Kikusui TOS5050A Operation Manual
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Kikusui TOS5050A Operation Manual

Tos5000 series, withstanding voltage tester
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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.
Part No. Z1-002-972, IB004839
Aug. 2009

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  • Page 1 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...
  • Page 2 If you find any incorrectly arranged or missing pages in this manual, they will be replaced. If the manual gets lost or soiled, a new copy can be provided for a fee. In either case, please contact Kikusui distributor/ agent, and provide the “Kikusui Part No.” given on the cover.
  • Page 3 Function” in this manual. Then, operate the tester appropriately using the interlock function. About this manual This is the operation manual for the TOS5050A/TOS5051A Withstanding Voltage tester. ■ ROM version of the product to which this manual applies • TOS5050A: Ver.1.0X •...
  • Page 4 To the supervisor in charge of operation • If the operator does not read the language used in this manual, translate the manual into the appropriate language. • Help the operator in understanding this manual before operation. • Keep this manual near the tester for easy access by the operator. For your own safety (to avoid electric shock) While the tester is delivering its test voltage, never touch the following areas, or else, you will receive electric shock, and run the risk of death.

  • Page 5: Power Requirements Of This Product

    Power Requirements of this Product Power requirements of this product have been changed and the relevant sections of the Operation Manual should be revised accordingly. ✓ (Revision should be applied to items indicated by a check mark Input voltage The input voltage of this product is VAC, and the voltage range is VAC.

  • Page 6: Safety Symbols

    Safety Symbols For the safe use and safe maintenance of this product, the following symbols are used throughout this manual and on the product. Under- stand the meanings of the symbols and observe the instructions they indicate (the choice of symbols used depends on the products). Indicates that a high voltage (over 1000 V) is used here.

  • Page 7: Safety Precautions

    Safety Precautions The following safety precautions must be observed to avoid fire haz- ard, electrical shock, accidents, and other failures. Keep them in mind and make sure that all of them are observed properly. Users • This product must be used only by qualified personnel who understand the con- tents of this operation manual.
  • Page 8 • To maintain performance and safe operation of the product, it is recommended that periodic maintenance, checking, cleaning, and calibration be performed. Service • Internal service is to be done by Kikusui service engineers. If the product must be adjusted or repaired, contact Kikusui distributor/agent. VI Safety Precautions...
  • Page 9 120V AC L I NE 50 60Hz 220V 800VA MAX 230V KIKUSUI ELECTRONICS CORP. 240V MADE IN JAPAN For your safety, be sure to connect to the earth ground. See section 2.6, “Grounding (Earth).” * The SIGNAL I/O connector on this tester is not compatible with that on the old model TOS5050/5051 (different pin assignments).

  • Page 10: Table Of Contents

    Contents Power Requirements of this Product ___________________________ III Safety Symbols ___________________________________________ IV Safety Precautions _________________________________________ V Chapter 1 General ________________________________________ 1-1 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2 Options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5...
  • Page 11 Display Items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-13 Description of Rear Panel Items - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-19 Chapter 5 Preparative Test Procedures _______________________ 5-1...
  • Page 12 RS-232C Commands and Responses - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Sample Program - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-10 Chapter 8 Operating Principle _______________________________ 8-1 Block Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2 Zero-turn-on Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4...

  • Page 13: Chapter 1 General

    Chapter 1 General This chapter gives an overview and introduces the features of the tester. TOS5051A/5050A...

  • Page 14: Overview

    The TOS5051A/5050A is a tester for carrying out withstanding voltage tests on elec- tronic devices and electronic parts. The TOS5051A is capable of carrying out both AC tests and DC tests; the TOS5050A is capable of carrying out AC tests. This tester integrates new ideas and technologies with the conventional, consistent philosophy of providing the highest safety, reliability, and operability to the operator.
  • Page 15 0.1 mA to 110 mAAC 200 steps 0.1 mA to 11 mADC 101 steps TOS5050A 0.1 mA to 110 mAAC 200 steps 8. A digital timer The timer allows you to preset the period during which the test voltage is to be applied to the DUT.
  • Page 16 Weight TOS5051A 16 kg 320 mm (W) × 132 mm (H) × 300 mm (D) TOS5050A 15 kg 12.Memory backup function When you turn the tester OFF, the tester stores its existing test state in its non- volatile memory. When you turn the tester ON the next time, the tester recalls the stored information and restores the test state that existed when you turned OFF the power last time.

  • Page 17: Options

    18.Noise-resistant circuits The internal circuits of the tester are designed to be highly resistant against noise, thereby enhancing the operation reliability. 19.Automatic discharge function (TOS5051A only) When the DC test output voltage is turned off, the output circuit is automati- cally discharged, thereby discharging the charge in the device under test (DUT).
  • Page 18 Model HP01A-TOS/HP02A-TOS high voltage test probe The high voltage test probe renders a three-fold oper- ating safety. The test voltage is not delivered unless you squeeze with one hand the slide lever of the grip of the probe and pull the trigger while you press with the other hand the switch on top of the probe.

  • Page 19: Chapter 2 Installation And Preparation

    Chapter 2 Installation and Preparation This chapter describes the procedures from unpacking to preparation before use. TOS5051A/5050A...

  • Page 20: Checking The Package Contents

    When you receive the product, check that all accessories are included and that the product and accessories have not been damaged during transportation. If any of the accessories are damaged or missing, contact Kikusui distributor/agent. Rated voltage: 125 Vac Rated voltage: 250 Vac...

  • Page 21: Precautions Concerning Installation Location

    Precautions Concerning Installation Location This section describes the precautions to be taken when installing the product. Make sure to observe them. ■ Do not use the tester in a flammable atmosphere. To prevent the possibility of explosion or fire, do not use the product near alcohol, thinner or other combustible materials, or in an atmosphere containing such vapors.

  • Page 22: Precautions When Moving The Tester

    ■ Do not use the tester near highly sensitive measuring instru- ments or transceivers. Do not operate the tester near highly sensitive measuring instruments such as com- munication receivers, because the noise generated by the tester may interfere with such devices. Above 3 kV test voltage, the tester may produce corona discharge between its test lead clips which will generate a significant amount of broadband RF emission.

  • Page 23: Connecting The Power Cord

    220 V 230 V 240 V WARNING • Do not modify your tester by yourself. Consult Kikusui distributor/agent to have your tester modified. Connecting the Power Cord WARNING • This product is designed to be connected to a power supply classified as overvoltage category II.

  • Page 24: Grounding (Earth)

    Grounding (Earth) WARNING • Electric shock may occur, if proper grounding is not furnished. • This product is designed as a Class I equipment (equipment furnished with electric shock protection through protective grounding in addition to the basic insulation). Be sure to connect the protective ground terminal to an appropriate earth ground.

  • Page 25: Chapter 3 Handling Precautions

    Chapter 3 Handling Precautions This chapter gives warnings and cautions you must observe when operating the tester. WARNING • The tester delivers a 5 kV test voltage which can cause electric shock. When operating the tester, be extremely careful and observe the cautions, warnings, and other instructions given in this chapter.

  • Page 26: Preparative Procedures

    Wearing Insulation Gloves When handling the tester, be sure to wear insulation gloves in order to protect your- self against high voltages. If you cannot obtain insulation gloves, please contact Kikusui distributor/agent for them. 3.1.2 Grounding the Tester Be sure to ground the tester. To do this, connect securely (using a tool) an earth line to the protective grounding terminal on the rear panel of the tester.

  • Page 27: Connecting The High Test Lead

    When connecting the tester to a DUT (device under test), connect the low test lead first (and the high test lead next) and be sure that it securely connects the LOW out- put terminal of the tester to the corresponding terminal (chassis protective ground- ing terminal) of the DUT.

  • Page 28: Precautions For Pausing Tests

    3.2.5 Precautions for Pausing Tests When you pause a test, be sure to turn the TEST VOLTAGE control knob to the “0” position (fully counterclockwise) and press the STOP switch. If you are not going to resume the test soon or if you are leaving the test area, be sure to turn OFF the switch.

  • Page 29: Warnings After Turning Off The Power

    Warnings after Turning OFF the Power 3.3.1 Check Items after Turning OFF the Power If you have to touch the DUT, test leads, probes, and/or output terminals and their vicinities for re-connections or other reasons, be sure of the following two matters: •...

  • Page 30: Warnings For Remote Control

    Table3-1 Discharge time Test voltage Discharge time Note Time until the output terminal voltage TOS5051A alone Approx. 16 ms of the TOS5051A attenuates to 30 V 5 kV Time until the DUT voltage attenu- Approx. 50 ms ates to 30 V The tester has an internal circuit to discharge the residual high voltage of its output circuit when the output is turned off.

  • Page 31: Actions To Be Taken In Emergency

    If such behavior is observed, immediately turn OFF the power switch and disconnect 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 STOP switch.

  • Page 32: Wattage, Heat, And Other Limiting Conditions Of Use

    Wattage, Heat, and Other Limiting Conditions of Use ■ Use at a voltage less than or equal to 5 kV The maximum output voltage of the tester when there is no load may be higher than 5 kV. It may be even higher depending on AC line voltage fluctuation. Be sure to operate the tester at an output voltage less than or equal to 5 kV.
  • Page 33 Table 3-3 Conditions for maximum continuous test period (DC mode) Ambient temperature Upper cutoff current Maximum allowable Pause period t (°C) I (mA) continuous test period At least 5 times of t ≤ 30°C 6 < I ≤ 11 ≤ 30 s test period At least 10 times of 6 <...
  • Page 34 3-10 TOS5051A/5050A...

  • Page 35: 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. TOS5051A/5050A...

  • Page 36: Description Of Front Panel Items

    Description of Front Panel Items Fig.4-1 Front panel (TOS5050A) Fig. 4-2 Front panel (TOS5051A) POWER switch The POWER switch turns ON/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, etc.) that existed when you turned OFF the POWER switch last time.
  • Page 37 By pressing the POWER switch while Item Initial setup data holding down the SHIFT key, you can Upper cutoff current 0.2 mA initialize the test conditions to the ini- tial setup (factory default setup) as Lower cutoff current 0.1 mA shown to the right.
  • Page 38 START switch If you press the START switch when the tester is in the READY state (“READY” is lit), the tester will execute the test with parameters shown on the display screen. If the “REMOTE” message is shown, the START switch is disabled and the remote start control signal applied through the REMOTE CONTROL connector or the SIG- NAL I/O connector is enabled.
  • Page 39 4. Clear the PROTECTION status (“PROTECTION” is lit) The tester will clear the PROTECTION status and behave follows: (a) Turns OFF the “PROTECTION” message. (b) Turns OFF the PROTECTION signal fed through the SIGNAL I/O connector. However, the tester will not clear the PROTECTION status if the interlock pins of the SIGNAL I/O connector are open or if the high voltage supply section is over- heated during a DC test (TOS5051A only).
  • Page 40 • To clear the PROTECTION status, press the STOP switch. TEST VOLTAGE switch The TEST VOLTAGE switch selects the test voltage range and switches the test mode between AC and DC (TOS5050A has no DC test mode). Model Selectable ranges and mode...
  • Page 41 0 kV to 5 kVAC or more 0 kV to 2.5 kVAC or more 0 kV to 5 kVDC or more 0 kV to 2.5 kVDC or more TOS5050A 0 kV to 5 kVAC or more 0 kV to 2.5 kVAC or more NOTE •...
  • Page 42 Model Measuring Range TOS5051A 0 kV to 5 kVAC 0 kV to 5 kVDC TOS5050A 0 kV to 5 kVAC — [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 switch is OFF.
  • Page 43 Model AC mode test Upper cutoff current range Lower cutoff current range TOS5051A to 110 mA 0.1 mA to 110 mA, OFF TOS5050A Model DC mode test Upper cutoff current range Lower cutoff current range to 11 mA TOS5051A 0.1 mA to 11 mA, OFF TOS5050A —...
  • Page 44 1. When the key alone is pressed Each time you press the key, the upper or lower cutoff current is selected and the “UPPER” message or the “LOWER” message appears. The “UPPER” message means that the upper cutoff current has been selected, the value is displayed on the CURRENT readout, and you can adjust the value with the keys.
  • Page 45 [15] TIMER ON/OFF key The ON/OFF key turns ON or OFF the timer function. If you press the key while holding down the SHIFT key, the keylock function is turned ON or OFF. 1. When the ON/OFF key alone is pressed Each time you press the key, the timer function is turned ON or OFF.
  • Page 46 [16] SHIFT key 1. Press the POWER switch while holding down the SHIFT key. The test conditions are initialized. 2. Press the CUTOFF CURRENT key while holding down the SHIFT key. The upper or lower cutoff current is increased at a rate ten times the rate when the key is pressed alone.

  • Page 47: Display Items

    Display Items PASS PROTECTION READY TEST RANGE UPPER LOWER VOLTAGE CURRENT TIME FAIL LOWER ON TIMER ON UPPER KEYLOCK LOWER REMOTE Fig. 4-3 Fluorescent display [19] 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.
  • Page 48 TEST VOLTAGE switch. The selectable modes are AC or DC. NOTE • The TOS5050A only has the AC test mode. It has no DC test mode message. • When you change the modes with the TEST VOLTAGE switch, the message blinks to indicate that the modes have been changed.
  • Page 49 AC mode test Upper cutoff current range Lower cutoff current range TOS5051A 0.1 mA to 110 mA to 110 mA, OFF TOS5050A Model DC mode test Upper cutoff current range Lower cutoff current range 0.1 mA to 11 mA TOS5051A...
  • Page 50 [23] UPPER message This message indicates that the ammeter is displaying the upper cutoff current. Switchover between the upper and lower cutoff currents can be done with the UP/ LOW key when the tester is in the READY status (“READY” is lit) and the “KEY- LOCK”...
  • Page 51 2. Setting ranges, resolutions, and display formats Setting range Basic resolution Display format 0.5 s to 99.9 s, OFF 0.1 s XX.X 100 s to 999 s, OFF [27] TIMER ON message This message indicates that the TIMER function is ON. If the tester is in the TIMER-ON status (“TIMER ON”...
  • Page 52 [32] PROTECTION message This message (yellow) appears when the tester has tripped into the PROTECTION status and its output voltage is cut off, due to any of the causes as mentioned below. To clear the PROTECTION status, eliminate the cause of the trip and then press the STOP switch.

  • Page 53: Description Of Rear Panel Items

    120V AC LINE 50 60Hz 220V 230V 800VA MAX KIKUSUI ELECTRONICS CORP. 240V MADE IN JAPAN [35] Protective conductor terminal This terminal is for grounding the tester to an earth ground. For your safety, be sure to ground the tester. For a description of the grounding method, see section 2.6, “Grounding (Earth)”...
  • Page 54 [38] TEST MODE switches The TEST MODE switches allows you to select the four test modes below. Before changing the settings of these switches, be sure to turn the POWER switch OFF. DOUBLE ACTION mode PASS HOLD mode MOMENTARY mode FAIL mode For details, refer to section 6.5, “Settings for Special Test Modes”...

  • Page 55: Chapter 5 Preparative Test Procedures

    Chapter 5 Preparative Test Procedures This chapter describes the preparative procedures for test. TOS5051A/5050A...

  • Page 56: Initial Setup

    ■ Be sure to read Chapter 3 “Handling Precautions” and observe the instructions given there. Initial Setup Table 5-1 shows the initial setup (factory default setup) of the switches and knobs on the panels. Table5-1 Factory default setup of switches and knobs Item Setting POWER switch...
  • Page 57 REMOTE Version number Model No. Three LSD TOS5051A TOS5050A The initial test setup data will appear on the screen. If nothing appears on the fluorescent display after one minute elapses, redo the procedure from the beginning. CAUTION • Note that, if you initialize the test data using the above procedure, all test data that existed when you turned OFF the power of the tester last time is lost.

  • Page 58: Checking The Tester Operation

    FAIL LOWER ON TIMER ON UPPER KEYLOCK LOWER REMOTE Version number Model No. Three LSD TOS5051A TOS5050A After a few more seconds, the initial test setup data will appear. Lights up PASS PROTECTION TEST RANGE READY UPPER LOWER VOLTAGE CURRENT...
  • Page 59 Check that the PROTECTION status (“PROTECTION” is lit) is enabled by the interlock function. NOTE • Do not let the TEST VOLTAGE switch 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”...

  • Page 60: Checking The Tester Before Starting Test Operation

    Checking the Tester before Starting Test Operation Before starting test operation with the tester, check and adjust certain items of the tester as specified below. 1. Zero adjustment of the analog voltmeter Before turning ON the POWER switch, check that the pointer of the analog voltme- ter indicates the “0”...

  • Page 61: Chapter 6 Test Procedures

    Chapter 6 Test Procedures This chapter describes the procedures for individual types of withstanding voltage tests. TOS5051A/5050A...

  • Page 62: Ac Withstanding Voltage Test Procedure

    AC Withstanding Voltage Test Procedure Set the required test parameters to test your DUT. The ranges of test parameters available are as follows: Criterion for upper Criterion for lower Test voltage Test time cutoff current cutoff current 0 kV to 5 kV 0.1 mA to 110 mA 0.1 mA to 110 mA, OFF 0.5 s to 999 s, OFF...

  • Page 63: Setting The Lower Cutoff Current

    Setup procedure Select the upper cutoff current setting mode with the UP/LOW key. The “UPPER” message will appear and the preset upper limit current will be indicated on the CURRENT readout. Adjust the preset upper cutoff current value as required, with the key.
  • Page 64 Setup procedure Select the lower cutoff current setting mode with the UP/LOW key. The “LOWER” message will appear, and the preset lower limit current will be indicated on the CURRENT readout. Adjust the preset lower cutoff current value as required, with the key.

  • Page 65: Setting The Test Time

    6.1.4 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 elapses without any FAIL judgment, the tester terminates the test and gives a PASS judgment.

  • Page 66: Setting The Test Voltage

    6.1.5 Setting the Test Voltage This procedure is to set the test voltage (output voltage of the tester) to be applied to the DUT. NOTE • To get the stable test voltage (output voltage), the tester should be connected to the stable AC power supply.

  • Page 67: Executing A Test

    6.1.7 Executing a Test This procedure is to execute a test. Test condition setup example Test voltage range 5 kVAC NOTE • You can set the test voltage Test voltage 1.2 kV only by actually outputting Upper cutoff current 10 mA the voltage.
  • Page 68 If the test result is PASS When the preset test time elapses, the tester will make a PASS judgment. If the test result is a PASS, the following actions will take place. ♦ The tester terminates the test and cuts off the test voltage. ♦...
  • Page 69 If the timer is set to OFF If the timer function is OFF and the “TIMER ON” message is OFF, the test does not terminate automatically. You must manually stop the test by pressing the STOP switch. In this case the tester does not make the PASS judgment and the following actions will take place.
  • Page 70 The following actions will take place. ♦ The tester terminates the test and cuts off the test voltage. ♦ The “TEST” message disappears. ♦ The TEST signal of the SIGNAL I/O connector is turned OFF. ♦ The DANGER lamp turns OFF. (It does not go out as long as a residual test voltage remains in the output circuit.) ♦...

  • Page 71: Dc Withstanding Voltage Test Procedure (Tos5051A Only)

    DC Withstanding Voltage Test Procedure (TOS5051A Only) Set the required test parameters to test your DUTs. The ranges of test parameters available with the tester are as follows: Criterion for upper Criterion for lower Test voltage Test time cutoff current cutoff current 0 kV to 5 kV 0.1 mA to 11 mA...

  • Page 72: Setting The Upper Cutoff Current

    6.2.2 Setting the Upper Cutoff Current This procedure sets the upper cutoff current, the criterion for pass/fail judgment on the DUT. If the leak current is larger than this limit, the DUT is judged to be FAIL. • Test time and pause period are limited by setting upper cutoff current. “ON 15s” NOTE of the front panel character shows a maximum test time and “OFF 150s”...

  • Page 73: Setting The Lower Cutoff Current

    6.2.3 Setting the Lower Cutoff Current This procedure is to set the lower cutoff current, the criterion for pass/fail judgment on the DUT. If the leak current that flows through the DUT is less than this limit, the DUT is judged to be FAIL. If dispersion of leak currents of DUTs is within a predictable range and their lowest values are within the range detectable with the tester, you may set the low cutoff cur- rent at a value slightly less than the lowest leak currents.

  • Page 74: Setting The Test Time

    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 elapses without any FAIL judgment events, the tester terminates the test and gives a PASS judgment.

  • Page 75: Setting The Test Voltage

    6.2.5 Setting the Test Voltage This procedure is to set the test voltage (output voltage of the tester) to be applied to the DUT. Setup procedure Turn OFF the lower pass/fail judgment function by pressing the UP/ LOW key while holding down the SHIFT key. The “LOWER ON”...

  • Page 76: Executing A Test

    6.2.7 Executing a Test Given the following test conditions: Test condition setup example Test voltage range 5 kVDC NOTE • You can set the test voltage Test voltage only by actually outputting Upper cutoff current 1 mA the voltage. See section 6.2.5, “Setting the Lower pass/fail Test Voltage”...
  • Page 77 If the test result is PASS When the preset test time elapses, the tester will make a PASS judgment. When the test result is a PASS, the following actions will take place. ♦ The tester terminates the test and cuts off the test voltage. ♦...
  • Page 78 If the timer functions is set to OFF If the timer function is OFF and the “TIMER ON” message is OFF, the test does not terminate automatically. You must manually stop the test by pressing the STOP switch. In this case the tester makes no PASS judgment and the following actions will take place.
  • Page 79 The following actions will take place. ♦ The tester terminates the test and cuts off the test voltage. ♦ The “TEST” message disappears. ♦ The TEST signal of the SIGNAL I/O connector is turned OFF. ♦ The DANGER lamp turns OFF. (It does not go out as long as a residual test voltage remains in the output circuit.) ♦...

  • Page 80: Remote Control

    Remote Control WARNING • Be extremely careful when operating the tester in the remote control mode in which the dangerous high test voltage is ON/OFF-controlled remotely. Provide means to assure that the tester does not enter the TEST-ON state (state that the test voltage is being delivered) by inadvertent operation. Provide means to assure that none can touch the DUT, test leads, probes, output terminals and their vicinities when in the TEST-ON state.

  • Page 81: Remote Control Through The Signal I/O Connector

    NOTE • If you remove the REMOTE connector while the POWER switch is turned ON, the tester enters the PROTECTION status (“PROTECTION” is lit), and the high voltage output is shut down. However, if the forced stop function of the optional remote control box is ON, the PROTECTION status is released when the plug is inserted.
  • Page 82 SIGNAL I/O Specifications Table6-1 Specifications of the SIGNAL I/O Signals Item Specifications READY Input signal control section L FAIL U FAIL High-level input voltage 11 V to 15 V PASS Low-level input voltage 0 V to 4 V TEST H. V ON Low-level input current -5 mA maximum INTERLOCK+...
  • Page 83 Internal construction The signal output on the SIGNAL I/O connector is an open-collector output (see the figure), and is isolated from the internal circuit by photocouplers. However, the cir- cuit common is shared with the input signal. 1 INTERLOCK+ 2 H. V ON 3 TEST 4 PASS 5 U FAIL...

  • Page 84: Interlock Function

    14 13 12 11 10 – 5.6 V INTERLOCK Door switch TOS5050A/5051A internal circuit Fig. 6-3 Circuit diagram of the interlock input section WARNING • If you turn on the power to the tester simply after taking the tester out from the box, the interlock function will be activated and the tester will not start operating.

  • Page 85: Start/Stop Control

    6.3.4 Start/Stop Control Pins 10, 11, and 12 of the SIGNAL I/O connector are used to remotely control start/ stop. Control procedure Set pin 12, the remote control enable signal (RR ENABLE), to low level by shorting the pin to pin 13 or 14 (ISOL COM). This disables the START switch on the panel.
  • Page 86 tester to that of the external device. (Do not connect the ISOL COM pins to the shielding line or an earth ground.) This will isolate the SIGNAL I/O circuits from the external environments and will become more resistant against noise. DESCRIPTION •...

  • Page 87: Output Signal

    6.3.5 Output Signal The tester status can be output from pins 2 to 8 of the SIGNAL I/O connector. Con- struct the circuit by referring to the pin assignments given in Table 6-2 and the example shown below. When driving the relay Drive the relay with the H.V ON signal.

  • Page 88: Status Out

    STATUS OUT This is a 100 VAC output with which to drive the optional warning light unit or the buzzer unit. The 100 VAC output is delivered when the corresponding status has occurred if one of the DIP switches is set to ON. If two or more switches are set to ON, the status signal is delivered on the logical sum of the corresponding statuses.

  • Page 89: Settings For Special Test Modes

    Settings for Special Test Modes The TEST MODE switch on the rear panel can be used to set four types of modes. Four special test modes are selectable with the DIP switches. The factory-default settings of DOUBLE ACTION PASS HOLD these switches as the tester is shipped from the MOMENTARY factory are as shown on the right.

  • Page 90: Momentary Switch

    6.5.3 MOMENTARY Switch If you set this switch to ON, the test is executed only during the period you keep pressed the START switch. As you release the switch, the test terminates. Thus, the safety of test is enhanced. This function is applicable also when in the remote control mode.

  • Page 91: Chapter 7 Rs-232C Interface

    Chapter 7 RS-232C Interface This chapter describes the RS-232C interface. TOS5051A/5050A...

  • Page 92: Connecting The Cable

    Connecting the Cable Turn OFF the POWER switch on the tester and the device to be con- nected. Connect a cross RS-232C cable to the 9-pin RS-232C connector on the rear panel of the tester. Fig. 7-1 shows the connector pin assignments. 1: CD (carrier detect) 2: RXD (receive data) 3: TXD (transmit data)

  • Page 93: Communication Method

    Communication Method Communication is performed using commands from the PC and responses from the tester. One response is always returned for one command. Commands cannot be sent continuously. Confirm the response before sending the next command. Talk Mode The RS-232C on the tester has four talk modes. Table 7-2 Talk modes Talk mode...
  • Page 94 Print samples on the serial printer Talk mode 1 Talk mode 2 Talk mode 3 Setting the talk mode Set the talk mode according to the procedure below. Check that the POWER switch is turned OFF. Turn ON the POWER switch while holding down the key indicated in Table 7-3 according to the desired talk mode.

  • Page 95: Before Using The Rs-232C

    REMOTE Version number Model name 3-digit display TOS5051A TOS5050A If nothing appears on the fluorescent display after one minute elapses, redo the procedure from the beginning. Check that the talk mode number specified in step 2 is displayed. NOTE • If you carry out initial setup of the data, the talk mode is set to 0. For details, see section 5.1, “Initial Setup”...
  • Page 96 Releasing the PROTECTION status • The PROTECTION status cannot be released using the STOP command. For a description on releasing the PROTECTION status, see , “3. Tester not in PRO- TECTION status” on Page 5-6 . Test start operation and REMOTE message •...

  • Page 97: Rs-232C Commands And Responses

    The command inside the parentheses is the abbreviated form of the command. *IDN? Queries the model name and ROM version of the tester. Response Returned as in the example below. Comma separator KIKUSUI ELECTRONICS CORP.,TOS5051A,0,1.00 Company name Model name Version number Not used Fig. 7-2 Response example of *IDN? *RST Resets the tester (the talk mode is set to default (0) in this version).
  • Page 98 MODE? Queries the timer setting, the lower cutoff current setting, the voltage mode setting, and the voltage range setting. Response Returned as in the example below. TIMEON,LOWEON,VOLTAC,RANG2.5 TIMEOFF,LOWEOFF,VOLTDC,RANG5.0 MEASURE? (MEAS?) Queries the measured value of the tester. Response The response varies when the test is in progress and when it is not. •...
  • Page 99 TMODE? (TMOD?) Queries the test mode setting. Response Returns any of the following: TMODE0, TMODE1, TMODE2, or TMODE3 REMOTE Enables the START command through the RS-232C.(RS-232C REMOTE mode) The “REMOTE” message on the panel lights. Response Returns OK. NOTE • 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”...

  • Page 100: Sample Program

    TextBox1.Text = KiUniDrv1.GetString Cells(2, 5) = TextBox1.Text KiUniDrv1.SetString "LOCAL" TextBox2.Text = KiUniDrv1.GetString KiUniDrv1.Disconnect End Sub The sample program is created using the following tools. • Kikusui Universal Instrument Driver V1.5 • Microsoft Visual Basic 6.0 • Microsoft (R) Excel 2000 7-10 TOS5051A/5050A...

  • Page 101: Chapter 8 Operating Principle

    Chapter 8 Operating Principle This chapter describes the operating principle of the tester. TOS5051A/5050A...

  • Page 102: Block Diagrams

    Block Diagrams AC line Voltage Relay regulator transformer Output terminal Current Control circuit detector START STOP TOS5050A Power supply DC/DC converter AC/DC switching Discharge circuit circuit AC line Voltage Relay regulator transformeter Output terminal Current Control circuit detector START STOP TOS5051A Fig.
  • Page 103 Current detector The current detector measures the leakage current. It consists of an absolute-value circuit, current detecting resistors, and an integrating circuit. Control circuit The circuit controls overall operation of the tester, including voltage measurement, current measurement, pass/fail judgment, test time management, and test sequence control.

  • Page 104: Zero-Turn-On Switch

    Zero-turn-on Switch If a regular mechanical contact type relay is used for on-off control operation of the primary circuit of the high voltage transformer, transient spike voltages may be pro- duced, thereby applying an abnormal high voltage to the DUT and causing a possi- bility of rejecting an acceptable DUT or damaging it.

  • Page 105: Delay Time For Pass/Fail Judgment In Dc Mode

    Delay Time for Pass/Fail Judgment in DC Mode When testing in the DC mode a DUT which has a larger capacitance, the DUT will draw a larger initial charge current. Lest the pass/fail judgment should be affected by this current, a delay time is rendered before making the pass/fail judgment. The delay time is set at approximately 0.3 seconds.
  • Page 106 TOS5051A/5050A...

  • Page 107: Chapter 9 Maintenance

    Chapter 9 Maintenance This chapter describes the maintenance procedures for the tester. TOS5051A/5050A...

  • Page 108: Cleaning

    Periodic calibration is required to maintain the accuracy of the tester over extended time. To have your tester calibrated, contact Kikusui distributor/agent. Cleaning When the panels of the tester has become dirty, clean them by wiping them with a soft cloth moistened with neutral soapsuds.

  • Page 109: Maintenance

    Maintenance WARNING • The cover must be opened to replace parts. Let Kikusui service personnel take care of all replacements. If replacements are necessary, contact Kikusui distributor/agent. High voltage relay The high voltage relay of the internal discharge circuit (TOS5051A only) is a con- sumable component.
  • Page 110 TOS5051A/5050A...

  • Page 111: Chapter 10 Specifications

    Chapter 10 Specifications This chapter describes the electrical and mechanical specifications of the tester. TOS5051A/5050A 10-1...

  • Page 112: 10.1 Basic Performance

    10.1 Basic Performance Item TOS5050A TOS5051A Test voltage Applied voltage AC/DC 0 kV to 2.5 kV/0 kV to 5 kV 0 kV to 2.5 kV/0 kV to 5 kV 500 VA/5 kV, 100 mA Output rating (with nominal line voltage)
  • Page 113 TOS5050A/TOS5051A Ambient temperature Upper cutoff current Maximum allowable Pause period t (°C) I (mA) continuous test period t ≤ 40 °C 50 < I ≤ 110 Not less than test period ≤ 30 min I ≤ 50 Not required Continuous When the nominal power supply voltage can be maintained with the output shorted.
  • Page 114 Item TOS5050A TOS5051A Pass/fail judgment Type of judgment • Window comparator type • 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 FAIL judgment.

  • Page 115: 10.2 Interface And Other Functions

    10.2 Interface and Other Functions Item TOS5050A/TOS5051A Remote control function The tester has the following functions for remote-control of test start/stop. REMOTE connector • To control the tester from an optional (5-pin DIN connector on Remote control box RC01-TOS or RC02-TOS.
  • Page 116 Signal Output Signal Name Conditions for Signal Generation Description During the test time (period the tester delivers H.V ON Open-collector signal , DANGER lamp the test voltage) Open-collector signal TEST During the test Vacuum Fluorescent Display For PASS judgment. Delivered for approxi- Open-collector signal PASS mately 0.2 s.

  • Page 117: General Specifications

    10.3 General Specifications Item TOS5050A TOS5051A Environment Spec assured temperature and 5 °C to 35 °C (41 °F to 95 °F), 20 % to 80 % RH humidity Operable temperature and humidity 0 °C to 40 °C (32 °F to 104 °F), 20 % to 80 % RH Storage temperature and humidity -20 °C to 70 °C (-4 °F to 158 °F), 80 % RH or less...

  • Page 118: 10.4 Outline Drawing

    High voltage test leads 1 set (5 kV or less: TL01-TOS (1.5 m) 14-pin Amphenol plug Assembly type “HIGH VOLTAGE DANGER” sticker Operation manual 10.4 Outline Drawing MAX30 300±3 (11.81±0.12) (1.18) MAX365 (14.37) Unit: mm (inch) Fig.10-1 TOS5050A/TOS5051A outline drawing 10-8 TOS5051A/5050A...

  • Page 119: Index

    Index AC power supply 2-5 initial setup 5-2 AC/DC test mode message 4-14 input range, allowable 2-4 accessories 2-2 input voltage range 2-5 alligator clip 3-4 installation location 2-3 ammeter 4-15 insulation gloves 3-2 analog voltmeter 4-8 interlock function 6-24 analog voltmeter, zero adjustment of 4-8 KEYLOCK message 4-18 BUZZER 4-12...
  • Page 120 READY message 4-17 REMOTE connector 4-6 6-20 remote control 6-20 remote control box 1-5 REMOTE message 4-18 RS-232C connector 4-20 SHIFT key 4-12 SIGNAL I/O connector 4-19 6-21 START switch 4-4 STATUS OUT 4-20 6-28 STOP switch 4-4 talk mode 7-3 test lead 3-4 TEST message 4-17 TEST MODE switches 4-20...

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