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Part No. Z1-002-972, IB004839

Aug. 2009

OPERATION MANUAL

WITHSTANDING VOLTAGE TESTER
TOS5000 Series

TOS5050A
TOS5051A

DANGER

This Tester generates high voltage.

• Any incorrect handling may cause death.
• Read “Handling Precautions” in this manual to

prevent accident.

• Keep this manual near the tester for easy access

of the operator.

Содержание TOS5050A

Страница 1: ...NDING VOLTAGE TESTER TOS5000 Series TOS5050A TOS5051A DANGER This Tester generates high voltage Any incorrect handling may cause death Read Handling Precautions in this manual to prevent accident Keep...

Страница 2: ...n Union EU used electric and electronic products carrying the symbol below must be disposed of separately from general household waste This includes the power cords and other accessories bundled with...

Страница 3: ...shared between the new and old models If you connect the Amphenol plug which you use for the old model to this tester testing is not possible because the protection is not released To use the Amphenol...

Страница 4: ...run the risk of death the output terminal the test leads connected to the output terminal the Device Under Test DUT any area electrically connected to the output terminal any area electrically connect...

Страница 5: ...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 power cord or turn off t...

Страница 6: ...tially hazardous situation which if ignored may result in damage to the product and other property Shows that the act indicated is prohibited Is placed before the sign DANGER WARNING or CAU TION to em...

Страница 7: ...l 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 app...

Страница 8: ...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 power cord B...

Страница 9: ...E 50 60Hz 800VA MAX No IF THIS COLUMN IS BLANK THE UNIT IS WIRED IN 100V STATUS OUT Be sure to stop the tester before changing test parameters Be sure to read the manual before controlling the tester...

Страница 10: ...Gloves 3 2 3 1 2 Grounding the Tester 3 2 3 2 Warnings and Cautions When Operating the Tester 3 2 3 2 1 Before Turning ON the AC Input Power 3 2 3 2 2 Connecting the Low Test Lead 3 2 3 2 3 Connectin...

Страница 11: ...Withstanding Voltage Test Procedure TOS5051A Only 6 11 6 2 1 Selecting a DC Test Voltage Range 6 11 6 2 2 Setting the Upper Cutoff Current 6 12 6 2 3 Setting the Lower Cutoff Current 6 13 6 2 4 Settin...

Страница 12: ...e 8 5 8 4 Automatic Discharge Function 8 5 Chapter 9 Maintenance ____________________________________ 9 1 9 1 Cleaning 9 2 9 2 Checking the Cord and Leads 9 2 9 3 Maintenance 9 3 9 4 Calibration 9 3 C...

Страница 13: ...TOS5051A 5050A 1 1 Chap 1 General Chapter 1 General This chapter gives an overview and introduces the features of the tester 1 1...

Страница 14: ...lectronic devices and electronic parts in compliance with JIS UL CSA BS and other major electrical standards and ordinances 2 Transformer capacity of 500 VA The tester is equipped with a transformer r...

Страница 15: ...ch type of failure U type and L type This allows you to immediately find out whether the failure is a withstand voltage failure or an open circuit bad contact failure You can preset the upper limit an...

Страница 16: ...age output terminal is structured with a restriction for safer connection 14 A DANGER lamp The tester has a large and bright DANGER lamp This lamp lights when elec tric charge is remaining on the outp...

Страница 17: ...er 1 3 Options Model RC01 TOS RC02 TOS remote control box Model RC01 TOS or RC02 TOS remote control box is used to remotely control the start stop of test operation of the tester Connect the Control B...

Страница 18: ...be sure that the test voltage is OFF the LED is OFF If you need to perform a test in compliance to the UL Standard by using the probe turn the FAIL MODE switch DIP switch on the rear panel of the tes...

Страница 19: ...TOS5051A 5050A 2 1 Chap 2 Installation and Preparation Chapter 2 Installation and Preparation This chapter describes the procedures from unpacking to preparation before use 2 2...

Страница 20: ...is not compatible with that on the old model TOS5050 5051 different pin assignments Therefore the 14 pinAmphenol plug that is supplied with the tester cannot be shared between the new and old models I...

Страница 21: ...even within the operating humidity range In such case do not use the product until the condensation dries up completely Do not place the tester in a corrosive atmosphere Do not install the tester in a...

Страница 22: ...ester to the installation location or when transporting the tester note the following points Turn OFF the POWER switch Moving the tester with the power ON may result in electric shock or damage Remove...

Страница 23: ...ed 2 5 Connecting the Power Cord This product is designed to be connected to a power supply classified as overvoltage category II Do not connect to a power supply classified as overvoltage category II...

Страница 24: ...ternal noise or the noise generated by the product may become large Make sure to ground the unit for your safety There are two types of methods in grounding the tester Make sure to ground the tester u...

Страница 25: ...apter gives warnings and cautions you must observe when operating the tester The tester delivers a 5 kV test voltage which can cause electric shock When operating the tester be extremely careful and o...

Страница 26: ...1 the tester chassis can be charged up to the high voltage that can cause electric shock For a description of the grounding method see section 2 6 Grounding Earth Page 2 6 1 The term AC line here mea...

Страница 27: ...lead connections the low test lead first and the high test lead next To connect the tester to a DUT proceed as follows 1 Press the STOP switch 2 Check that the output voltmeter reading is 0 3 Check th...

Страница 28: ...2 6 Items Charged Up to Dangerous High Voltages While the test is in progress TEST is lit touching a section charged with high voltage near the DUT test lead probe or output terminal is dangerous Fig...

Страница 29: ...es are charged up to high voltages Even after you turn off the DC output these voltages remain there for a period that depends on the conditions of the test Within this period never touch the DUT test...

Страница 30: ...ation of turning ON OFF the power switch rapidly If you do the protectors of the tester may not be able to ren der their protective functions properly Do not turn OFF the power switch without turning...

Страница 31: ...sconnect the power cord from the AC line receptacle Never attempt to repair the tester by yourself Please contact Kikusui distributor agent The DANGER lamp does not turn OFF even though you press the...

Страница 32: ...gh voltage transformer may blow out The information below does not apply when the CUTOFF CURRENT is less than 50 mA Table 3 2 Conditions for maximum continuous test period AC mode During a DC test TOS...

Страница 33: ...UT b For several tens of milliseconds when starting up the tester Take into account the capacity of the AC line and to other devices connected to the same line Do not connect the tester to a regulated...

Страница 34: ...3 10 TOS5051A 5050A...

Страница 35: ...TOS5051A 5050A 4 1 Chap 4 Description of Front and Rear Panel Items Chapter 4 Description of Front and Rear Panel Items This chapter describes the items on the front and rear panels of the tester 4 4...

Страница 36: ...OFF the AC mains power of the tester The tester has a resume function When you turn ON the POWER switch the tester automatically resumes the conditions of test settings of cutoff current test period...

Страница 37: ...tus with the STOP switch and then start operating the tester For details refer to section 6 3 3 Interlock Function b The high voltage supply section is overheated during the DC test TOS5051A only In t...

Страница 38: ...itch The STOP switch is used to stop the test and reset the tester When you press this switch the tester will behave as follows 1 Clear the TEST status TEST is lit The tester will stop the test and be...

Страница 39: ...r the READY status 1 The cause of PROTECTION status remaining un eliminated a The interlock pins of the SIGNAL I O connector on the rear panel are open For details refer to section 6 3 3 Interlock Fun...

Страница 40: ...e the REMOTE CONTROL connector on the front panel Use the SIGNAL I O connector on the rear panel instead Do not remote control the tester simultaneously from both the REMOTE CON TROL connector and the...

Страница 41: ...the test voltage range message shows a blinking 0 kV to notify that the setting has not been confirmed in addition if the TOS5051A is in the middle of switching between AC and DC both AC and DC light...

Страница 42: ...he voltmeter serves both AC and DC modes 11 Zero adjustment of analog voltmeter This is the mechanical zero adjustment of the analog voltmeter Before making a zero adjustment be sure that the POWER sw...

Страница 43: ...no setting value may be stored Wait for five seconds or more after the setting change and then turn OFF the POWER switch 13 CUTOFF CURRENT UP LOW key The key selects the upper or lower cutoff current...

Страница 44: ...e applies automatically to the other mode also 14 TIMER keys These keys are used to increment decrement the test time The keys are enabled when the tester is in the READY status READY is lit and the K...

Страница 45: ...n the TEST ON status TEST is lit or when the tester is deliver ing the result of PASS FAIL judgment When PASS or FAIL is lit On the TOS5051A the ON OFF key is used to turn ON or OFF the timer func tio...

Страница 46: ...the TIMER key while holding down the SHIFT key The test period is increased at a rate ten times the rate when the key is pressed alone 6 Press the TIMER key while holding down the SHIFT key The test p...

Страница 47: ...on of the switch does not conform with the TEST VOLTAGE RANGE mes sage or the AC DC test mode message Do not let the TEST VOLTAGE switch get caught between two range positions If you turn ON the POWER...

Страница 48: ...and DC both AC and DC light up simultaneously The READY message will disappear to show that the tester is not in the READY status If this happens turn the TEST VOLTAGE switch accurately to a range pos...

Страница 49: ...than the upper cutoff current and the lower pass fail judgment function is ON mA unit of measure blinks and the READY message disappears to alert you to that the setting is illogical and the test cann...

Страница 50: ...READY status READY is lit and the KEYLOCK message is OFF Even when the lower pass fail is turned OFF and the LOWER ON message is OFF display and adjustment of the preset cutoff current can be done On...

Страница 51: ...ay screen 29 TEST message This message red means that the tester is in the TEST ON status status that the tester is executing the test by delivering the test voltage To clear this status press the STO...

Страница 52: ...ssage appears when the keylock function is ON it disappears when the function is OFF The keylock function disables the following keys a CUTOFF CURRENT keys b CUTOFF CURRENT UP LOW key c TIMER keys d T...

Страница 53: ...in assignments are different from the old model TOS5050 5051 Therefore the 14 pin Amphenol plug that is supplied with the tester cannot be shared between the new and old models H V ON TEST PASS U FAIL...

Страница 54: ...ems is set to ON If two or more items are set to ON the status signal is delivered on the logical sum of such items For details refer to section 6 4 STATUS OUT Page 6 28 Even when the tester is operat...

Страница 55: ...TOS5051A 5050A 5 1 Chap 5 Preparative Test Procedures Chapter 5 Preparative Test Procedures This chapter describes the preparative procedures for test 5 5...

Страница 56: ...the setup data stored in the internal memory of the tester Table 5 2 Factory default setup data Item Setting POWER switch OFF position TEST VOLTAGE switch 2 5 kVAC range TEST VOLTAGE control 0 positio...

Страница 57: ...ress the POWER switch The Vacuum Fluorescent Display will start illuminating indicating that power has been turned ON 5 Release both SHIFT key and POWER switch After several tens of seconds the fluore...

Страница 58: ...See Fig 5 1 3 Check that the Amphenol plug that is supplied is not connected to the SIGNAL I O connector on the rear panel of the tester 4 Check that the power cord is correctly connected 5 While hold...

Страница 59: ...range position As you do so the tester will enter the READY status status that the READY message appears In this status blinking stops as you press the STOP switch The digital voltmeter may not displ...

Страница 60: ...to Section 6 3 3 Interlock Function on Page 6 24 3 Tester not in PROTECTION status If the tester is in the PROTECTION status status that the PROTECTION mes sage appears the tester will not start the...

Страница 61: ...TOS5051A 5050A 6 1 Chap 6 Test Procedures Chapter 6 Test Procedures This chapter describes the procedures for individual types of withstanding voltage tests 6 6...

Страница 62: ...get caught between two range positions If you turn ON the POWER switch while the TEST VOLTAGE switch is caught in the middle the test voltage range message shows a blinking 0 kV to notify that the set...

Страница 63: ...sappears to indicate that such test condition is not allowed The READY status resumes and the blinking stops if the lower cutoff current is set at a value lower than the upper cutoff current or if the...

Страница 64: ...at such test condition is not allowed The READY status resumes and the blinking stops if the lower cutoff current is set at a value lower than the upper cutoff current or if the pass fail judgment fun...

Страница 65: ...ormats The ON OFF key is enabled when the tester is in the READY status status that the READY message appears and the KEYLOCK message is OFF They are disabled when in the TEST ON status status that th...

Страница 66: ...essage appears Then press the START switch 4 Monitoring the output voltage on the analog voltmeter or VOLTAGE readout raise the output voltage to the desired value by turning gradu ally the TEST VOLTA...

Страница 67: ...en the tester is not in the TEST ON status The CURRENT readout displays the measured output current The TIME display shows the remaining test time or the elapsed test time The Vacuum Fluorescent Displ...

Страница 68: ...e READY message appears within approximately 0 2 seconds from the PASS status and the following actions will take place The PASS message disappears The buzzer stops The PASS signal of the SIGNAL I O c...

Страница 69: ...esult is FAIL If the leak current measured during the test is beyond the limits shown below the tester will give a FAIL judgment and cut off the test voltage and terminate the test When the measured c...

Страница 70: ...ment the tester will automatically reset to the READY status allowing you to repeat the test simply by pressing the START switch The same applies also when the tester is controlled remotely The tester...

Страница 71: ...orm with the TEST VOLTAGE RANGE mes sage or the AC DC test mode message When the test is terminated the switch is enabled and the selected test voltage range and AC DC mode take effect Do not change t...

Страница 72: ...tus status that the READY message appears and the KEYLOCK message is OFF They are dis abled when in the TEST ON status status that the TEST message appears or when the tester is delivering the result...

Страница 73: ...key press the UP LOW key and the lower pass fail judgment function will be brought into effect The LOWER ON message will appear Lower cutoff current setting range 0 1 mA to 11 mA OFF Resolutions and...

Страница 74: ...ats The keys are enabled when the tester is in the READY status status that the READY message appears and the KEYLOCK message is OFF They are dis abled when in the TEST ON status status that the TEST...

Страница 75: ...raise the output voltage to the desired value by turning gradu ally the TEST VOLTAGE control clockwise 5 Press the STOP switch to cut off the output voltage 6 Turn ON the timer function by pressing t...

Страница 76: ...tester is not in the TEST ON status The CURRENT readout displays the measured output current The TIME display shows the remaining test time or the elapsed test time The Vacuum Fluorescent Display will...

Страница 77: ...atus status that the READY message appears within approximately 0 2 seconds from the PASS status and the following actions will take place The PASS message disappears The buzzer stops The PASS signal...

Страница 78: ...If the leak current measured during the test is beyond the limits shown below the tester will give a FAIL judgment and cut off the test voltage and terminate the test When the measured current is lar...

Страница 79: ...a PASS judgment the tester will automatically reset to the READY status allowing you to repeat the test simply by pressing the START switch The same applies also when the tester is controlled remotel...

Страница 80: ...6 2 and Fig 6 3 6 3 1 Remote Control through the REMOTE Connector The REMOTE connector is used to turn the high voltage ON OFF according to the signal received from the optional remote control box RC...

Страница 81: ...r less in AC test mode and 5 kV or less in DC test mode Lay the control signal wires apart more than 500 mm from the HV test leads and DUT Never short the HV test lead to a signal wire If you do it ma...

Страница 82: ...I O Connector Pin layout Pin No Signal I O Output condition and signal description 1 INTERLOCK I Interlock signal input pin 2 H V ON O ON while high voltage is applied across the output terminals 3 T...

Страница 83: ...e internal circuit by photocouplers However the cir cuit common is shared with the input signal Fig 6 2 Internal construction of the SIGNAL I O connector 1 INTERLOCK 2 H V ON 3 TEST 4 PASS 5 U FAIL 6...

Страница 84: ...TOP signal Reference circuit When the door opens the contact opens Consequently the interlock function is acti vated Fig 6 3 Circuit diagram of the interlock input section If you turn on the power to...

Страница 85: ...of the tester When the remote control enable signal RR ENABLE is changed the tester enters the PROTECTION status PROTECTION is lit once Release the pro tection using the STOP switch on the panel or th...

Страница 86: ...esistors When the upper cutoff current is not greater than 10 mA resistors of 470 Rated Power 3 W Impulse Dielectric Withstanding Voltage 30 kV will be appropriate When you have connected these resist...

Страница 87: ...be damaged if the output cir cuit is shorted It is recommended to provide a protective fuse in the output cir cuit The internal control circuits of the tester has been designed to be resistant agains...

Страница 88: ...struction Table6 1 STATUS OUT signal specifications Item Specifications Type of signal Triac output Output voltage Approx 100 VAC Leak current 1 mA or less Maximum output current 0 3 A Isolation Photo...

Страница 89: ...he START switch within approximately 0 5 sec onds after releasing the STOP switch When more than 0 5 seconds elapses the test opera tion cannot be started with the START switch alone This enhances the...

Страница 90: ...y of test is enhanced still more 6 5 4 FAIL MODE Switch If you set this switch to ON the tester cannot be reset from the FAIL judgment or PROTECTION status with the STOP signal applied from the remote...

Страница 91: ...TOS5051A 5050A 7 1 Chap 7 RS 232C Interface Chapter 7 RS 232C Interface This chapter describes the RS 232C interface 7 7...

Страница 92: ...be transmitted from the tester Turn on the power to the PC or serial printer after turning on the power to the tester Item Specifications Transmission system Start stop synchronization half duplex Tra...

Страница 93: ...hese modes allow the test log to be printed directly Talk mode Description 0 Mode in which the tester responds only to commands from the PC default setting 1 Mode in which the tester automatically res...

Страница 94: ...in Table 7 3 according to the desired talk mode Table 7 3 Talk mode setup key The Vacuum Fluorescent Display will start illuminating 3 Release the key and the POWER switch After several tens of secon...

Страница 95: ...AIL the returned current is not the measured value but the upper cutoff current or the lower cutoff current Actual test time The maximum actual test time that can be returned is 999 seconds 999 second...

Страница 96: ...message on the display lights up only when remote control is possible Table 7 4 Combinations of control sources Combination Remote control source START function Display REMOTE message Front panel REMO...

Страница 97: ...r Response Returned as in the example below Fig 7 2 Response example of IDN RST Resets the tester the talk mode is set to default 0 in this version Response Returns OK The talk mode setting specified...

Страница 98: ...test time When the test is not in progress Returns the result of the previous test as follows Returns the maximum measured voltage maximum measured current actual test time and status any of the foll...

Страница 99: ...s OK The tester returns to LOCAL mode when the tester is power cycled LOCAL Disables the START command through the RS 232C RS 232C LOCAL mode The REMOTE message on the panel turns OFF Response Returns...

Страница 100: ...iUniDrv1 GetString KiUniDrv1 SetString START TextBox2 Text KiUniDrv1 GetString Call Sleep 1000 KiUniDrv1 SetString STOP TextBox2 Text KiUniDrv1 GetString KiUniDrv1 SetString MEASURE TextBox1 Text KiUn...

Страница 101: ...TOS5051A 5050A 8 1 Chap 8 Operating Principle Chapter 8 Operating Principle This chapter describes the operating principle of the tester 8 8...

Страница 102: ...ator output with a ratio of approximately 1 25 or 1 50 into a high output voltage of 0 kV to 2 5 kV or 0 kV to 5 kV The AC rating is 5 kV 100 mA 500 VA These stand when the AC line voltage is at its n...

Страница 103: ...ltage 8 Discharge circuit When in the DC test mode the test leads probe DUT and other items connected to the output circuit can be charged up to the high DC test voltage Even after the test is over an...

Страница 104: ...ately 0 volt level thereby reducing transient overshoots Fig 8 2 Timing chart Be sure to observe the following instructions when using a HV test probe HP01A TOS or HP02A TOS Do not connect the probe t...

Страница 105: ...ltage is cut off these items can remain in the charged state for a substantial period of time The discharge circuit is to rapidly discharge the charges stored in these items When the output voltage is...

Страница 106: ...8 6 TOS5051A 5050A...

Страница 107: ...TOS5051A 5050A 9 1 Chap 9 Maintenance Chapter 9 Maintenance This chapter describes the maintenance procedures for the tester 9 9...

Страница 108: ...erase printed characters or cloud the display 9 2 Checking the Cord and Leads If the test lead is damaged its sheath is damaged or its core wire is open circuited it can cause electric shock Never us...

Страница 109: ...of use Contact Kikusui distributor agent to have your tester overhauled Cooling fan The cooling fan TOS5051A only is a consumable component It is recommended that the tester be overhauled every appro...

Страница 110: ...9 4 TOS5051A 5050A...

Страница 111: ...TOS5051A 5050A 10 1 Chap 10 Specifications Chapter 10Specifications This chapter describes the electrical and mechanical specifications of the tester 10 10...

Страница 112: ...n the output voltage is 900 V or more at 2 5 kV range or 1 3 kV or more at 5 kV range Waveform3 AC line voltage waveform Voltage regulation with nominal line voltage 15 or better against change from m...

Страница 113: ...or may trip and the tester may be driven into the PROTECTION status When this has occurred pause the test operation until the tester cools off and then resume the test operation As the tester is coole...

Страница 114: ...pe If the current detected is larger than the preset upper cutoff cur rent the tester gives a FAIL judgment If the current detected is less than the preset lower cutoff cur rent the tester gives a FAI...

Страница 115: ...t voltage is less than 4 kVACrms or 5 kV DC SIGNAL I O connector 14 pin Amphenol con nector on the rear panel To control the tester from a make contact device such as a relay or a switch To control th...

Страница 116: ...GER lamp TEST During the test Open collector signal8 Vacuum Fluorescent Display PASS For PASS judgment Delivered for approxi mately 0 2 s Open collector signal8 Vacuum Fluorescent Display buzzer9 U FA...

Страница 117: ...nts of the following directive and standard EMC Directive 2004 108 EC EN 61326 1 EN 61000 3 2 EN 61000 3 3 Under following conditions 1 Used HV test leadwires TL01 TOS which is supplied 2 No discharge...

Страница 118: ...Drawing Fig 10 1 TOS5050A TOS5051A outline drawing Item TOS5050A TOS5051A Dimensions See Outline Drawing Weight13 Approx 15 kg 33 07 lb Approx 16 kg 35 27 lb Item Q ty Remarks Power cord 1 High voltag...

Страница 119: ...6 H high test lead 3 3 HIGH VOLTAGE terminal 4 8 high voltage test probe 1 6 HP01A TOS 1 6 HP02A TOS 1 6 I initial setup 5 2 input range allowable 2 4 input voltage range 2 5 installation location 2...

Страница 120: ...1 START switch 4 4 STATUS OUT 4 20 6 28 STOP switch 4 4 T talk mode 7 3 test lead 3 4 TEST message 4 17 TEST MODE switches 4 20 TEST VOLTAGE control 4 7 TEST VOLTAGE RANGE message 4 13 TEST VOLTAGE sw...

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