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OPERATION MANUAL
DANGER
• This Tester generates high voltage.
• Any incorrect handling may cause death.
• Read Chapter 3 "WARNINGS AND CAUTIONS FOR OPERATING THE TESTER"
in this manual to prevent accident.
• This manual should be placed within the reach of the operator so that he or she
may read it whenever necessary.
TOS5000 SERIES
WITHSTANDING VOLTAGE TESTER
WARNINGS Against HIGH VOLTAGE
TOS5101
TOS5051
TOS5050
Part No. Z1-000-632 IB000598, MAR/2004
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Summary of Contents for Kikusui TOS5101
- Page 1 OPERATION MANUAL TOS5000 SERIES WITHSTANDING VOLTAGE TESTER TOS5101 TOS5051 TOS5050 DANGER WARNINGS Against HIGH VOLTAGE • This Tester generates high voltage. • Any incorrect handling may cause death. • Read Chapter 3 "WARNINGS AND CAUTIONS FOR OPERATING THE TESTER" in this manual to prevent accident.
- Page 2 All or any parts of this manual may not be reproduced in any forms, without express written permission of Kikusui Electronics Corporation. The contents of this manual, including the specifications of the instrument, are subject to change without notice. ©1993-2004 Copyright Kikusui Electronics Corporation.
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Page 9: Table Of Contents
4.1.1 Turning ON/OFF the AC Input Power ..............4.1.2 Start/Stop of Test ....................4.1.3 Test Voltage ......................4.1.4 Cutoff Currents ..................... 4-12 4.1.5 Test Time ......................4-15 4.1.6 Others ........................4-17 4.2 Display Items ........................ 4-18 4.2.1 Test Voltage Display ..................... 4-18 4.2.2 Readout for Cutoff Current and Measured Current .......... - Page 10 ........................9.2 TOS5101 and TOS5051 ....................9.3 Overall Dimensions ...................... 9-18 9.3.1 Dimensions of Models TOS5050 and TOS5051 ..........9-18 9.3.2 Dimensions of Model TOS5101 ................9-18 10. OPTIONS .......................... 10-1 10.1 Model RC01-TOS/RC02-TOS Remote Control Box ........... 10-2 10.2 Model HP01A-TOS/HP02A-TOS High Voltage Test Probe .......
- Page 22 When you receive the Tester, inspect it for any obvious damages that may have occurred during shipment. Immediately report any damages to the carrier and your Kikusui agent. You should also find the standard accessories as shown below accompany the Tester in the same package.
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Page 26: Environmental Conditions
Chapter 2 GENERAL PRELIMINARY NOTES AND PRECAUTIONS 2.2.3 Environmental Conditions Be sure to observe the following precautions when installing the tester. ■ Do not use the tester in a flammable atmosphere. To prevent explosion or fire, do not use the tester near alcohol, thinner, or other combustible materials, or in an atmosphere containing such vapors. - Page 27 Chapter 2 GENERAL PRELIMINARY NOTES AND PRECAUTIONS ■ Do not use the tester in locations near a sensitive measuring instrument or receiver. Operation in a location subject, may cause such equipment may be affected by noise generated by the tester. At a test voltage exceeding 3 kV, corona discharge may be generated to produce substantial amounts of RF broadband emissions between grips on the test leadwire.
- Page 28 Transport the tester in its original package to prevent vibration and falls, which may damage the tester. If you require packing material, contact Kikusui distributor/agent. ■ Have two or more people move the tester. The TOS5101 weighs approximately 21 kg. Two persons are required to carry the TOS5101. Take extreme care when moving the TOS5101.
- Page 31 Test leadwire (black) to DUT Install the leadwire clamp as this Figure 3.3 Connecting the LOW Test Leadwire (TOS5101) 3.2.2 Connecting the HIGH Test Leadwire Be sure to observe the order of leadwire connections — the LOW test leadwire first and the HIGH test leadwire next.
- Page 34 The period of time the residual high voltages take to be discharged vary depending on test conditions — such as the properties of DUT and the test voltage delivered by Tester (Model TOS5101 or TOS5051). When no DUT is connected, the period the Tester itself (internal capacitor of the Tester)
- Page 39 Chapter 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. Table of contents Page 4.1 Description of Front Panel Items ........4-2 4.1.1 Turning ON/OFF the AC Input Power .....
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Page 40: Description Of Front Panel Items
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 4.1 Description of Front Panel Items 10 11 13 16 14 Figure 4.1 TOS5050 Front Panel Figure 4.2 TOS5051 Front Panel... -
Page 41: Turning On/Off The Ac Input Power
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 10 11 Figure 4.3 TOS5101 Front Panel 4.1.1 Turning ON/OFF the AC Input Power Switch POWER POWER switch turns ON/OFF the AC mains power of the Tester. The Tester has a “resume” function. When you turn ON the... - Page 42 STOP and then start operating the Tester. ii. When in DC test (for TOS5101 and TOS5051 only), the high voltage supply section is overheated. If the above is the case, wait until the Tester cools off and then reset from the PROTECTION status with the...
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Page 43: Start/Stop Of Test
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 4.1.2 Start/Stop of Test Switch START START If you press the switch when the Tester is in the READY state (state that the READY message appears), the Tester will execute the test with parameters shown on the display screen (Vaccum Fluorescent Display). - Page 44 DC test (for TOS5101 and TOS5051 only). If this is the case, eliminate the interlock signal (For detail refer to Section 6.3.3 “Interlock Function”) or wait until the Tester cools...
- Page 45 The interlock pins of the SIGNAL I/O connector on the rear panel are open. (For details, refer to Section 6.3.3 “Interlock Function.”) (b) When in DC test (for TOS5101 and TOS5051 only), the high voltage supply section is overheated. The test voltage remaining undischarged...
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Page 46: Options
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS REMOTE CONTROL Connector This connector is for remote control of start/stop of test operation from an optional device such as Remote Control Box (RC01-TOS or RC02-TOS) or H.V Test Probe (HP01A-TOS or HP02A-TOS). -
Page 47: Test Voltage
. When the test period has elapsed, the switch is enabled and the selected test voltage range and AC/DC mode (mode selection is for TOS5101 and TOS5051 only) are ef- fected. Do not operate the Tester in this manner — that is, do not... - Page 48 The “MAX” position is for the highest test voltage corresponding to the voltage range value selected by the TEST VOLTAGE switch For the AC/DC models (TOS5101 and TOS5051), the control is for both AC and DC test modes. Model...
- Page 49 , test leadwires, DUT, or other charged objects. Analog Voltmeter The VOLTAGE display (analog voltmeter) indicates directly the output terminal voltage. Of the AC/DC models (TOS5101 and TOS5051), the voltmeter serves in common for both AC and Model Measuring Range TOS5101 0 to 10kV AC...
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Page 50: Cutoff Currents
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 4.1.4 Cutoff Currents Caution • Test time and pause period are limited by setting upper cutoff current. "ON … " of the front panel character shows a maximum test time and "OFF …... -
Page 51: Tos5050
TOS5050 — — For the AC/DC models (TOS5101 and TOS5051), the upper and lower cutoff currents can be set for AC and DC modes of tests. The settings of cutoff currents for the AC mode and DC mode, however, are mutually independent. - Page 52 , and you can adjust the value with the keys For the AC/DC models (TOS5101 and TOS5051), the upper and lower cutoff currents for both AC and DC modes of tests can be selected with this key. The settings of cutoff currents for the AC mode and DC mode, however, are mutually independent.
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Page 53: Test Time
100 to 999 s., OFF 1 s. □ □□s For the AC/DC models (TOS5101 and TOS5051), the test period can be set with the keys for both AC and DC modes of tests. This test condition applies in common to both AC and DC modes of tests. - Page 54 Tester is delivering the result of PASS/FAIL judgement (when the PASS message or the FAIL message appears). For the AC/DC models (TOS5101 and TOS5051), the timer function can be turned ON or OFF with the for both AC and DC modes of tests. This test condition ON/OFF applies in common to both AC and DC modes of tests.
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Page 55: Others
(d) Test time (e) ON/OFF of timer function is enabled regardless of the statuses of the Tester. ON/OFF For the AC/DC models (TOS5101 and TOS5051), the keylock function applies in common to both AC and DC modes of tests. 4.1.6 Others SHIFT... -
Page 56: Display Items
TEST VOLTAGE RANGE Message This message, which is a 7-segment 2-digit message, indicates the test voltage range selected with the TEST VOLTAGE switch . The selectable test voltage ranges are as follows: Model Test voltage range TOS5101 10kV TOS5051 2.5kV TOS5050 2.5kV Caution •... - Page 57 This message indicates whether the AC or DC test mode has been selected with the TEST VOLTAGE switch . The selectable modes are as follows: Model Test Mode TOS5101 TOS5051 TOS5050 — Caution • The TOS5050 is for the AC test mode only. It has no DC test mode message •...
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Page 58: Tos5101 And Tos5051
3-digit 7- segment readout. It constantly monitors the output terminal voltage. For the AC/DC models (TOS5101 and TOS5051), the digital voltmeter acts either as an AC voltmeter or a DC voltmeters in response to the AC or DC mode selected by the TEST... -
Page 59: Readout For Cutoff Current And Measured Current
OFF, the mA display automatically stops blinking and the Tester resumes the READY status. Of the AC/DC models (TOS5101 and TOS5051), the upper cutoff currents can be preset mutually independently for AC test mode and DC test mode, and the lower cutoff currents also can be preset mutually independently for AC test mode and DC test mode. - Page 60 OFF and the LOWER ON message has disappeared, display and adjustment of the preset cutoff current can be done. For the AC/DC models (TOS5101 and TOS5051), this test condition setting is applied in common to both AC and DC modes of tests.
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Page 61: Test Time Display
For the AC/DC models (TOS5101 and TOS5051), the preset test period applies in common to both AC and DC modes of tests. -
Page 62: Ready Message
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 4.2.4 READY Message READY Message This message means that the Tester is ready to start the test operation. As you press the switch while this message is displayed, the Tester will start the test operation with START the test parameters displayed on the display screen 4.2.5 TEST Message... -
Page 63: Protection Message
The status of the REMOTE ENABLE signal input pins of the SIGNAL I/O connector has changed. The INTERLOCK signal input pins of the SIGNAL I/O connector are make open. The high voltage supply circuit of the DC test section (TOS5101 and TOS5051 only) is overheated. 4.2.9 Others KEYLOCK Message This message appears when the keylock function is ON;... -
Page 64: Description Of Rear Panel Items
Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 4.3 Description of Rear Panel Items Figure 4.5 TOS5050/TOS5051 Rear Panel Figure 4.6 TOS 5101 Rear Panel Protective Grounding Terminal This terminal is for grounding the Tester to an earth ground. WARNING •... - Page 65 Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS AC LINE Connector The AC LINE connector is for the AC input power. It serves also as an input power fuse holder. SIGNAL I/O Connector The SIGNAL I/O connector is a 14-pin Amphenol connector for the interlock input signal, remote control signal for test start/stop, and status output signal.
- Page 66 Chapter 4 DESCRIPTION OF FRONT AND REAR PANEL ITEMS 4-28...
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Page 77: Test Procedures
SHIFT by a factor of 10. The current value is displayed on the CURRENT readout Upper Cutoff Current Setting Range Model Upper cutoff current range TOS5101 0.1 to 55mA TOS5051 0.1 to 110mA TOS5050 0.1 to 110mA... - Page 79 OFF. • As noted in Chapter 9 “SPECIFICATIONS” (Note 4 for TOS5050 and Note 5 for TOS5101 and TOS5051), when a test is done with a high AC voltage and a high sensitivity, the lower pass/fail judgement may not be correctly done in a particular case that the output current that flows due to the stray capacitances of the output circuit (such as test leadwires, etc.) is...
- Page 85 Chapter 6 TEST PROCEDURES • When the measured current is less than the lower cutoff current: Assuming that the lower cutoff current is set at 1 mA and the lower pass/fail judgement function is ON, the items shown on the Vacuum Fluorescent Display will be as follows.
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Page 87: Setting The Upper Cutoff Current
. When the test period has elapsed, the switch is enabled and the selected test voltage range and AC/DC mode (mode selection is for TOS5101 and TOS5051 only) are effected. Do not operate the Tester in TEST VOLTAGE this manner — that is, do not change the switch during the TEST-ON period. -
Page 90: Setting The Test Time
Chapter 6 TEST PROCEDURES 6.2.4 Setting the Test Time This procedure is to set the test period of time during which the Tester remains in the TEST-ON status (status that the Tester delivers the test voltage). When this period has elapsed without any FAIL judgement events, the Tester terminates the test and gives a PASS judgement. - Page 95 Chapter 6 TEST PROCEDURES UPPER FAIL RANGE UPPER VOLTAGE CURRENT TIME FAIL TIMER ON UPPER In this case, the UPPER FAIL message will appear. • When the measured current is less than the lower cutoff current: Assuming that the lower cutoff current is set at 0.5 mA and the lower pass/fail judgement function is ON, the items shown on the display screen will be as follows.
- Page 117 Chapter 9 SPECIFICATIONS Chapter 9 SPECIFICATIONS This chapter indicates the specifications of Models TOS5101, TOS5051, and TOS5050. Table of contents Page 9.1 TOS5050 ................9-2 9.2 TOS5101 and TOS5051 ........... 9-9 9.3 Overall Dimensions ............9-18 9.3.1 Dimensions of Models TOS5050 and TOS5051 ..9-18...
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Page 118: Tos5050
Chapter 9 SPECIFICATIONS 9.1 TOS5050 Model TOS5050 Test Applied voltage 0 to 2.5 or 0 to 5kV AC voltage Output rating 500VA/5kV, 100mA (Note 1) (with nominal AC line voltage) Transformer rating 500VA Short-circuit current (Note 2) 200 mA or more (when the output voltage is 900 V or more at 2.5 kV range or 1.3 kV or more at 5 kV range.) Waveform (Note 3) - Page 119 Chapter 9 SPECIFICATIONS Note 1: Pay attention to the limitations on output voltage delivery time as follows: The heat dissipation of the high voltage generator section of the Tester is one-half of the normal wattage with respect to the rated output from the viewpoints of size, weight, and cost of the Tester.
- Page 120 Chapter 9 SPECIFICATIONS Model TOS5050 Ambient temperature Specification range 5 to 35˚C (41 to 95˚F), 20 to 80% RH and humidity Operable range 0 to 40˚C (32 to 104˚F), 20 to 80% RH Storage range –20 to 70˚C (–4 to 158˚F), ≤ 80% RH SAFETY Conforms to the requirements of the following (Note 6)
- Page 121 Chapter 9 SPECIFICATIONS Model TOS5050 Insulation resistance ≥ 30MΩ, with 500V DC Withstanding voltage 1390 V AC (2 seconds), between AC line and chassis 1200V AC (1 second), UL-approved products only Dimensions Excluding protrusions 320 W × 132 H × 300 D mm (12.6 W ×...
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Page 122: Remote Control
Chapter 9 SPECIFICATIONS Model TOS5050 Remote control function The Tester has the following provisions for remote-control of test start/stop. REMOTE connector • To control the Tester from an optional (5-pin DIN connector, Remote Control Box RC01-TOS or RC02-TOS. on front panel) •... - Page 123 Chapter 9 SPECIFICATIONS Signal Output Functions Signal Name Conditions for Signal Generation Types of Signals H.V ON During the test time (period the Open-collector signal (No te 9), Tester delivers the test voltage) DANGER lamp TEST During the test time (period the Open-collector signal (No te 9), Vacuum Tester delivers the test voltage) Fluorescent Display...
- Page 124 Chapter 9 SPECIFICATIONS Accessories Item Q’ty Remarks AC input power cable H.V test leadwires TL01-TOS (1.5 meters long) 1 set 14-pin Amphenol plug Assembly type “DANGER! HIGH VOLTAGE” sticker Operation manual AC power fuses In fuse holder cap (one for present use and the other for spare)
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Page 125: Tos5101 And Tos5051
Chapter 9 SPECIFICATIONS 9.2 TOS5101 and TOS5051 Model TOS5101 TOS5051 Test Applied voltage AC/DC voltage 0 ~ 5/0 ~ 10kV 0 ~ 2.5/0 ~ 5KV Output rating 500VA/10kV, 50mA 500VA/5kV, 50mA (Note 1) (with nominal line voltage) (with nominal line voltage) - Page 126 Tester. Due to this, be sure to operate the Tester within the limits shown in the below tables. If you operate the Tester exceeding these limits, the thermal fuse in the Tester may blow out. TOS5101 Ambient Upper cutoff...
- Page 127 Chapter 9 SPECIFICATIONS TOS5101 Ambient Upper cutoff Maximum allowable Pause period temperature t current I (mA) continuous test period t ≤ 30˚C 3 < I ≤ 5.5 ≤ 30 s At least 5 times of test period (t ≤ 86˚F) 3 <...
- Page 128 Chapter 9 SPECIFICATIONS Model TOS5101 TOS5051 Pass/fail judgement Type of • Window comparator type judgement • If the current detected is larger than the preset upper cutoff current, the Tester gives a FAIL judgement. • If the current detected is less than the preset lower cutoff current, the Tester gives a FAIL judgement.
- Page 129 Chapter 9 SPECIFICATIONS Model TOS5101 Ambient temperature Specification range 5 to 35˚C (41 to 95˚F), 20 to 80% RH and humidity Operable range 0 to 40˚C (32 to 104˚F), 20 to 80% RH Storage range –20 to 70˚C (–4 to 158˚F), ≤ 80% RH...
- Page 130 Chapter 9 SPECIFICATIONS Model TOS5051 Ambient temperature Specification range 5 to 35˚C (41 to 95˚F), 20 to 80% RH and humidity Operable range 0 to 40˚C (32 to 104˚F), 20 to 80% RH Storage range –20 to 70˚C (–4 to 158˚F), ≤ 80% RH SAFETY Conforms to the requirements of the following (Note 15)
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Page 131: Interlock Function
Chapter 9 SPECIFICATIONS Model TOS5101 TOS5051 Withstanding voltage 1390 V AC (2 seconds), between AC line and chassis 1200V AC (1 second), UL-approved products only Dimensions Excluding 430 W × 177 H × 370 D mm 320 W × 132 H × 300 D mm protrusions (16.9 W ×... -
Page 132: Output Signals
Chapter 9 SPECIFICATIONS Signal Output Functions Signal Name Conditions for Signal Generation Types of Signals H.V ON During the test time (period the Open-collector signal (Note 11), DANGER Tester delivers the test voltage) lamp TEST During the test time (period the Open-collector signal (Note 11), Vacuum Tester delivers the test voltage) Fluorescent Display... - Page 133 Note 14: The TL03-TOS H.V Test Leadwires (for test voltages up to 10kV) that accompany the TOS5101 Tester are H.V silicone leadwires whose diameter is approximately 12 mm. Be sure to use these leadwires when the test voltage is higher than 5kV.
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Page 134: Overall Dimensions
Chapter 9 SPECIFICATIONS 9.3 Overall Dimensions 9.3.1 Dimensions of Models TOS5050 and TOS5051 9.3.2 Dimensions of Model TOS5101 9-18... -
Page 135: Model Rc01-Tos/Rc02-Tos Remote Control Box
Chapter 10 OPTIONS Chapter 10 OPTIONS This chapter introduces optional devices for the Tester. Table of contents Page 10.1 Model RC01-TOS/RC02-TOS Remote Control Box ..10-2 10.2 Model HP01A-TOS/HP02A-TOS High Voltage Test Probe ............... 10-3 10.3 Model PL01-TOS Warning Light Unit......10-4 10.4 Model BZ01-TOS Buzzer Unit ........ -
Page 139: Initial Test Setup Data
INDEX INDEX AC line ............4-27 AC line requirements ........2-4 ON/OFF Key ..........4-16 AC power cable takeup Output Signals ........1-4, 6-27 High voltage test leadwires ...... 10-4 Output voltage display ........4-20 AC/DC test Mode Message ......4-19 Automatic discharge function ....
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