5
C hapt er 10 P ac kage c ont ent s and war r ant y ................................................................ .................. 10 - 1
Pa ckage content s ................................................................................................ ................... 10 - 1
W ar r ant y 10 - 1
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PT5040 Operation Manual
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!
Operation
Do not put heavy objects on the tester.
There is acooling fan on the rear side of this instrument, so any block of the air inlet is
prohibited.
Rigid power input
The stability of high voltage depends on stable power input. Be sure to provide rated AC
power or corrected power.
Grounding
For the safety of personnel and instrument, ensure the grounding terminal, designed in
power cord, be grounded correctly.
Test cable
To avoid electrical shock hazard, do not touch test terminals and test samples. The reason
is that ahigh voltage test cable is connected to the rear panel of this instrument, thus when
testing, the cable and test samples connected will carry ahigh voltage.
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.
Carry or move
Before moving the instrument, unplug the AC power sockets and remove high voltage test
line or external control line.
Maintenance
In non-use state, the instrument should be covered with aplastic or cloth cover. To clean
the tester, wipe the dirty parts with asoft 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.
Location
Do not locate the instrument in the environment of high temperature, direct sunlight or
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Production introdu
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PT5040 Operation Manual
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.
ction
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 anew 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 aperfect 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 acoil at just aglance. 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 acorona or layer discharge.
Figure 1-1 Simplified diagram for principles of impulse winding test
In figure 1-2, the self-oscillation attenuation wave has aclose relation with the inductance Land
quality factor Q, while Land 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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PT5040 Operation Manual
Figure 1-2 Typical self-attenuation oscillation wave
Operation environment
Power supply
Voltage: 198V-242V AC, 99V-121V AC
Power frequency: 47.5Hz-63Hz
Consumption: ≤50VA
Environment temperature
Normal working temperature: 0 ℃ ~40 ℃ ,Humidity: ≤90%RH
Referential working temperature: 20 ℃ ±8 ℃ ,Humidity: ≤80%RH
Transferring environment temperature: 0 ℃ ~50 ℃ m, Humidity: ≤93%RH
Warm
The warm-up time should not be less than 15 minutes.
Dimensions and weight
Dimensions (W*H*D): 398mm×129mm×370mm
Weight: Approx. 6kg
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PT5040 Operation Manual Chapter 2General specifications
Chapter 2 General specifications
Specifications
Specifications PT5020 PT5030
Output for impulse voltage 100V~3000V 100V~5000V
10V steps 10V steps
5%±1 0V 5%±2 0V
Inductance test range >10μH >10μH
Impulse energy Max 250milli-Joules Max 250 milli-Joules
Contents in waveform 800×480 dot-matrix LCD
display area on LCD 256×6 50 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 6times/sec
Number of test impulse 1 to 32 averaging rate
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 ±1%
accuracy
Area difference ±1%
measurement accuracy
Comparison output OK/NG display
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Differential
PT5040 Operation Manual Chapter 2General specifications
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
Comparison methods
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 Aand
B. The percent deviation is the ratio of the area size difference to the area size of the standard
waveform between Aand B, expressed as apercentage.
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 ashort circuit between layers, the short circuit area is reflected as an
increase of energy loss.
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 Ato 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
Aand B, expressed as apercentage.
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PT5040 Operation Manual Chapter 2General specifications
Figure 2-2 Differential Area Comparison
The differential area size reflects the value of inductance and total energy loss. This method is
especially effective to detect the differences of inductance Lbetween the standard winding and
thetested winding.
Corona dischar comparison
When comparison method is set to Corona Discharge, PT50xx detects the high frequency energy
of corona discharge from Ato Bas shown in Figure 2-3. When the corona evaluation value is
less than the corona difference limit, then the comparison result will be PASS. When the corona
evaluation value is more than the corona difference limit, then the comparison result will be
FAIL. The corona evaluation value and difference limit are both expressed as an integer.
Figure 2-3 Corona Discharge Comparison
User can sample some coil samples (e.g. 10 samples) to set an effective corona discharge value.
First, applying an impulse voltage to each coil will gain the corona discharge value of each coil.
Then, anew effective value can be set by adding 20% to the maximum corona discharge value.
In order to ensure the correctness of the new value, user can test these coils once more and
observe the corona PASS or FAIL.
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