Hioki TS2400 Instruction Manual

TS2400
HIOKI SF2400A961-01
Instruction Manual
WPT TEST SYSTEM
Be sure to read this manual before using the instrument.
When using the instrument for the
rst time
Parts Names and Functions
Preparations
Nov. 2020 Revised edition 1 SF2400A961-01 20-11H
Troubleshooting
p.17 Maintenance and Service
p.35
Error display
p.95
p.107
EN
HIOKI SF2400A961-01

Contents

HIOKI SF2400A961-01
Measurement Workow Introduction Term Description Product Conguration
Safety Notes
Usage Notes
Installing the Instrument
........................................................2
...............................................2
Options
Installing the Z5016 WPT Testing Platform Installing the Z5025 WPT Vehicle Assembly Mount
.......................................................3
......................................................4
......................................................5
...................................1
......................................3
...................................8
...8
....................................... 11
1 Overview 15
1.1 Product Overview
1.2 Features
.................................................15
.................................15
2 Parts Names and
Functions
2.1 Model SF2400 WPT Testing
Software
License key
Main window
Numerical data window
Graph window
2.2 Model Z5017 PLC Rack
2.3 Model Z5016 WPT Testing Platform
2.4 Model Z5018 Switch Box
17
.................................................17
..............................................17
.............................................17
.............................18
..........................................21
......................27
..31
.....................34
3 Preparations 35
3.8 Determining the Home Position of the Stage Coordinates
3.9 Setting the Measuring Instrument
Setting the power meter (When
measuring a power efciency)
Setting the LCR meter (When
measuring a coupling coefcient) Setting the Memory HiLogger (When measuring voltage and temperature) Setting the Magnetic Field HiTester (When measuring a eld intensity) Setting the Electromagnetic Field HiTester
Setting the CAN
Setting the Thermography
3.10 External Output and Workpiece Load
Setting the External Instruments Setting the Work Load
3.11 Setting the Measured Value Warning
3.12 Setting Data Items to be Saved
3.13 Setting the Calculation Formula
3.14 Setting Labels
3.15 Setting Real Time Data Display
.......................................................68
Items
3.16 Measured Data Display Items
3.17 Positioning a Workpiece
3.18 Connecting the Measuring Instrument and a Workpiece
When measuring a coupling coefcient When measuring a power efciency and
other items
3.19 Determining the Z-Axis Limit Sensor Position
........................................59
.......................................67
...............................................73
.....................................74
.........................50
......52
...................52
..............54
.........56
.............57
.........................60
................61
...............................62
..........64
.........65
............69
......................70
...............71
......71
.58
61
63
1
2
3
4
5
6
Appx.
3.1 Connecting the Measuring
Instrument and the PC
3.2 Connecting the Z5018 to the
Z5017 and LCR Meter
3.3 Connecting an External Control Instrument and the External I/O Terminals of the Instrument
3.4 Setting Up the PC (As Needed)
Connection Setting the security Setting the network Changing the BIOS Installing the Model FT3470-51/-52 Magnetic Field HiTester driver
3.5 Performing Daily/Startup Checks
3.6 Turning On/Off the Instrument
Turning on the power Turning off the power
3.7 Setting Communication between
the Measuring Instrument and the
...........................................................48
PC
SF2400A961-01
...............................................38
.........................35
.........................36
.................37
.........38
...................................39
...................................40
...................................42
...................43
............46
................................46
................................47
.......45
4 Measurement 75
4.1 Manual measurement
4.2 Automatic measurement
Creating a sub-sequence
Adding movement steps at the same time
..........................75
.....................76
.........................78
.80
5 Specications 83
5.1 Model TS2400 WPT Test System
General Specications
5.2 Model SF2400 WPT Testing
Software
General Specications Function Specications Calculation Items Control and Data Collection Mode Function Screen display Processing During Data Collection Measured Value Warning Function
.................................................84
...................................................85
..........................................86
..............................83
..............................84
.............................84
......................................85
......83
............86
............86
i
HIOKI SF2400A961-01
5.3 Model Z5015 PC System
General Specications
5.4 Model Z5016 WPT Testing Platform
General Specications Mechanical Unit Specications
5.5 Model Z5017 PLC Rack
General Specications Operation/Display Unit Specications I/O Specications
......................................91
5.6 Model Z5018 Switch Box
General Specications Input/Output/Measurement Specications
....................87
..............................87
..88
..............................88
..................88
......................90
..............................90
........90
.....................93
..............................93
..93
6 Maintenance and Service 95
Calibration and repair Replacement parts and service life
6.1 Troubleshooting
6.2 Cleaning
...............................................104
6.3 Scheduled check (monthly)
Lubrication
..............................................105
6.4 Error display
Window display when an error occurs Replacing batteries for PLC and servo pack
.......................................................108
6.5 Disposing of the Instrument
................................95
............95
....................................96
...............104
........................................107
......107
..............109
Appendix Appx.1
Appx. 1 Work Table Installation
Dimensions
............................. Appx.1
ii
Measurement Workow
HIOKI SF2400A961-01
Performing Startup Checks (p. 45)
Check that there is nothing wrong with model TS2400 WPT Test System and the optional units or accessories.
Turning On the Instrument (p. 46)
Turn on the power of the measuring instrument to be used and start up the WPT Test System.
Making Various Settings
Setting Communication between the Measuring Instrument and the PC
Determining the Home Position of the Stage Coordinates
Setting the Measuring Instrument
Setting the Measured Value Warning
Setting Data Items to be Saved (in the PC)
Setting the Calculation Formula (As necessary)
Setting Labels (As necessary)
Setting the Real Time Data Display Items
Positioning a Workpiece (p. 70)
Move the work table so that a workpiece can be easily set and secured.
Connecting the Measuring Instrument and Workpiece
When measuring a coupling coefcient
(Connect the LCR meter with a workpiece.)
When measuring a power efciency and other items
(Connect the power analyzer, etc. with a workpiece.)
p. 71
p. 73
p. 48
p. 50
p. 52
p. 63
p. 64
p. 65
p. 67
p. 68
Determining the Z-Axis Limit Sensor Position (p. 74)
Adjust the position of the Z-axis limit sensor according to the thickness of the workpiece to be measured.
Performing Measurements
Manual measurement (Measure one place at a time.)
Automatic measurement (Measure according to the preset settings and order.)
p. 75
p. 76
1

Introduction

HIOKI SF2400A961-01
Introduction
Thank you for purchasing the Hioki TS2400 WPT Test System. To obtain maximum performance from the instrument over the long term, please read this manual carefully, and keep it handy for future reference.
For the safety, inspection, precautions, handling, and disposal of the optional instruments and the
Z5015 PC System, please refer to the Instruction Manuals provided with the instruments and PC.
Trademark
• Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and other countries.
• SERVOPACK is the trademarks of YASKAWA Electric Corporation in the US and Japan.
Precautions during shipment
Handle it carefully so that it is not damaged due to a vibration or shock.
Target audience
This manual has been written for use by individuals who use the product in question or who teach others to do so. It is assumed that the reader possesses basic electrical knowledge (equivalent to that of someone who graduated from the electrical program at a technical high school).

Term Description

Term Explanation
WPT Wireless power transmission
Workpiece Indicates an evaluation target, such as a WPT coil, electrode, etc.
2
Product Conguration
HIOKI SF2400A961-01
The conguration of the TS2400 WPT Test System (the instrument) is as follows.
Product name Description Accessories
Product Conguration
SF2400 WPT Testing
Software
Z5015 PC System PC • AC adapter for PC
Z5016 WPT Testing
Platform
Z5017 PLC Rack • Stage control instrument
Z5018 Switch Box Change of transmission and
Measurement/control software The latest version can be downloaded from our website.
Workpiece positioning stage • Grease gun
• Above instrument and measuring instrument storage rack
reception coils connection method Primary side change Secondary side short circuit/open
• Instruction manual (this manual)
• License key (USB)
• Sample measurement data
• Display ×2
• Keyboard
• Mouse
• Instruction Manual
Recovery media (USB ash drive)
• Grease

Options

The options listed below are available for the instrument. To order an option, please contact your authorized Hioki distributor or reseller. Options are subject to change. Please check Hioki’s website for the latest information.
Product name Description Measurement/calculation item
PW6001
IM3570 Impedance Analyzer Measurement and
IM3536 LCR Meter
8423 Memory HiLogger Measurement and
FT3470-51, -52*Magnetic Field HiTester Measurement and
Z5025
EHP-200A Electric and Magnetic
USB-8502 CAN Interface Device Measurement and
FLIR E53 Optic - Advanced
*
Power Analyzer Measurement and
calculation
calculation
calculation
calculation
WPT Vehicle Assembly Mount
Field Probe - Analyzer
Thermal Camera
Secondary-side coil positioning turret
Measurement and calculation
calculation
Measurement and calculation
Current, voltage, active power, frequency, voltage/current/ power phase, power factor, and
efciency
Inductance, capacity, and DC resistance
Voltage and temperature
Field intensity
-
Electric eld intensity,
Field intensity
CAN communication
Temperature
*: Two instruments can be controlled.
3

Safety Notes

HIOKI SF2400A961-01
Safety Notes
Using the instrument in a way not described in the Instruction Manual may negate the provided safety features. Before using the instrument, be certain to carefully read the following safety notes:
DANGER
Mishandling during use could result in injury or death, as well as damage to the instrument. Be certain that you understand the instructions and precautions in
the manual before use.
WARNING
With regard to the electricity supply, there are risks of electric shock, heat generation, re, and arc ash due to short circuits. Individuals using an electrical measuring instrument for the rst time should be supervised by a technician who
has experience in electrical measurement.
Intended users of the manual
Personnel who perform procedures described in this manual should be familiar with the instrument and the way in which the instrument is operated.
Notation
In this document, the risk seriousness and the hazard levels are classied as follows.
DANGER
WARNING
CAUTION
IMPORTANT
Boldface
Indicates an imminently hazardous situation that will result in death or serious injury to the operator.
Indicates a potentially hazardous situation that may result in death or serious injury to the operator.
Indicates a potentially hazardous situation that may result in minor or moderate injury to the operator or damage to the instrument or malfunction.
Indicates information related to the operation of the instrument or maintenance tasks with which the operators must be fully familiar.
Indicates prohibited actions.
Indicates the action which must be performed.
Indicates the names and keys on the windows in boldface. The operation display unit and pendant unit display are indicated with [ ].
Symbols afxed to the instrument
4
* Additional information is presented below.
Indicates cautions and hazards. When the symbol is printed on the instrument, refer to a corresponding topic in the Instruction Manual.
Indicates a protective conductor terminal.
Indicates that dangerous voltage may be present at this terminal.

Usage Notes

HIOKI SF2400A961-01
Follow these precautions to ensure safe operation and to obtain the full benets of the various functions. Ensure that your use of the instrument falls within the specications not only of the
instrument itself, but also of any accessories, options and other equipment being used.
Before using the instrument for the rst time
Upon delivery, check that the main unit and all necessary accessories are included in the package. Furthermore, check that the main unit, accessories, panel switches, and terminals are all functioning normally and that none is faulty or damaged.
WARNING
If any item is faulty or damaged, do not use the instrument in its present state. Contact your authorized Hioki distributor or reseller.
Inspection
Before using the instrument each time, verify that it operates normally to ensure that there is no damage.
If you nd any damage, contact your authorized Hioki distributor or reseller.
Usage Notes
Tape switches are installed around the moving parts of the model Z5016 WPT Testing Platform so that any unsafe contact is detected and the testing platform
is stopped. In addition, EMERGENCY STOP buttons are installed on the front side and the pendant unit of the model Z5017 PLC Rack. Prior to using this instrument, check the following. If the operation of the instrument is different from the description below, turn off the main breaker on the front side of the Z5017 PLC Rack and contact your authorized Hioki distributor or reseller.
1. The [EMERGENCY STOP] indicator lights up when something comes in
contact with the tape switches and the EMERGENCY STOP button is
pressed.
2. When the [READY] button is pressed when the [EMERGENCY STOP] indicator
lit, the instrument does not start up.
• Always turn off the main breaker before lubricating the axis guide and ball screw units.
Operating environment
Installing the instrument in inappropriate locations may cause a malfunction of
instrument or may give rise to an accident. Avoid the following locations:
• Exposed to direct sunlight or high temperature
• Exposed to corrosive or combustible gases
• Susceptible to vibration
Exposed to water, oil, chemicals, or solvents
• Exposed to high humidity or condensation
• Exposed to high quantities of dust particles
WARNING
WARNING
5
Usage Notes
HIOKI SF2400A961-01
Wire material
WARNING
To avoid electric shock, use the recommended wire type to connect to the current input terminals, or otherwise ensure that the wire used has sufcient current
handling capacity and insulation.
Connection of the power input terminals and external I/O terminals
WARNING
Connect wires to the power input terminals and external I/O terminals
securely. If a terminal is loose, the contact resistance will increase, resulting in overheating, equipment burnout, re, or malfunction.
• To avoid electric shock or damage to the instrument, always observe the
following precautions when connecting to the power input terminals or external
I/O terminals.
Always turn off the power to the instrument and to any devices to be connected before making connections.
Be careful to avoid exceeding the ratings of the power input terminals and external I/O terminals.
During operation, a wire becoming dislocated and contacting another
conductive object can be serious hazard. Use screws to secure for the connection to the power input terminals and external I/O terminals.
Ensure that instruments and systems to be connected to the power input terminals and external I/O terminals are properly isolated.
6
Connection of the USB terminal
HIOKI SF2400A961-01
CAUTION
• To avoid equipment failure, do not disconnect the USB cable while communications
are in progress.
• Use a common ground for both the instrument and the computer. Using different
ground circuits will result in a potential difference between the instrumentʼs ground and the computerʼs ground. If the USB cable is connected while such a potential
difference exists, it may result in equipment malfunction or failure.
Earth bar (protective conductor terminal)
WARNING
Observe the following to avoid electric shock.
Connect the protective conductor terminal to earth (earth ground) before
making any other connections.
Be sure to connect the protective conductor to earth (earth ground).
Usage Notes
Handling the Z5018 Switch Box
To avoid damaging the measurement terminal of the LCR meter, be sure to release the locking mechanism, and grip the head of the BNC connector (not the cord) of Model
Z5018, and pull it out.
Turning on the power
Before turning the instrument on, make sure the supply voltage matches that indicated on its power connector. Connection to an improper supply voltage may damage the instrument and present an electrical hazard.
CAUTION
WARNING
7

Installing the Instrument

HIOKI SF2400A961-01
Installing the Instrument

Installing the Z5016 WPT Testing Platform

Surroundings of the Z5017 PLC Rack
WARNING
There are vent holes on the model Z5017 PLC Rack to release heat. Do not
block the vent holes by placing objects around them. Doing so may cause a
malfunction of the instrument or re.
600
Rear
Main breaker
Installing the instrument
• Secure the adjusters in place to prevent from falling and shifting out of position.
Improper installation may result in signicant vibration, which can cause damage to the instrument and peripheral equipment.
When a lift or jack is used, be sure to jack up the main unit at the specied fork positions. Otherwise, the exterior panels may be deformed.
Z5017 top
Front
1200
CAUTION
Unit: mm
8
When moving the instrument, remove any workpieces from the instrument and position the stage at the following position. X-axis and Y-axis: Stroke center, Z-axis: Lowest point
Required items:
Wrench (for adjusting the leveling jacks) with width across at of 24 mm Level (sensitivity of 0.05 or higher)
Lock nut
HIOKI SF2400A961-01
Adjuster nut
Adjuster
Installing the Instrument
C
D
B
Move the instrument to the desired
1
installation location.
Place a level at the center of the work
3
table (shaded area in the gure).
Adjust so that the level readings are
5
within 5 seconds of level.
2
4
6
A
Loosen the lock nuts using a 24 mm wrench.
Turn the adjuster nuts of adjusters A, C, and D and set the adjusters on the oor. Turn the adjuster nuts twice (720°) in the direction in which the adjusters
stick out.
Level along the X-axis with adjusters C and D and along the Y-axis with adjusters A and D.
Tighten the lock nuts and lock the adjusters.
9
Installing the Instrument
HIOKI SF2400A961-01
Check that the reading of the level is
7
within 5 seconds.
Secure jack bolt F in the same manner
9
(on the opposite side as well).
8
10
With jack bolt E against the base plate, turn it 90° in the direction in which it
approaches the base plate and then tighten the nut to secure the jack bolt. (Secure jack bolt E on the opposite side
as well.)
Secure jack bolt G in the same manner
(on the opposite side as well).
G
Jack bolt
G
F
E
F
Nut
10
Base plate
Installing the Instrument
HIOKI SF2400A961-01

Installing the Z5025 WPT Vehicle Assembly Mount

Surroundings
The handles move the Z5025’s vehicle assembly mount plate up and down. Leave space between the Z5025 and any nearby objects that could impede its movement.
Z5016
Handle
1200
Front
Handle
1200
Rear
Z5025
Unit: mm
Installing the instrument
CAUTION
Be sure to secure the instrument so that it cannot move. Do not place it on an unstable or inclined surface. Doing so could allow it to fall off the surface or overturn, causing injury or damage.
Required items:
Wrench (for adjusting the leveling jacks) with width across at of 24 mm Hexagon wrench (for use with M8 low-head hexagon socket bolts) with width across at of 5 mm Hexagon wrench (for use with M8 hexagon socket bolts) with width across at of 6 mm
Install the Z5025 WPT Vehicle Assembly Mount after installing the Z5016 WPT Testing Platform.
Lower the Z5016’s Z-axis to the limit position.
11
Installing the Instrument
HIOKI SF2400A961-01
Remove frame 1 (×2), frame 2 (×2), and the
1
connecting plates (×12). * After installation, do not use
frame 1 (×2) or the connecting plates (×4).
Z5025 WPT Vehicle Assembly Mount
Connecting plate (Do not use after installation.)
2
Move the Z5025 to the bracket’s
position.
Bracket
Z5016 WPT Testing Platform
Frame 1
Frame 2
12
Installing the Instrument
HIOKI SF2400A961-01
Loosen the four leveling jack lock nuts
3
and rotate the leveling jacks uniformly.
Adjust to match the height of the Z5016 frame.
Tighten the lock nuts on the leveling jacks.
5
Lock nut
4
Frame of the Z5016 WPT Testing Platform
connecting plates (×8) at their original positions to connect the Z5025 to the Z5016.
Connect the Z5016 and the Z5025 with the brackets (×4).
Use the low-head hexagon socket bolts (×8) at the locations shown below.
Reattach frame 2 (×2) and the
Lock nut
Leveling jacks
Connecting plate
Frame 2
Bracket
Low-head hexagon socket bolts
13
Installing the Instrument
HIOKI SF2400A961-01
14
1
HIOKI SF2400A961-01

Overview

1.1 Product Overview

Model TS2400 WPT Test System is an automatic measurement system for reproducible data required for wireless power transmission (WPT) evaluation. One software program can control the setting of various measuring instruments, positioning of power transmission and reception workpieces, and data collection.
Multiple points can be measured in a short
period of time.
Various graph display and calculation
functions
Combining the above features, WPT devices can be analyzed in detail and the evaluation man-hours can be
reduced signicantly.

1.2 Features

1
Automatic positioning of power transmission and reception workpieces
The workpiece position can be automatically set using the 3-axis (X, Y, and Z) control on the model Z5016 WPT Testing Platform. It improves the repeatability of evaluation and can reduce man-hours.
Automatic measurement data collection
The measurement data of the connected measuring instrument can be automatically collected
using the timing or period specied by the model SF2400 WPT Testing Software. (Other settings required for measurement can also be set in the SF2400.)
Relative graph display of measurement data
The collected measurement data and workpiece position correlation can be displayed in a graphical format. The parameters to be displayed can be arbitrarily set.
User-dened calculation function
In addition to the standard calculation items, any calculation can be dened as required. The dened parameters can be handled in the same way as for other parameters in the model SF2400 WPT Testing Software.
Compatible with various measuring instruments (Hioki) as the standard specication
The following Hioki measuring instruments that are required for WPT evaluation are supported as
the standard specication.
• PW6001 Power Analyzer
• IM3570 Impedance Analyzer
• IM3536 LCR Meter
FT3470-51, -52 Magnetic Field HiTester
• 8423 Memory HiLogger
15
Product Overview
HIOKI SF2400A961-01
16
2
HIOKI SF2400A961-01

Parts Names and Functions

2.1 Model SF2400 WPT Testing Software

License key

The license key is inserted into the USB port of the PC. Only when it is inserted, the stage and measuring instrument control is enabled.
Serial number
Serial number is tagged to the license key. The serial number consists of 9 digits.
The rst two (from the left) indicate the year of manufacture, and the
next two indicate the month of manufacture.

Main window

The window display is set. The measuring instrument and stage control are set.
2
Menu bar
Items selected here are displayed in the window.
Menu Explanation
Data File Save: Saves the measurement le.
Open: Opens the measurement le for the data to be checked. Sample measurement data of
the accessories can also be checked. (Sample.csv in the SF2400 folder in the C drive)
System
Version Displays the version of the application and PLC.
The application’s language can be set to Chinese, Japanese, or English.
17
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01

Numerical data window

Various numerical data can be checked.
Power Analyzer Real-Time Data
Values measured by a power meter can be checked in real time.
LCR Meter Real-Time Data
Values measured by an LCR meter can be checked in real time.
Memory HiLogger Real-Time Data
Values measured by a Memory HiLogger can be checked in real time.
18
Stage Position Real-Time Data
HIOKI SF2400A961-01
The present stage coordinates can be checked.
Model SF2400 WPT Testing Software
2
CAN Real-Time Data
CAN measured values can be checked as numerical values in real time.
19
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01
Real-Time Electric and Magnetic Field
Magnetic eld measured values can be checked as numerical values (and some graphs) in real
time.
Measured Data List
Measured data can be checked in a list.
User Dened Function Real-Time Data
Calculation results can be checked.
A calculation formula must be set in advance (p. 65).
20
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01

Graph window

Various numerical data can be checked in a graphical or Smith chart format.
Trend graph
The transition of each measuring instrument can be checked. Two types of trend graphs are shown below.
The type can be switched between stack plot and overlay plot.
Stack plot
A graph is displayed for each item.
2
Overlay plot
Items are displayed in one graph.
21
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01
RealTime Power Analyzer Harmonic Graphs
This graph is displayed only when a power meter is used.
One item can be selected from vector diagram, harmonic graph, and harmonic data.
Vector diagram
Vectors and measured values of voltage (U) and current (I) can be checked.
If the vector line is short and difcult to see, the magnication can be adjusted so that it is easier to see.
Harmonic voltage, voltage phase, current, and current phase selected in Order.
Harmonic graph
Bar graphs of voltage (U), current (I), and power (P) can be checked.
Select the channel (CH) to be displayed in the graph.
22
Right side: Select linear display (Linear) or logarithm display (Log) (voltage and current only). Left side: Select phase angle (Phase) or amplitude (Level).
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01
Harmonic data
Data 1 to 25 of voltage (U), current (I), and power (P) can be checked.
Enter the channel (CH) in which data is to be displayed.
Select phase angle (Phase) or amplitude (Level).
Select voltage (U), current (I), or power (P).
2
23
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01
Measured Data Graphs
Measured data can be checked in a graphical format.
2D: Plot graph of X-axis and Y-axis 3D: Plot graph of X-axis, Y-axis, and Z-axis 4D: Color plot graph of 3 stage axes and one measured value Smith: Locus of Smith data
2D graph
Go back to the old data.
Proceed to the latest data.
The stage axis and measurement item selected here are displayed.
24
3D graph
HIOKI SF2400A961-01
Model SF2400 WPT Testing Software
2
The stage axis and measurement item selected here are displayed.
4D graph
Select the stage axes.
When the checkbox is checked,
you can select the preset Z-axis value.
The selected measurement item is displayed.
The set value is divided equally and a color is assigned.
The 4D graph is not
automatically updated. Press this button to update the graph.
25
Model SF2400 WPT Testing Software
HIOKI SF2400A961-01
Real time Smith chart
The real axis impedance and imaginary axis impedance on the power transmission side and power
receiving side are normalized and can be checked (only when a power meter is used).
Real-Time Thermometer Data
The heat distribution can be displayed as a graph.
26
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