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TOS5200 User`s Manual - Kikusui Electronics Corp.

1. Basic item Test voltage Voltage SET key rotary knob Limit voltage LIMIT LIMIT SHIFT SET key rotary knob Upper limit UPPER UPR LWR key rotary knob Lower limit LOWER UPR LWR key rotary knob on off ON OFF SHIFT UPR LWR key Test time TEST TEST key rotary knob on off ON OFF SHIFT TEST key Voltage rise time RISE TEST key rotary knob Additional items Test voltage frequency Frequency MORE key rotary knob Start voltage Start Voltage MORE key rotary knob Voltage fall time Fall Time MORE key rotary knob Voltage current measurement mode Measurement MORE key rotary knob Test conditions basic items Test voltage Voltage For details on how to select settings and enter values see Panel Operation Basics SET unn TEST MORE De ONOFF ONOFF KEY LOCK LOCAL For details on how to connect the TOS5200 to the DUT see Connecting to the Device under Test DUT For details on the LOWER and UPPER settings see also About Judgment Sets the test voltage You cannot specify a voltage that is greater than or equal to the limit voltage Test voltage 0 00 kV to 5 50 kV Limit voltage LIMIT Sets the limit voltage This prevents an unnecessarily high voltage from being applied to the DUT because of incorrect operations of the TOS5200
2. Internal construction signal The input signal circuit and the output signal circuit share the amp Output signal 1 same common Output The input signals are pulled up to controller Output signal 2 15 V If the input terminals are opened the input signal circuit is 15 V put into the same state as when a high level signal is applied O Input signal 1 Input signal controller 15 V O Input signal 2 P gt 4 COM Internal construction of the SIGNAL H O connector Input signal usage example ee S1 COM C COM Using a make contact to control input Use a make contact such as a relay or switch to set the input ter minal to low level Using a logic element to control input Use a logic element such as a transistor in place of the switch in the above example Design the circuit so that a transistor collector current ic of 5 mA or greater flows Output signal usage example A m 400 mA or less COM Driving a relay Relay Use the output signal to drive a relay To improve the safety of the circuit we recom L mend that you insert a protection fuse or connect T30 Vor a diode less 56 TOS5200 Starting a Test T30 V or Low level during signal less COM generation Obtaining a low level digital signal R Use the output signal to obtain a low leve
3. PART NO 18027963 9 KIKUSUI n 2 5 User s Manual Withstanding Voltage Tester TOS5200 FMA MAA DANGER This product generates high voltage Improper operation can lead to serious accidents o To prevent accidents be sure to read the section Safety Precautions during Testing in this manual o Keep this manual close to the product so that the operators can read the manual at any time O Search by Topic 8 Component Names 10 General Description 13 Product Overview 14 Options 16 Installation and Preparation 19 Connecting the Power Cord 20 Using the Protection Cover 21 Turning the Power On 22 Connecting to the Device under Test DUT 24 Safety Precautions for Testing 27 Pre Test Inspection 28 Testing Precautions 28 Remote Control Precautions 29 Interrupting Testing or Operations 29 Emergency Measures 29 Forbidden Actions 30 About Malfunctions 30 To Use the Product for a Long Time Free of Malfunctions 30 Panel Operation Basics 31 Parts of the Screen 32 Panel Operations 34 Panel Memory 37 Withstanding Voltage Test 39 About Judgment 40 Invalid Settings 40 Setting Test Conditions 41 CONFIG Settings 44 Starting a Test 48 Finishing a Test 51 External Control 53 SIGNAL I O Connector 54 Starting a Test 57 Recalling Panel Memory and Test Modes 57 Interlock Feature 58 STATUS OUT connector 59 Maintenance 61 Pre T
4. Tests are only executed while the START switch is held down Fail mode feature This feature enables you to prevent remotely transmitted stop signals from clearing FAIL judgments and PROTECTION modes Timer feature The test ends when the specified time elapses Output voltage monitor feature Volt Error If output voltage exceeds setting 350 V or is lower than setting 350 V the TOS5200 switches to PROTECTION mode output is turned off and testing finishes Memory Up to three sets of test conditions can be saved to memory Key lock Protection functions Locks panel key operations settings and changes Under any of the following conditions the TOS5200 switches to the PROTECTION state immediately turns output off and stops testing PROTECTION on the screen lights Interlock Protection An interlock signal has been detected Power Supply Protection An error was detected in the power supply Volt Error Protection While monitoring the output voltage a voltage outside of the rated limits was detected Withstanding voltage test 350 V Over Load Protection While monitoring the output power power exceeding the output power limit was detected Withstanding voltage test 550 VA Over Heat Protection The internal temperature of the TOS5200 became too high Over Rating Protection The output current was generated for a length of time that exceeds the reg
5. VOT vd PROTECTION de m l Counts up the l voltage rise time 48 TOS5200 Starting a Test If the start voltage has been turned off and the voltage rise time has not been set After 0 1 seconds the TEST LED lights in red and the test starts If the test time has been set or if the test time has been turned off 41 42 The TEST LED lights in red during testing If the test time has been turned on the display ened Pel x Bs counts down from the set test time If it is set to OFF the display counts up the test time The time display after you start testing differs depending on I5 ni Nn 15 1 whether TIMER is set L LI Tu LILI I mA l to ON or OFF TIMER ON The timer s remaining test time is counted down TIMER OFF The elapsed test time is counted up When the test time exceeds 999 seconds 999 blinks To change the voltage setting during a test While the TEST LED is lit in red press SET to select the voltage setting value and then use the rotary knob to change the value The voltage is changed immediately The changed voltage is immediately applied to the test but the voltage value on the display shows the measured value After the test finishes when the TOS5200 returns to the READY state the new voltage value is shown on the display If you cannot start testing In the following conditions you will not be able to start testing The READY LED will not light e The memory number is not fi
6. Input time width 5 ms minimum 1 INTERLOCK If you open the positive and negative terminals the output is turned off and the TOS5200 is switched to Protection mode Open If the resistance between the terminals is 1 2 KQ or greater Short If the resistance between the terminals is 1 KQ or less 2 PMO Panel memory selection signal The selection signal is latched PMO PM1 Recalled panel memory number on the rising edge of the input H H Memory 1 Sep strobe signal to recall panel L H Memory 2 memory H L Memory 3 The selection of memory is pri L L oritized over TEST SEL and AUTO SEL 4 NC 5 NC 6 NC 7 NC 8 NC 9 STB Panel memory strobe signal input terminal 10 TEST SEL NA 11 AUTO SEL NA 12 COM Circuit common terminal 13 INTERLOCK If you open the positive and negative terminals the output is turned off and the TOS5200 is switched to Protection mode Open If the resistance between the terminals is 1 2 KQ or greater Short If the resistance between the terminals is 1 KQ or less 14 HV ON On during testing and when a voltage remains across the output terminals 15 TEST On during testing excluding when voltage is rising or falling 16 PASS On for approximately 0 2 seconds when a PASS judgment occurs On continuously when the PASS HOLD time is set to HOLD 17 U FAIL On continuously when UPPER FAIL results from judgme
7. 2 EN 61000 3 3 Applicable under the following conditions The maximum length of all cabling and wiring connected to the TOS5200 is less than 2 5 m Shielded cables are being used when using the SIGNAL I O The high voltage test lead TL31 TOS is being used Electrical discharges are not occurring outside the DUT Safety Complies with the requirements of the following directive and stand ards Low Voltage Directive 2006 95 EC EN 61010 1 ed3 Class H Pollution degree 2 Dimensions See Outline drawing Weight Approx 14 kg 30 9 Ib Accessories Power cord 1 pc High voltage test lead TL31 TOS 1 set 1 red wire and 1 black wire each with alligator clips 1 5 m SIGNAL I O plug 1 set assembly type High voltage warning sticker 1 pc Setup Guide 1 pe Quick Reference English 1 pc Japanese 1 pc Safety Information 1 pe CD ROM 1 pe 1 Limited to products that have the CE mark on their panels Does not apply to specially made or modified TOS5200s 2 This product confirms to Class A This product is intended for use in an industrial environment This product may cause interference if used in residential areas Such use must be avoided unless the user takes special measures to reduce electromagnetic emis sions to prevent interference to the reception of radio and television broadcasts 3 This product confirms to Group 1 This product does not generate and or use intentiona
8. FUNCTION ACW TOS5200 Panel Operations Locking panel operations key lock The key lock feature can be used to prevent changes to the test conditions due to incorrect operations To lock the panel operations press KEY LOCK SHIFT MORE In this state only the START and STOP switches are enabled When keys are locked the key lock icon amp appears on the screen If you try to use a locked key the key lock icon 4 blinks for approximately 2 seconds To release the key lock hold down KEY LOCK SHIFT MORE until the key lock icon amp dis appears If you will run tests using conditions that you have recalled from memory we recommend that you use the protection cover Talk mode This feature enables you to control the product in the same manner as remote control without using commands from a PC It can reduce processing on the PC If you turn talk mode on you cannot control the product from a PC To control the product from a PC turn talk mode off For details on talk mode see the communication interface manual TOS5200 See p 73 3 MEMORY 1 2 3 RECALL TOS5200 Panel Memory You can save up to three sets of test conditions the test conditions currently being used to internal memory Test conditions and values that can be saved PROTECTION Test voltage 0 00 kV to 5 50 kV Output freguency 50 Hz 60 Hz Upper l
9. If you will not use the product for some time or if the operator will be away from the product be sure to turn the POWER switch off STOP e e The TEST and DANGER LEDs are both off Emergency Measures There are two actions that you must carry out if due to a malfunction in the product or the DUT there is a possibility of an emergency occurring such as electric shock or damage to the DUT e Turn the POWER switch off e Remove the power cord plug from the outlet Turn the POWER switch off Remove the power plug from the outlet Ge POWER KE E TOS5200 Safety Precautions for 29 30 Forbidden Actions Turning the power on and off repeatedly After you turn the POWER switch off wait for at least 10 seconds before you turn it back on It is dangerous to do otherwise because the protective features of the product may not work effectively This may cause the product to malfunction and it may reduce the life of the POWER switch and internal parts such as the fuses About Malfunctions Z WARNING Risk of electric shock e Until you get the product fixed make sure that nobody can use it e For repairs contact your Kikusui agent or distributor If the TOS5200 is in one of the states explained below it may be malfunctioning in a very dangerous manner it may not be possible to turn off the high voltage that is being gener ated If the tester is not operating properly it may be generating a high voltage
10. Location in the Safety information manual The following precautions pertain only to this product e When installing this product be sure to observe the temper ature and humidity ranges indicated below Operating temperature range 0 C to 40 C 32 F to 104 F Operating humidity range 20 rh to 80 rh no condensation e When storing this product be sure to observe the tempera ture and humidity ranges indicated below Storage temperature range 20 C to 70 C 4 F to 158 F Storage humidity range 90 rh or less no condensation Donotuse the productin a poorly ventilated location The product uses forced air cooling It sucks air through the inlet holes on its right and left panels and then expels air through its rear panel Secure adeguate space around the product s inlet and outlet holes to prevent the possibility of fire caused by accumulation of heat Allow at least 20 cm of space between the inlet and outlet holes on the side and rear panels and the walls or obsta cles Hot air approximately 20 C 68 F hotter than the ambient temperature is expelled from the outlet holes Do not place objects that are affected by heat near the air outlet Left panel inlet ae gt Right panel inlet holes Do not use this product near highly sensitive measuring instruments or receivers Noise generated by this product may affect other devices At a test voltage of 3 kV or greater the product may produce
11. Operations nmmenneeneannaeeaaneneennnnanananeeannnnananaeeaaneneanaaae 3 Safety Precautions ieenennnennanaaanenennnenaaanaaeennananaannananannnanaaaeannnnnanna 4 Precautions Concerning Installation Location emnannneennnenannnae 4 Notations Used in This Manual nemenenenanneeneeananannenenannanneeanannnenee 4 SEACH 4 0 41 K9 0 35 AA AAA 8 Component NAMES iis 53370010 anise e M LLU pa kak EM ALS ni ll ede V hk ah aa m AAA os 10 General Description Product OVO VI OW MA EEGENEN 14 FeaAlurSS issi ska asusin EE Eege AER ENEE SEENEN 14 Options Installation and Preparation Connecting the Power Cord USING The Protection COVER eier T rningthe Power OM sicsscssssscticesassscossectosnstsvsssocesensanusstssonnasnnaiogsesdhaveuonuateiuisssbisvnavedg odaconenaassssenddseshnnsaststesbdtessstavere Checking indicators and the status of the interlock feature s ssssssesreeseeeeee 22 Turning the POWER switch on 23 Turning the POWER switch oft 23 Connecting to the Device under Test DUT 24 Using test lO e EE 24 Using the optional high voltage test probe model HOT A TOS HPOZA TO 26 Disconnecting test leads from the DUT 26 Safety Precautions for Testing Erectestlospeioft tege 28 BK eine PRECAUTIONS MSS AEA 28 Remote Control Precautions EE 29 Interrupting Testing or Operations EE 29 Em
12. TOS5200 When the product is shipped from the factory a protection cover is attached to the front panel This cover prevents unintentional changes to the test conditions Remove this cover when you want to set the test conditions Even when the cover is attached you can still recall settings from memory start and stop tests perform remote operations and control the TOS5200 through its USB port If the tester will be used to repeatedly perform tests with fixed conditions such as when being used as part of a manufacturing line attach the protection cover to ensure safe operation of the tester This is useful in preventing incorrect operation of the tester If the cover is damaged or lost contact your Kikusui agent or distributor E Removing the protection cover Loosen the screw and then pull the hook centered at the bottom of the cover towards you to remove the pro tection cover from the panel E Attaching the protection cover Insert the tabs at the top of the cover into the slots in the panel push the bottom part of the cover until it is attached to the panel and then use the screw to fix the cover in place H Storing the protection cover gt When you want to use the gt TOS5200 without the protection cover attached such as when you Use the screw to fasten i i the cover in place will repeatedly perform tests with xs O frequently changed test condi tions you can store the protection cover on t
13. corona discharge between its test lead clips This will gener ate a significant amount of broadband RF emission To min imize this effect keep the alligator clips away from each other Also keep the alligator clips and test leads away from conducting surfaces especially sharp metal edges Notations Used in This Manual The TOS5200 Withstanding Voltage Tester is also referred to as the TOS5200 Device under test is also referred to as DUT The term PC is used to refer generally to both personal computers and workstations The following markings are used in the explanations in this manual Indicates a potentially hazardous situation which if ignored could result in death or serious injury N CAUTION Indicates a potentially hazardous situation which if ignored may result in damage to the product or other property NOTE Indicates information that you should know DESCRIPTION Explanation of terminology or operation principle See Indicates a reference to detailed information SHIFT key name blue letters Indicates an operation that requires you to press a key indicated in blue letters while holding down SHIFT Memo Indicates useful information TOS5200 Contents TOS5200 About the Manuals sic ssvcvvetestieeetesdeceeeetie NEEN EENS NEEN 2 Checking the Package Content c ccccseeeeseseeceeeeeeeeeeeceeeeeesaaeeeeneteeseaeeeseneeetas 2 Notes to the supervisor ek 3 Dangerous
14. if you let go of the probe Thus you can definitely check the status Withstanding Voltage Test off 0 The fail mode feature is turned off factory default setting on 1 The fail mode feature is turned on Judgment result hold time Pass Hold This feature enables you to set the length of time that the TOS5200 maintains a PASS judg ment state If you set Pass Hold to HOLD the measured results remain displayed on the screen until you press STOP When a FAIL judgment occurs the FAIL judgment s measured results remain displayed on the screen until you press STOP regardless of the value of the Pass Hold setting 50 ms 0 to 5 5 s 5 0 50 ms factory default setting 1 100 ms 2 200 ms 3 15 4 25 5 55 HOLD 6 The results are maintained until you press STOP Buzzer volume level for PASS judgment PASS You can setthe volume level of the buzzer that is sounded when a PASS judgment occurs 0to9 0 1 2 3 factory default setting 4 5 6 7 8 9 TOS5200 eoooe A QO CONFIG Settings Buzzer volume level for FAIL judgment FAIL You can set the volume level of the buzzer that is sounded when a FAIL judgment occurs 0to9 0 1 2 3 4 5 factory default setting 6 7 8 9 RS232C baudrate You can setthe baud rate for the RS232C interface 9600 0 to 115200 4 0 9600 factory default setting 1 19200 2 38400 3 57600 4 115200 Talk mode This featu
15. power cord and all cables are correctly connected Press the side of the front panel POWER switch to turn the TOS5200 on Check that all the front panel indicators light The firmware version screen will be displayed for a few seconds and then a message indicating that the TOS5200 is in PROTECTION mode will be displayed Check that the tester is in PROTECTION mode through the interlock feature 2 Check that nothing is connected to the SIGNAL I O connector Firmware version screen Interlock protection mode 4 Press the O side of the front panel POWER switch to turn the TOS5200 off TOS5200 Turning the Power On Turning the POWER switch on See p 72 1 Connect the included SIGNAL I O plug to the SIGNAL I O connector Connecting the SIGNAL I O plug will release the interlock feature 2 Press the side of the POWER switch to turn the TOS5200 on 3 Check the firmware version Ver x xx that is displayed on the screen Check that the firmware version screen is displayed for a few seconds that the setup screen for setting the withstanding voltage test conditions is displayed thereafter and that the tester is then in READY mode that the READY LED lights _ PROTECTION Firmware version 1 00 display example The first time that the POWER switch is turned on the firmware version is displayed and then the setup screen for setting the withstanding voltage test conditions is displayed with the factory
16. settings If the remedy does not correct the problem contact your Kikusui agent or distributor The power does not turn on Symptom Items to check and possible remedy See The TOS5200 does not operate when Is the power cord disconnected p 20 the POWER switch is turned on Has the interlock feature been activated p 22 Release the interlock feature p 58 Unable to carry out panel operations Symptom Items to check and possible remedy Testing does not begin when the Is a probe connected to the REMOTE connector START switch is pressed When a probe is connected only the probe s START switch is enabled Is a STOP signal being applied to the SIGNAL I O connector When you are using the SIGNAL I O connector to control the TOS5200 the p 57 START switch on the panel is disabled Is the TEST LED blinking The TOS5200 is in the middle of the voltage rise time The test will begin when p 48 the rise time elapses p 26 If a PROTECTION message is displayed on the screen The TOS5200 is in PROTECTION mode See Protection Functions p Is the double action feature on Press STOP and then press START within 0 5 seconds of pressing STOP p 45 Alternatively turn the double action feature off 74 You cannot start tests while panel memory is being accessed p 37 Is a message displayed on the screen 40 A setting is invalid Specify settings that are within the correct range P Panel oper
17. 0 5 seconds If you do not press START within this time limit the test does not start the READY LED turns off This feature ensures that tests are started safely because it requires you to use both the STOP and START switches off 0 The double action feature is turned off factory default setting on 1 The double action feature is turned on Momentary feature This feature enables you to perform tests only while you are pressing START This ensures safe testing because it means that your hand must be fixed to the panel or to an optional RC01 TOS START switch While this feature is on testing stops as soon as you release START The stop operation is the same as if you had pressed STOP Using this feature with the optional RC02 TOS two hand type remote control box See p 16 CR provides an even higher level of safety off 0 The momentary feature is turned off factory default setting on 1 The momentary feature is turned on Fail mode feature This feature prevents FAIL judgments and protection modes from being cleared even when a stop signal is sent with a command To clear the FAIL judgment when the fail mode feature is turned on press STOP on the front panel If you are using the optional high voltage test probe HP01A TOS HP02A TOS Seep 17 we recommend that you turn on the fail mode feature When a test ends with a FAIL judgment or ends in protection mode the FAIL judgment is not cleared even
18. 1 TOS RC02 TOS remote control box The remote control box can be used to start and stop withstanding voltage test One model is for use with one hand and the other model is for use with two hands RC01 TOS one hand RC02 TOS two hands Model DD 5P 9P remote control adapter cable This is an adapter cable for connecting the product to a remote control box 16 TOS5200 Options Model HP01A TOS HP02A TOS high voltage test probe This is a probe for generating the test voltage To prevent the test voltage from being generated unintentionally this probe has been designed so that the test voltage is only generated when the user operates the probe with both hands When using the test probe make sure that the rated voltage is not exceeded Rated voltage AC 4kV DC 5 kV Model PL02 TOS warning light unit The warning light unit indicates that the TOS5200 is performing a test This enables you to see that a testis in progress from a dis tance TOS5200 General Description E 17 18 This page is intentionally blank TOS5200 Installation and Preparation This chapter describes how to prepare this product for use 20 Connecting the Power Cord Z WARNING e This product conforms to IEC Safety Class equipment that has a protective con ductor terminal Be sure to earth ground the product to prevent electric shock e The product is grounded through the power cord ground wire Con
19. 18 Start voltage on and off OFF Voltage rise time Dis Voltage fall time OFF Test voltage frequency 50 Hz Interface setting USB CONFIG settings Test Mode Double Action OFF Pass Hold 50 ms Momentary OFF Fail Mode OFF Buzzer Volume Level Pass 3 Fail 5 Baudrate 9600 Talk Mode OFF Status Signal Output H V ON OFF Test OFF Pass OFF Upper Fail OFF Lower Fail OFF Ready OFF Protection OFF Power ON OFF TOS5200 List of Default Settings Default panel memory values TOS5200 There are three panel memory entries Initially these entries all contain AC withstanding volt age test conditions that comply with safety standards If you initialize the TOS5200 the panel memory entries are also returned to their default val ues Memory number Setting Setting after initialization 1to3 Test mode ACW Output frequency 50 Hz Test voltage 0 00 kV Upper limit 0 02 mA Lower limit OFF Test time 0 1s Start voltage OFF Voltage rise time Dis Voltage fall time OFF 73 74 B Protection Functions If one or more of the causes of the following problems occur the protective circuits will acti vate and you will no longer be able to use the TOS5200 This is referred to as PROTECTION mode When the TOS5200 switches to PROTECTION mode PROTECTION on the screen lights Follow the instructions below to remove the cause of the problem and clear the PROTEC TION mode If the TOS5200 has switched to PROTECTION
20. 47 USB Protection MESA MAA 74 79 80 vV VEISION EE 2 Volt Error Protection mmmmnnenennnneneenna 74 W W COMP 2iiiiissta dadada v ik ke a 32 40 Veure RE 64 TOS5200 KIKUSUI ELECTRONICS CORP 1 1 3 Higashiyamata Tsuzuki ku Yokohama 224 0023 Japan Tel 81 45 593 7570 Fax 81 45 593 7571 Website http www kikusui co jp
21. Limit voltage 0 00 kV to 5 50 kV TOS5200 Withstanding Voltage Test E 41 Setting Test Conditions Upper limit UPPER Sets the upper current limit that is used in judgments If a current that is greater than or equal to the upper limit is measured a U FAIL judgment occurs Upper limit 0 01 mA to 110 mA Lower limit LOWER Sets the lower current limit that is used in judgments While LOWER is on if a current that is less than or equal to the lower limit is measured an L FAIL judgment occurs You can turn on and off the lower limit function using the ON OFF SHIFT UPR LWR key Lower limit 0 01 mA to 110 mA Test time TEST Set the test time The test time begins when the voltage rise time elapses and ends when the specified time elapses You can turn on and off the test time using the ON OFF SHIFT TEST key If the test time is set to off PASS judgment is not performed Press STOP to stop testing Test time 0 1 s to 999s Voltage rise time RISE Separate from the test time you can set the time that the TOS5200 takes to raise the voltage to the test voltage Voltage rise time 0 1 s to 10 0 s Test conditions additional items MORE Press MORE to display the items that are not displayed Start voltage setting 0 off 1 on Frequency setting 0 50 Hz 1 60 Hz 42 TOS5200 Setting Test Conditions A 1 Press MORE to display the More
22. PDF files are included in the accompanying CD ROM You can view the PDF files using Adobe Reader 9 2 or later Every effort has been made to ensure the accuracy of this manual However if you have any questions or find any errors or omissions please contact your Kikusui agent or distributor If you find any misplaced or missing pages in the manuals 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 your Kikusui agent or distributor At that time inform your agent or distributor of the Part No written on the front cover of this manual After you have finished reading this manual store it so that you can use it for reference at any time Firmware versions that this manual covers This manual covers firmware versions 1 0X When contacting us about the product please provide us with Model marked in the top section of the front panel The firmware version see page 23 The serial number marked in the bottom section of the rear panel Trademarks Microsoft Windows and Visual Basic are registered trade marks of Microsoft Corporation in the United States and or other countries All company names and product names used in this manual are trademarks or registered trademarks of their respective companies Copyrights The contents of this manual may not be reproduced in whole or in part without the prior consent of the copyright holder The specif
23. PROTECTION FMS To save press KG Recall while m holding down SHIFT 34 TOS5200 Panel Operations Selecting items To select an item use the SET UPR LWR or TEST key PROTECTION MS SET UPR LWR TEST MORE LIMIT ON OFF ON OFF KEY LOCK LOCAL On the basic setup screen press SET to select the voltage Example Selecting the voltage blinking If the item that you want to select is not displayed press LIMIT SHIFT SET ON OFF SHIFT UPR LWR ON OFF SHIFT TEST or press MORE key On the basic setup screen hold down SHIFT and press SET to select the limit voltage Example Selecting the limit voltage blinking j se nae 1 1 TEST LIMIT 1 wm ON OFF ON OFF KEYLOCK EI LOCAL 1 m l i FAIL Je LU i Ll I EC Panel Operation Basics D SHIFT K When you enter the setup screen for additional test conditions MORE or a CONFIG setup screen the MEMORY 2 and MEMORY 3 keys become left and right movement keys MORE ES MNA MANN LEY LILI Entering values You can set the value of the blinking item by turning the rotary knob Turn the rotary knob to set the value Rotary knob Kai 1 TEST aen r 1 TEST 1T a 1 e he MA s i Lii td If you hold down SHIFT and turn the rotary knob you can change the setting resolution While you hold down SHIFT the values change quickly Rotary knob
24. Test Conditions setup More screen PH Memo a ad 2 Press MEMORY 2 or MEMORY 3 to move to the item that you want to set MEMORY 3 keys to move and then use the rotary knob to set the value between settings Each time you press one of A ee these kts the cursor Press STOP or press a key other than MORE to exit the More Test Conditions setup screen moves to the next setting and return to the basic setup screen After selecting a setting use the rotary knob to set its value Frequency Sets the test voltage frequency 50 Hz 0 The test voltage frequency is set to 50 Hz factory default setting 60 Hz 1 The test voltage frequency is set to 60 Hz Start voltage Start Voltage Separate from the test voltage you can set the start voltage of withstanding voltage tests You can set the start voltage to 50 of the test voltage The output voltage reaches this value approximately 0 1 seconds after the start of testing off 0 The start voltage is not set factory default setting on 1 The start voltage is set to 50 of the test voltage SH TEST LED READY LED lit 1 Off blinking TEST LED lit Output on 0 1s Voltage rise time Voltage fall time Fall Time Separate from the test time you can set the time that the TOS5200 takes to lower the voltage after a withstanding voltage test ends This setting is used only when a PASS judgment occurs off 0 The output voltage is shut off imme
25. Voltage rise time 0 1 sto 10 05 Resolution 0 15 Voltage fall time 0 1 s OFF only enabled when a PASS judgment occurs Test time 0 1 sto 999 s can be turned off TIMER OFF Resolution 0 1 s to 99 9 s 0 1 s 100 s to 999 s 1 s Accuracy 100 ppm 20 ms 2 Q 1 Regarding the output time limits Ka Taking size weight and cost into consideration the heat dissipation capability of the voltage generator that is used for withstanding 2 voltage tests has been designed to be one half that of the rated output Use the TOS5200 within the following limits If you use the Oo product in a manner that exceeds these limits the output section may overheat and the internal protection circuits may be activat 2 ed If this happens stop testing and wait until the TOS5200 returns to its normal temperature dp Ambient temperature Upper limit Pause time Output time t lt 40 C 50 mA lt i lt 110 mA Greater than or equal to the output time 30 min max i lt 50 mA Not necessary Continuous output possible Output time voltage rise time test time voltage fall time 2 Regarding the test voltage waveform Waveform distortions may occur if an DUT whose capacitance is dependent on voltage for example an DUT that consists of ce ramic capacitors is connected as the load However if the test voltage is 1 5 kV the effect of a capacitance of 1000 pF or less can be ignored Because the product s high voltage power supply uses the PWM switching method if t
26. aks Pre Test Inspection e What do I need to keep in mind to use the TOS5200 for a long time without malfunctions gt To Use the Product for a Long Time Free of Malfunctions Component Names Front Panel IKIKUSUI TOS5200 3 OUTPUT RMS AVE CONFIG MORE CAL RMT ei LOWER W COMP FUNCTION VOLTAGE CURRENT TIMER HIGH VOLTAGE CONFIG DANGER A Es CA 5 e EEN pee e E MENON E SET UPR LWR TEST RISE MORE ON PFF KEYLOCN LOCAL 7 8 Testconditions 9 10 11 12 13 1415161718 19 operating unit The protection cover is attached to the TOS5200 when the product is shipped from the factory REMOTE USB g Oo T 20 Loosen the screw and pull this part towards you to remove the cover No Name Function 1 DANGER LED Lights in red when a test is being performed p 48 READY Lights in white when the TOS5200 is ready to perform a test p 48 TEST Lights in red when a test is being performed p 48 2 Status indicators PASS Lights in green when a test passes p 51 FAIL Lights in yellow when a test fails p 51 3 Display Displays the settings measured values and other information p 32 LU e 10 TOS5200 o No Name Function See Press these keys to display the settings that are saved to mem
27. anenennnenneananaa 70 Over Heat Protection immnmnennni 74 Over Load Protection mumereanaa 74 Over Rating Protection 74 P panel MOMONSY 1 isii tiimmvevatteraabkvdva aada t nava uknatv atu ava 73 panel memory saving nnmnenennneee 37 PASS Sue 40 47 PASS Hold WE 45 power cord ET 20 KONEN E E T 47 Power Supply Protection mea 74 power turning ON mminerennaenenananenenennannanaa 22 PIOLEGUONM eege ebe Eege eege 47 PROTECTION mode 74 protection mode parni 74 R rack mount adapter mmnenennnneenannee 16 Ready eege daki E kat Maa TAA ja G Eege 47 Remote Protection mmmnerenenenenananenaa 74 RISE eege ees 32 RISE TIME desen 41 rise time control ssrnennennnaenennaa 32 41 S SIGNAL I O connector mumeneneeanaa 54 SIGNAL I O Protection 74 Start Voltage imeeneneaneeannenaneeanna 43 T talk MOU E 36 TEST eieiei eit Wie ee 47 kost PIODG E Senge ieed deeded apa aie 17 26 tast TPIS erreia tive Miedesatu ves ain chbeccebiesdncnsdouanseindestends 51 tast SEAMING creo ccestsecenicdacetesdacsastcvescneasetneceensaceetsoeneaia 48 troubleshooting mremnnsenanme 76 U EEA EE E E 40 Upper Fall ticceccsetcnscutctedscceadec cdddvate var ahav eka vana taadu
28. angerous Never come close to these parts during testing LS If connections are incomplete the entire DUT may be charged to a high voltage This is dangerous so be sure to connect the DUT correctly Be sure to connect the low voltage test lead black first 1 Check that the POWER switch is off and that the DANGER LED is off KKIKUsUI TOS5200 POWER A OUTPUT Off Off A DANGER Ae d Check that there are no tears or breaks in the test lead insulation p 62 Raise the front panel LOW VOLTAGE terminal s cable lock and then connect the low voltage test lead black E Raise the cable lock 74 AA VA Ray Low voltage test lead black 4 Lower the cable lock to secure the lead in place 24 TOS5200 Connecting to the Device under Test DUT TOS5200 Connect the low voltage test lead black to the DUT Connect the high voltage test lead red to the DUT a 63 071 Connect the high voltage test lead red to the front panel HIGH VOLT AGE terminal 8 Check that the DANGER LED is turned off KIKUSUI TOS5200 OUTPUT Off A DANGER Ae Reducing the effect of noise Noise may be generated if the outputs are shorted or if the DUT insulation is damaged Elec tronic devices in the surrounding area may malfunction due to the effect of this noise To reduce the effect of noise connect a toroidal core or a resisto
29. apses when TIMER is set to ON b If a current greater than or equal to the upper limit U FAIL or less than or equal to the lower limit L FAIL is measured c If you press STOP After a test finishes the DANGER LED turns off and the high voltage output is turned off If a test finishes under condition a or b given above the judgment result is displayed on the screen PROTECTION e zm TEST KS DU fw ELL A Sma ds Measured voltage Measured current Test time If the test time Timer has been set Example Display of a PASS judgment after testing finished After the test time elapses the PASS LED lights in green and the test finishes The PASS LED remains lit in green for the length of time specified by Pass Hold The READY LED then lights in light white and the TOS5200 switches to the READY state READY PROTECTION P m 50Hz For details on how measured values are judged see About Judgment The operations that the TOS5200 performs after testing finishes for each judgment condition are shown below Operation PASS U FAIL L FAIL Display PASS LED lights in green FAIL LED yellow and FAIL LED yellow and Measured value remains UPPER lights LOWER lights displayed for the length of time specified by Pass Hold Buzzer Sounds for 50 ms Sounds until STOP is pressed SIGNAL UO The PASS signal is gener The U FAIL signal is gener The L FAIL signal is gener connector ate
30. ations are not being Is KEY LOCK Er displayed or blinking in the upper right of the screen p 36 registered Release the key lock Is a RMT displayed on the screen The product is being controlled remotely To control the TOS5200 from the panel press the LOCAL key to switch to local mode The TOS5200 does not switch to Was a local lockout LLO command sent through the communication inter local mode even when I press the face LOCAL key Use a communication command to clear LLO command Unable to perform measurements Symptom Items to check and possible remedy The measured values are abnormal Are the test leads connected to the correct terminals 24 Connect the test leads properly p e o 76 TOS5200 o Troubleshooting PROTECTION mode cannot be cleared Symptom Items to check and possible remedy PROTECTION mode cannot be Is an interlock signal being applied 58 cleared even if press STOP and Stop the interlock signal input E EES Is the internal temperature too high Confirm that the internal temperature of the TOS5200 has decreased and then clear the mode Is the REMOTE connector connected properly 11 Check the REMOTE connector P During remote control operation did the USB or RS232C connector become disconnected or are there problems with the connector Check the USB or RS232C connector Unable to use remote control Symptom Items to check and possible remed
31. below Status indicators switch on Status indicators These display the status T UPPER Test condition display Icon area pus AVE LOWER W COMP Data input Display Description READY Lights when the TOS5200 is ready to perform a test TEST Lights when a test is being performed PASS Lights when a test result is success Lights when a test result is fail Lights when a protection function is activated Test condition display This displays test conditions Display Description RMS Lights when the measurement mode is true rms response AVE Lights when the measurement mode is mean value response CONFIG Lights when CONFIG items are displayed MORE Lights when items other than CONFIG items are displayed CAL Lights during calibration RMT Lights when the TOS5200 is being remotely controlled LIMIT Lights when a limit voltage is set 50 Hz Lights when the frequency is 50 Hz 60 Hz Lights when the frequency is 60 Hz UPPER Lights when the ammeter is displaying the upper limit LOWER Lights when the ammeter is displaying the lower limit W COMP Lights during lower limit judgment RISE Lights when the voltage rise time is displayed TEST Lights when the test time is displayed TOS5200 Parts of the Screen TOS5200 Icon area The TOS5200 status is displayed using icons or characters Display icon Status See ep Mod
32. c settings that are shown on the panel what test conditions can be set gt Test conditions additional items gt CONFIG Settings How do use each of the two test leads gt Using test leads p 24 How are measured values judged gt About Judgment want to check that measurements are being performed correctly before start testing gt Pre Test Inspection p 62 How does the TOS5200 display the judgment results gt When a test finishes I want to know more about the interlock feature gt Interlock Feature How can hold the PASS judgment result Judgment result hold time Pass Hold p 45 TOS5200 Operation Maintenance How do I save the present test conditions and use them later gt Panel Memory p 37 How do start tests with a greater level of safety gt Double action feature p 45 How do prevent unintentional key operations from changing the test conditions gt Using the Protection Cover gt Locking panel operations key lock How do control the TOS5200 using external signal input gt SIGNAL I O Connector How do release the interlock feature gt Turing the Power On Troubleshooting See Troubleshooting on page 76 TOS5200 e How do I check that the test leads are not damaged for example that they have no bre
33. d for the length of time ated until the FAIL judgment ated until the FAIL judgment specified by the Pass Hold is cleared setting is cleared 1 The length of time that the buzzer sounds when a PASS judgment occurs is fixed to 50 ms The specified Pass Hold time has no effect Withstanding Voltage Test E 51 52 Finishing a Test To clear judgment results Press STOP to switch the TOS5200 to the READY state the READY LED lights TOS5200 External Control This chapter explains how to use the SIG NAL I O connector to externally start tests and recall panel memory entries and sequence programs SIGNAL I O Connector uN Risk of electric shock Ensure that all devices are off before you connect or discon WARNING nect cables between them AC AUTION Risk of damage to the internal circuitry e Keep the signal wire at least 500 mm away from the high voltage test lead and the DUT Do not short the output voltage circuit e If you use the TOS5200 with incomplete connections burn outs caused by heating may occur when the output is turned on e Do not touch the contacts or attach insulators to them Doing so may reduce the quality of the contacts or cause other problems e Do not short the 24 V of pin 24 to the chassis or the circuit common The SIGNAL I O connector is the D sub 25 pin connector on the rear panel This connector is used to start and stop tests recall panel memory entries and test mod
34. d voltage rise time 15 p 35 p 41 ON OFF key SHIFT key Turns the test time Test Time on and off Communica 16 USB port USB interface connector tion interface manual i LOCAL key Switches between local mode and remote mode SHIFT key Press to access the features that are written in blue Press to select additional test condition settings 18 MORE Key Frequency start voltage voltage fall time and measurement mode SES KEY LOCK key SHIFT key Locks panel key operations settings and changes p 36 19 POWER switch Turns the power on and off O p 22 20 Protection cover Cover designed to prevent incorrect operation of the TOS5200 p 21 1 This indicates an operation that requires you to press a key while holding down SHIFT e e TOS5200 e 11 LI 12 Rear Panel AWARNING S DO NOT REMOVE COVERS NO OPERATOR SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL UNPLUG THE MAINS SUPPLY CORD BEFORE HANDLING AC INPUT THE CORD OR LOAD WIRES IROD SCY 400 240V KURDA IE Wl DUSCHEN 50 60Hz 800VA MAX ARO AAR IS SAL ANE te EAT DIT EHL TCHS ZER t UEL BTEBRISTEROT DDTOTHERSL Ko ce OO STATUS OUT conf STRIP GAUGE AWG 10 His ey OO RS232C SIGNAL I O KIKUSUI ELECTRONICS CORP yo ES A 5 No Name Function 1 Chassis terminal Functional ground terminal 2 AC LINE connector AC inlet p 20 3 Ai
35. default settings The product stores the settings that are in use before it is turned off so the next time that the POWER switch is turned on the TOS5200 starts with these settings Turning the POWER switch off N WARNING TOS5200 Press the O side of the POWER switch to turn the TOS5200 off The panel settings that were in use immediately before the POWER switch was turned off are saved If the POWER switch is turned off immediately after the settings have been changed the last settings may not be stored Risk of electric shock e After you turn the POWER switch off wait at least 10 seconds before you turn the POWER switch back on It is dangerous to do otherwise because the protective fea tures of the product may not work effectively This may cause the product to malfunction and it may reduce the life of the POWER switch and internal parts such as the fuses e Except in an emergency do not turn the POWER switch off while output is being generated Installation and Preparation KIE Connecting to the Device under Test DUT AA WARNING Risk of electric shock During testing while the TEST LED or DANGER LED is lit never touch the HIGH VOLTAGE terminal test leads and DUT Using test leads ZN WARNING Risk ofelectric shock Never come close to this area Parts of the included test leads near the alligator clips during testing protrude from the vinyl insulation when the wires are connected These parts are d
36. diately after a test ends with a PASS judgment factory default setting on 1 The output voltage falls over approximately 0 1 seconds after a test ends with a PASS judgment Measurement mode Measurement Selects the voltage current measurement mode RMS 0 Measurement is performed using true rms response factory default setting AVE 1 Measurement is performed using mean value response The measurement mode on Kikusui TOS9200 series TOS8870A TOS8850 TOS8850A TOS5000 series and TOS5000A series is mean value response NOTE TOS5200 Withstanding Voltage Test Q 44 CONFIG Settings FUNCTION CONFIG settings are provided on the CONFIG screen and CONFIG screen CONFIG 1 CONFIG 2 Double Action Double action feature H V ON Output when there is residual volt age or during testing Momentary Momentary feature Test Output during testing when the test voltage is at the set value Fail Mode Fail mode feature Pass PASS judgment output Pass Hold PASS judgment result hold Upper Fail Output when upper limit judgment time is FAIL Pass Buzzer volume level for PASS Lower Fail Output when lower limit judgment judgment is FAIL Fail Buzzer volume level for FAIL Ready Output when READY is displayed judgment Baudrate RS232C baud rate Protection Output during PROTECTION mode Talk Mode Talk mode Power ON Output when the POWER switch is on 1 Press CONFIG SHIFT FUNCTION to displa
37. displayed and the icon corresponding to the memory num ber is displayed in the icon area The TOS5200 is now set to the recalled test condi tions Example The test conditions that were saved in MEMORY 2 have been recalled If you change the recalled test conditions the memory number disappears Even if you set the test conditions back to the values that are stored in memory the memory number will not reappear TOS5200 Withstanding Voltage Test This chapter explains withstanding voltage test from how to set the test conditions to how to save test results 40 About Judgment The TOS5200 judges whether a test results in PASS L FAIL or U FAIL on the basis of the limits that are set in advance Judgment result Description Display Buzzer PASS When the test time elapses TIMER is 0 sec PASS LED lights in Sounds for onds if the condition lower limit lt meas green 50 ms ured value lt upper limit is true the Measured value judgment result is PASS and the test ends remains displayed for the length of time speci fied by Pass Hold L FAIL If the condition lower limit 2 measured FAIL LED yellow and Sounds value is true the judgment result is LOWER lights until STOP LOWER and the test is immediately is pressed stopped U FAIL If the condition upper limit lt measured FAIL LED yellow and value is true the judgment result is UPPER UPPER lights and the t
38. e power cord is connected to a properly grounded outlet e There is no damage such as tears or breaks in the test lead insulation e When the POWER switch is turned on the DANGER LED and the status indicators light e During testing do not touch the items that are charged to a high voltage the DUT the test leads and the areas near the output terminals e During testing do not turn the POWER switch off except in an emergency Testing Precautions During testing the TEST and DANGER LEDs light When these LEDs are lit the TOS5200 is generating a high voltage During testing be sure to wear rubber gloves for electrical work If obtaining these gloves is difficult contact your Kikusui agent or distributor TT Late e Lit The TEST and DANGER LEDs light A AS The TEST LED lights in red TOS5200 Remote Control Precautions When you are controlling the TOS5200 remotely external signals are used to turn the high voltage on and off To prevent accidents follow the safety measures given below e Make sure that high voltages are not generated unintentionally e Make it impossible to touch the DUT test leads test probes and the areas near the output terminals when high voltages are being generated Interrupting Testing or Operations zer Before you change test conditions or other settings press the STOP switch and then be sure to check the following items to ensure safety
39. el RC01 TOS RC02 TOS remote control box connected p 16 A Keys locked p 36 0068 Recalled memory number or CONFIG setup screen number p 37 Data input area This area is used to enter the test voltage limit voltage upper and lower current limits test time CONFIG values and additional test items The selected item blinks READY PROTECTION P TEST TEST 6 55 The selected item blinking Panel Operation Basics D 33 ee Panel Operations Switching screens On the TOS5200 you need to change the setup screen depending on the item you want to d Memo set erer From the basic setup screen you can switch to the additional test conditions setup screen or POWER switch is turned CONFIG setup screen on is referred to as the basic setup screen To display the setup screen for additional test conditions press MORE To display the CONFIG setup screen press CONFIG SHIFT FUNCTION Press once to show the CONFIG screen and twice to show the CONFIG screen To return to the basic setup screen press STOP Additional test conditions setup screen Basic setup screen MORE RMS READY PROreG TION key GaSe 7 CONFIG SHIFT FUNCTION key CONFIG setup screen CONFIG SHIFT FUNCTION key CONFIG setup screen To return to the basic setup screen press STOP To recall a memory entry press MEMORY 1 MEMORY 2 or MEMORY 3 To save press Recall while holding down SHIFT
40. ergency ET 29 Sales Eu 30 Turning the power on and off repeatedly AAA 30 About Malfunctions ENEE 30 To Use the Product for a Long Time Free of Malfunctions EE 30 Panel Operation Basics Parts Of the Green 32 Panel Operations ESSEN E ud SSS iaaea 34 Switching Screens mernrennnenanenennnennnnnnunanaaennnnannaennneananannenannnannae 34 Selecting JAIL 21 PS AT A 35 Entering VAIWCS ai 35 Locking panel operations key Joch 36 TAK TMOG E 36 Panel MEMORY sssisesscsscsnssscassonaseasioressaaneconsasiszvqsaveoconsusiusbunnasecs senaisspsnshnsa seconsssaistanssdaecdouipeastovnsvasdoredsgnnesnssaaislvgvivescs staies 37 saving ere e E 37 Recalling test CONGITIONS EENEG 38 5 Withstanding Voltage Test lee ee e Tu E 40 Effectiveness of the lower mt 40 Invalid Seting E 40 Setting Test COMAIUOMS saccscascsssnsssssasacancsinnsasbessvosecsnnnansessonteacohnssasestcnduovsnusscegsdotsbaussoveascoduonsansagvencandieisissagneaedoseesisdine 41 Test conditions basic Hemes 41 Test conditions additional eme 42 CONFIG Se tei 1 4 tiiniktvsiv aired E naha aaasta njaa seas ETA i CONFIG 1 settings CONFIG 2 settings Starting CR Tostat Atesten e eea aaa aieastetsasescceuvesdeasteetiny When artest starts sereni a a Main hota i eaea To change the voltage setting during a Test 49 If you cannot Start testingan irinenn 49 Finishing a TSS AAA EMASE ASUTADA 51 eeler 51 Whena test Un EE 51 To clear judgment re
41. es and monitor the status of the TOS5200 Connector on the rear panel XM3B 2522 D sub 25 pin female connector socket M2 6 x 0 45 screws manufactured by OMRON Corporation Compatible connector plug D sub 25 pin male with fix screw M2 6 DO NOT REMOVE COVERS NO OPERATOR SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL SIGNAL I O connector OMRON corporation XM3B 2522 RS2320 SIGNAL Si To avoid malfunctions caused by noise use shielded D sub E 25 pin connectors and a cable that is 2 5 m or less in length For information about how to obtain replacement parts contact your Kikusui agent or distrib utor For information about how to use these components see the OMRON Corporation catalogs Wire and tool that are necessary to make the connection Wire Single wire 0 32 mm AWG28 to 0 65 mm AWG22 in diameter Twisted wire 0 32 mm AWG22 to 0 08 mm AWG28 Wire stripper A wire stripper that matches the wires listed above SIGNAL I O specifications Input signal Output signal Low active control input Open collector output High level input voltage 11Vto15V Output withstanding voltage 30 Vdc Low level input voltage OVto4V Output saturation voltage Approx 1 1 V at 25 C Low level input current 5 mA max Maximum output current 400 mA total Input time width 5 ms minimum 1 Excluding the interlock signal 54 TOS5200 SIGNAL I O Connecto
42. ess STOP 888 SIGNAL I O Protection The SIGNAL I O connector s ENABLE Press STOP signal has changed gE USB Protection During remote control operation the Check the USB connector and then D USB connector was disconnected or press STOP a defect was detected If you cannot clear the PROTECTION mode even after you have corrected all the causes the TOS5200 may be malfunctioning Stop using the product and contact your Kikusui agent or distributor TOS5200 C Test Start Operation and Display TOS5200 The following table shows the control sources that are enabled depending on the combination of remote control sources Combination Enabled remote Indicator on the control source screen Front panel Rear panel SIG USB or RS232C RMT ED REMOTE NAL I O connec connector tor the RR ENABLE signal is at low level a Panel Off Off REMOTE connec Off On b Yes tor SIGNAL I O con Off On c Yes nector d _ _ Yes USB connector or On Off RS232C connector SIGNAL I O con Off On e Yes Yes nector 75 D Troubleshooting This section introduces troubleshooting measures Typical symptoms are listed Check whether any of the items listed below apply to your case In some cases the problem can be solved guite easily p 72 If none of the items apply to your case we recommend that you initialize the TOS5200 to its factory default
43. est Inspection 62 Specifications 63 Appendix 71 List of Default Settings 72 Protection Functions 74 Test Start Operation and Display 75 Troubleshooting 76 About the Manuals These manuals are intended for users of the Withstanding Voltage Tester and their instructors Explanations are given under the presumption that the reader has knowledge related to electricity Manual construction H Setup Guide This manual is intended for first time users of the product It gives an overview of the product connecting procedures safety precautions etc Please read this manual before you operate the product H Quick Reference The quick reference briefly explains the control panel and the basic operation of it H Safety Information This document contains general safety precautions for this product Keep them in mind and make sure to observe them H User s Manual this manual PDF This manual is intended for first time users of this product It provides an overview of the product notes on usage and specifications It also explains how to connect the product configure the product operate the product perform mainte nance on the product and so on H Communication Interface Manual PDF This manual explains how to control the product remotely using commands It is included on the CD ROM The interface manual is written for readers with sufficient basic knowledge of how to control measuring instruments using a PC
44. est is immediately stopped 1 The length of time that the buzzer sounds when a PASS judgment occurs is fixed to 50 ms The specified Pass Hold time has no effect Effectiveness of the lower limit Normally even a good DUT will have a certain degree of leakage current Setting the upper limits just within the boundaries of the characteristic range of the DUT is useful in detecting breaks in the test leads and poor connections enabling you to perform highly reliable testing In withstanding voltage tests you can perform tests effectively by enabling the lower limit with W COMP Invalid Settings If you specify an invalid value for a setting a message blinks on the screen While a message is blinking the READY LED turns off and you cannot start a test You also cannot select other items Specify a valid value READY LED turns off _ LIMIT blinks ER a Ri dl L g LIMIT VI TEST Example of LIMIT indicator blinking Message Description mA indicator blinking When the lower or upper limit is turned on and the upper limit has been set lower than the lower limit LIMIT indicator blinking When you try to setthe test voltage higher than the set limit voltage kV and mA indicators When the test voltage and the upper limit are set in the withstanding volt blinking simultaneously age test settings such that their product exceeds 550 VA TOS5200 Setting Test Conditions Test condition Panel operation
45. h that has a voltage 13 rating of 30 Vdc or greater and a current rating of 10 mA or INTERLOCK greater Using a transistor or optical device dI Photocoupler a 11 such as a transistor When the transistor collector current is 5 mA or less the i interlock feature is activated To release the interlock fea ture allow an ic of 6 mA or greater to flow and then press STOP or apply a STOP signal STATUS OUT connector TOS5200 This is the output connector for connecting the optional warning light unit PLO2 TOS In CONFIG setting 2 select the status that you want to output Select H V ON Test Pass Upper Fail Lower Fail Ready Protection or Power ON If you select multiple items the sta tus that is generated will be the logical sum of the items When the selected status is true the TOS5200 generates a 24 Vdc signal For details see the WARNING LIGHT PL02 TOS OPERATION MANUAL External Control Q 59 60 This page is intentionally blank TOS5200 Maintenance This chapter explains daily inspections such as measurement checks 62 Pre Test Inspection Inspection of test leads and the judgment feature p 41 p 42 Calibration Allow a current to flow between the HIGH VOLTAGE and LOW VOLTAGE terminals to check the judgment feature During this inspection the two test leads are shorted so you can check for breaks in the test leads at the same time We recommend that you
46. hat is recalled is shown in the table below PMO PM1 TEST SEL AUTO SEL Recalled test mode L L L ACW Interlock Feature This feature links the TOS5200 to an external device to stop output appropriately This ensures the safety of the operator While the interlock feature is active even if you press the START switch or apply a start sig nal from an external controller the TOS5200 will not perform testing While the interlock sig nal is being applied you cannot release PROTECTION mode by pressing the STOP switch or applying a stop signal By using the interlock feature you can control the TOS5200 output from an external source This ensures safe operation of the tester The first time that you turn the POWER switch on after you purchase the TOS5200 the tester will be in PROTECTION mode through the interlock feature You can use the included SIG NAL I O plug to easily release the PROTECTION mode Attaching the included SIGNAL I O plug connects pin numbers 1 and 13 the INTERLOCK and INTERLOCK pins Only use this plug to easily release the PROTECTION mode When you are actually performing tests use the interlock feature to ensure safety During withstanding voltage test in which you are using tools 1 placing a cover over the DUT so that output is turned off whenever the cover is removed to prevent electric shock and 2 placing a safety fence around the work area where withstanding voltage test is being per formed so that
47. he products bottom panel This is useful in preventing the cover from being lost Use the screw to fix the cover to the product s bottom panel Installation and gel 21 22 Turning the Power On Checking indicators and the status of the interlock feature The first time that you turn the POWER switch on after you purchase the TOS5200 the tester will be in PROTECTION mode through the interlock feature Connect the included SIGNAL I O plug to the SIGNAL I O connector to release the interlock feature Only use the included SIGNAL I O plug to easily release the PROTECTION mode When you are actually performing tests use the interlock feature to ensure safety During withstanding voltage test in which you are using tools 1 placing a cover over the DUT so that output is turned off whenever the cover is removed to prevent electric shock and 2 placing a safety fence around the work area where withstanding voltage test is being per formed so that output is turned off whenever the fence is opened are both examples of effec tive safety measures NOTE When the TOS5200 is turned on a self test is run and all the indicators on the front panel light To ensure safety check that all the indicators light before you use the TOS5200 It is especially dangerous to use the tester if its DANGER LED is broken When the power is turned on the DANGER LED lights but no voltage is generated See p 20 Check that the
48. he test voltage is 500 V or less the switching and spike noise proportions are large The lower the test voltage the greater the waveform is distorted 3 In either case true rms or mean value a response time of at least 50 ms is required to meet the measurement accuracy 4 Regarding ammeter and judgment accuracy During withstanding voltage tests current also flows in the stray capacitance of items such as the measurement leads and jigs This current that flows in the stray capacitances is added to the current that flows in the DUT and the sum of these currents is measured Especially if you want to perform judgments with high sensitivity and accuracy it is necessary to consider methods to limit the current that flows in these stray capacitances such as by adding upper and lower limits Output voltage 1 kV 2 kV 5 kV When using 350 mm long test leads that are suspended in air TYP 2 UA 4 pA 10 pA When using the accessory high voltage test lead TL31 TOS TYP 16 pA 32 HA 80 HA When the humidity is 70 or higher add 50 pA o TOS5200 2 65 o 66 Specifications Other features TOS5200 Test mode Double action feature Tests can only be started by pressing and releasing STOP and then pressing START within 0 5 seconds of releasing the STOP switch Length of time to hold a PASS judgment result You can set the length of time to hold a PASS judgment 50 ms 100 ms 200 ms 1 s 2s 5 s or HOLD Momentary feature
49. ications of this product and the contents of this man ual are subject to change without prior notice 2014 Kikusui Electronics Corporation Checking the Package Contents When you receive the product check that all accessories are included and that the accessories have not been damaged during transportation If any of the accessories are damaged or missing contact your Kikusui agent or distributor We recommend that you save all packing materials in case the product needs to be transported at a later date ACN Rating 125 Vac 10 A Rating 250 Vac 10 A Rating 250 Vac 10 A Plug NEMA5 15 Plug CEE7 7 Plug GB1002 85 AA 0003 85 AA 0005 85 10 0790 Power cord 1 pc The power cord that is provided varies depending on the destination for the product at the factory shipment High voltage test lead High voltage warning SIGNAL I O 1 set sticker 1 pc plug 1 set TL31 TOS A8 210 203 Assembly type D sub plug unit lt gt i Japanese 1 sheet Z1 006 150 English 1 sheet Z1 006 152 CD ROM 1 pc Quick Reference CP lt gt Setup Guide 1 pc Safety Information 1 pc Z1 006 140 Z1 005 040 TOS5200 Notes to the supervisor If the operators cannot understand the language used in this manual translate the manuals into the appropriate language Make sure that the opera
50. imit 0 01 mA to 110 MA Lower limit OFF 0 01 mA to 110 mA Test time OFF 0 1 s to 999 s Voltage rise time 0 1 s to 10 0 s Voltage fall time OFF 0 1 s Start voltage OFF 50 Initial panel memory settings Initially memory numbers 1 to 3 contain withstanding voltage test conditions Feel free to use these test conditions if they match the tests that you want to perform For details on the test conditions that are initially contained in memory see Default panel memory values Saving test conditions Display the basic setup screen and then set the test conditions Press MEMORY 1 MEMORY 2 or MEMORY 3 to select the memory num ber 1 to 3 in which you want to save the current test conditions The selected memory number blinks Press SHIFT RECALL to save the conditions in the selected memory number READY PROTECTION Example of saving to memory number 1 After the test conditions have been saved the basic setup screen is displayed in READY mode the READY LED lights Panel Operation a gt 38 Panel Memory Recalling test conditions 1 Press MEMORY 1 MEMORY 2 or MEMORY 3 to specify the memory number 1 to 3 from which you want to recall test conditions MEMORY i The test conditions that are saved in the memory number 1 to 3 that you specified C are displayed 2 6 2 Press RECALL to recall the test conditions that are saved in the speci fied memory number The basic setup screen is
51. irrespective of the settings made by the operator Immediately turn the POWER switch off and disconnect the power cord from the outlet Stop using the product immediately and contact your Kikusui agent or distributor e Even when you press the STOP switch the DANGER LED remains lit e During tests the DANGER LED does not light To Use the Product for a Long Time Free of Malfunctions Taking size weight and cost into consideration the heat dissipation capability of the voltage generator that is used for withstanding voltage tests has been designed to be one half that of the rated output Use the TOS5200 within the following limits If you use the product in a man ner that exceeds these limits the output section may overheat and the internal protection cir cuits may be activated If this happens stop testing and wait until the TOS5200 returns to its normal temperature H Output limits during withstanding voltage testing Ambient temperature Upper limit Pause time Output time t lt 40 C SOMA e up m Greater than or equal to zo min max the output time i lt 50 mA Not necessary Continuous output possible Output time voltage rise time test time voltage fall time TOS5200 Panel Operation Basics This chapter describes how to select items on the screen and how to enter values 32 Parts of the Screen The screen that is used to set the basic test conditions is made up of the four parts shown
52. l digital signal Starting a Test ENABLE IN a p o READY OUT 5 ms or more 1 I n h F START IN 1 I La 1 1 To use the SIGNAL I O connector to start a test set the ENABLE signal to low level When at least 1 ms has elapsed after the READY sig nal was set to low level set the START signal to low level for at least 5 ms After a valid START signal has been detected the READY signal is set to high level When the ENABLE signal is low the START 1 ms or more signal of the SIGNAL I O connector is enabled and the panel s START switch and the START input of the REMOTE terminal are disabled S Recalling Panel Memory and Test Modes Selecting the panel memory The PM and STB signals are processed with the timing shown below Check that the READY signal is low level The relationship between the PMO and PM1 signals and the panel memory number that is recalled is shown in the table below An interval of 1 ms or more is required before the next input signal is received Apply the START signal for at least 50 ms n STB IN 1 ms r 110 ms or more ore TOS5200 External Control Q 57 58 Interlock Feature PMO PM1 TEST SEL AUTOSEL Recalled panel memory number H H L L Memory 1 L H L L Memory 2 H L L L Memory 3 L L L L Selecting the test mode The relationship between the PMO PM1 TEST SEL and AUTO SEL signals and the test mode t
53. lly radio frequency energy in the form of electromagnetic radiation inductive and or capacitive coupling for the treatment of material or inspection analysis purpose 4 This product confirms to Class Be sure to ground the protective conductor terminal of this product If not grounded properly safe ty is not guaranteed TOS5200 Specifications Q 70 Specifications Outline drawing A a a A d ZER 5 Sc Se 65 Sa 250 9 84 F wn SIS A o 9 q pS 265 10 43 r TN TN e TT Hes gt i Le Dal SS y Ol NO aS MAX330 12 99 320 12 60 ji ZS el s DI o x lt mM GK Unit mm inch TOS5200 Appendix A List of Default Settings B Protection Functions C Test Start Operation and Display D Troubleshooting 72 A List of Default Settings Initializing the TOS5200 PROTECTION PR Default values Item While holding down SHIFT turn the POWER switch on When you initialize the TOS5200 all settings such as test conditions and saved data are reset to the default values shown below Setting after initialization Withstanding voltage Measurement mode RMS EREEREHERG Test voltage 0 00 kV Test voltage s limit voltage 5 50 kV Upper limit 0 02 mA Lower limit OFF Test time 0
54. measured current measured values test time 2 The input signals are all low active control The input terminal is pulled up to 12 V by a resistor Leaving the input terminal open is equivalent to applying a high level signal TOS5200 Specifications General TOS5200 Display LCD LED backlight custom design Environment Installation location Indoors at a height of up to 2000 m Spec guaranteed Temperature 5 Cto 35 C 41 F to 95 F range Humidity 20 rh to 80 rh no condensation Operating range Temperature 0 Cto 40 C 32 F to 104 F Humidity 20 rh to 80 rh no condensation Storage range Temperature 20 C to 70 C 4 F to 158 F Humidity 90 rh or less no condensation Power supply Nominal voltage ran range Power consumption ge allowable voltage When no load is connected READY 100 Vac to 240 Vac 90 Vac to 250 Vac 100 VA or less Rated load Allowable frequency range 800 VA max 47 Hz to 63 Hz Insulation resistance between AC LINE and the chassis 30 MO or more 500 Vdc Withstanding voltage between AC LINE and the chassis 1500 Vac 1 minute Earth continuity 25 Aac 0 1 Q or less Electromagnetic compatibility EMC 1 Complies with the requirements of the following directive and stand ards EMC Directive 2004 108 EC EN 61326 1 Class A EN 55011 Class A Group 19 EN 61000 3
55. mode because of several causes the cause with the highest priority is displayed After you eliminate the cause the cause with the next highest priority is displayed to indicate that there are more causes If you cannot clear the mode even by pressing STOP turn the TOS5200 off and then back on Display example when an interlock signal is detected Panel display Protection circuit Description Remedy E Interlock Protection An interlock signal was detected Remove the interlock signal input and then press STOP pr Power Supply Protection An error was detected in the power You can clear the PROTECTION e supply mode by pressing STOP but if the protection occurs frequently repairs are necessary 8886 Volt Error Protection An output voltage outside of the rated Press STOP LOL limits was detected Withstanding voltage test 350 V 1p Over Load Protection An output voltage causing the output Press STOP om power limit to be executed was detected Withstanding voltage test 550 VA Hp Over Heat Protection The internal temperature of the Confirm that the internal temperature e TOS5200 became too high of the TOS5200 has decreased and then press STOP Ap Over Rating Protection The output current was generated for Press STOP em a length of time that exceeds the regu lated time B8 Remote Protection A connection to or disconnection from Check the REMOTE connector and the REMOTE connector was detected then pr
56. nect the protec tive conductor terminal to earth ground NOTE e Use the supplied power cord to connect to the AC line If the supplied power cord cannot be used because the rated voltage or the plug shape is incompatible have a qualified engineer replace it with an appropriate power cord that is 3 m or less in length If obtaining a power cord is difficult contact your Kikusui agent or dis tributor e The power cord with a plug can be used to disconnect the product from the AC power line in an emergency Connect the plug to an easily accessible power outlet so that the plug can be removed from the outlet at any time Be sure to provide adeguate clearance around the power outlet Do not use the supplied power cord with other instruments This product conforms to IEC Overvoltage Category II energy consuming equipment that is sup plied from a fixed installation In addition to the supplied power cord Kikusui also provides other 200 V power cords with plugs sold separately 1 Check that the POWER switch is turned off 2 Check that the AC power line meets the nominal input rating of the prod uct The product can receive a nominal power supply voltage in the range of 100 Vac to 240 Vac 90 Vac to 250 Vac that has a freguency in the range of 47 Hz to 63 Hz 3 Connect the power cord to the rear panel AC inlet and then connect the power plug to an outlet that has a ground terminal TOS5200 Using the Protection Cover
57. nges stable tests can be performed even in locations where the power supply is unstable The AC inlet is designed for worldwide use The TOS5200 can be used without modifica tion provided the nominal power supply voltage is within the range of 100 Vac to 240 Vac 90 Vac to 250 Vac and the frequency is within the range of 47 Hz to 63 Hz e Rise time control feature that gradually increases the test voltage Instead of immediately applying the specified test voltage to the DUT after the test begins this makes it possible to perform tests in which the voltage is raised gradually to the test voltage As required by withstanding voltage tests defined by standards such as IEC and UL this makes it possible to perform tests in which no more than half of the test voltage is applied at the start of the test and the test voltage is gradually reached over the specified time e Fall time control feature that gradually decreases the test voltage The test voltage can be gradually decreased after a PASS judgment occurs during an AC withstanding voltage test e Window comparator feature for setting upper and lower judgment limits You can set not only the upper limit but the lower limit as well This is useful in determin ing whether there are breaks in test leads or whether there was a mistake during opera tions This leads to highly reliable tests e Ability to save three sets of test conditions You can save three sets of test conditions e Impro
58. nt because a value greater than or egual to the upper limit is detected TOS5200 Specifications E 67 68 Specifications TOS5200 SIGNAL UO continued 18 L FAIL o On continuously when FAIL results from judgment because a value less than or equal to the lower limit is detected 19 READY O On when the TOS5200 is waiting when it is in the READY state 20 PROTECTION o On when protective features have activated the TOS5200 is in the Protection state 21 START Start signal input terminal 22 STOP Stop signal input terminal 23 ENABLE l Start signal enable signal input terminal 24 24V 24 V internal power supply output terminal maximum output current 100 mA 25 COM Circuit common terminal STATUS SIGNAL OUTPUT Output terminal for a warning light Terminal A 24 V signal is generated from this terminal when output has been turned on COM 24 V circuit common terminal 1 Talk mode can be set when RS232C is in use Talk mode Description 0 Responds only to commands from a PC factory default setting Automatically responds at the start and end of a test The TOS5200 status settings and measured values are returned Response at the lt START gt start of a test Status lt PASS gt lt U_FAIL gt lt L_FAIL gt lt PROT gt or lt ABOUT gt Response at the end of a test Settings Test number program number test mode measured voltage
59. or the following settings and conditions The product is warmed up for at least 30 minutes e Values indicated by TYP are typical values They are not guaranteed performance val ues Values indicated by rdng are readout values e Values indicated by set are settings Withstanding voltage tester form TOS5200 AC output Output range 0 05 kV to 5 00 kV section Setting 2 of set 20 V at no load accuracy Setting range 0 00 kV to 5 50 kV Resolution 10 V STEP Max rated output 500 VA 5 kV 100 mA Max rated voltage 5 kV Max rated current 100 mA output voltage 0 5 kV or higher Transformer rating 500 VA Output voltage wave Sine Distortion If the output voltage is 0 5 kV or more 3 or less when no load or a pure resistive load is connected Crest factor Within 2 3 output voltage 800 V or higher at no load Frequency 50 Hz or 60 Hz Accuracy 0 5 excluding during voltage rise time Voltage regulation 10 or less when changing from maximum rated load to no load Input line regulation 0 3 5 kV at no load power supply voltage 90 V to 250 V Short circuit current 200 mA or more output voltage 1 0 kV or higher Output method PWM switching Start voltage The voltage at the start of withstanding voltage tests can be set to 50 of the test volt age Limit voltage The test voltage uppe
60. ory When test conditions or configuration items are being set these keys corre spond to the menus displayed on the screen A MEMORY keys MEMORY 1 key Displays the settings saved to MEMORY 1 p 37 p 44 MEMORY 2 key Displays the settings saved to MEMORY 2 MEMORY 3 key Displays the settings saved to MEMORY 3 RECALL key Recalls settings from panel memory SHIFT key Saves the current settings to panel memory START switch Starts testing p 48 6 STOP switch Stops testing and clears the current status p 51 p 74 7 nap VOLIAGE This terminal is for the high voltage line of the tester output p 24 terminal 8 Se This terminal is for the low voltage line of the tester output with cable lock p 24 FUNCTION key Does not use WW g ACW key CONFIG key SHIFT key Displays the CONFIG setup screen p 44 10 Rotary knob Changes settings p 33 p 41 p 44 11 Screw hole Fasten a screw to this hole to fix the protection cover in place SET key Press to select the voltage setting 12 p 35 p 41 LIMIT key SHIFT key Selects the voltage limit setting UPR LWR key Press to alternately select the upper and lower current limits 13 p 35 p 41 ON OFF key SHIFT key Turns the lower limit judgment feature on and off Specialized connector for connecting the optional remote control box RC01 14 REMOTE connector 7OS RC02 TOS or the high voltage test probe HPO1A TOS HPO2A TOS P 10 P 26 TEST RISE key Press to alternately select the test time an
61. output is turned off whenever the fence is opened are both examples of effec tive safety measures E Interlock signal input conditions Open across terminals e When the resistance across the positive and negative terminals is 1 2 KQ or greater s If you are using transistors or an optical device when the current across the positive and negative terminals is 5 mA or less E Interlock signal release conditions Short across terminals e When the resistance across the positive and negative terminals is 1 KQ or less s If you are using transistors or an optical device when the current across the positive and negative terminals is 6 mA or greater TOS5200 STATUS OUT connector How to use the interlock feature When SIGNAL UO connector pins 1 and 13 are opened the interlock feature is enabled When the pins are shorted the interlock feature is released When the interlock feature is active the TOS5200 is in PROTECTION mode To release the interlock feature connect the included SIGNAL I O plug to the rear panel SIGNAL I O con nector Then press STOP to release PROTECTION mode Using an open close switch Door switch or EE EE other type of switch A A 111 yP When the contact is open the interlock signal also Sa becomes open and the interlock feature is activated To release the interlock feature close the contact and then press STOP or apply a STOP signal Use a door switch or other type of switc
62. perform this pre test inspection before you use the TOS5200 The test leads are consumable parts Check them periodically for tears and breaks Breaks or tears in the insulation may cause electric shock or fire If a break or tear is found stop using the damaged test lead immediately Short the low voltage test lead black and high voltage test lead red Connect the low voltage test lead black to the LOW VOLTAGE terminal Connect the high voltage test lead red to the HIGH VOLTAGE terminal Set the test conditions Be sure to set the upper limit UPPER Press START to start a test oni ROKN If a test results in a U FAIL judgment based on this simple check both the test leads and the TOS5200 judgment feature are working properly If a U FAIL result does not occur even after you perform this check multiple times there may be breaks in the test leads Double check whether this is the case If there are no breaks in the test leads the TOS5200 needs to be repaired To have your TOS5200 repaired contact your Kikusui agent or distributor The product is calibrated before shipment To maintain long term reliable performance we recommend periodic calibration To have your product calibrated contact your Kikusui distributor or agent TOS5200 Specifications This chapter contains the specifications and gives the dimensions of the TOS5200 64 Specifications Unless specified otherwise the specifications are f
63. r H SIGNAL I O connector pinout Pin no Signal name VO TOS5200 INTERLOCK If you open the positive and negative terminals the output is turned off and the TOS5200 is switched to Protection mode Open The resistance between the two terminals is 1 2 kQ or greater Short The resistance between the two terminals is 1 KQ or less PMO Panel memory selection signal 2 The selection signal is latched on the ris PMO_ PM1_ Recalled panel memory number ing edge of the input strobe signal to H H Memory 1 PMI recall panel memory L H Memory 2 3 ANJA H L Memory 3 The selection of memory is prioritized over TEST SEL and AUTO SEL E E ae 4 NC 5 NC 6 NC 7 NC 8 NC 9 STB l Panel memory strobe signal input terminal 10 TEST SEL l NA 11 AUTO SEL l NA 12 COM Circuit common terminal INTERLOCK If you open the positive and negative terminals the output is turned off and the TOS5200 is switched to Protection mode Open The resistance between the two terminals is 1 2 KQ or greater 13 l Short The resistance between the two terminal
64. r limit can be set 0 00 kV to 5 50 kV Output voltage monitor feature If output voltage exceeds the specified value 350 V or is lower than the specified value 350 V output is turned off and protective features are activated Voltmeter Digital Measurement 0 000 kV to 6 500 kV range Display o 000 kV Accuracy V lt 500 V 1 5 of reading 20 V V2 500 V 1 5 of reading Response True rms Mean value response rms display Can be switched Hold feature After a test is finished the measured voltage is held until the PASS or FAIL judgment is cleared Ammeter Digital Measurement 0 00 mA to 110 mA range Display i measured current i lt 1mA 1mAsi lt 10mA 10 mAsi lt 100mA 100 mA lt i 0 000 mA o ooo mA 00 00 MA 000 0 MA Accuracy 1 00 mA lt i 1 5 of reading i lt 1 00 mA 1 5 of reading 30 pA Response True rms Mean value response rms display Can be switched Hold feature After a test is finished the measured current is held until the PASS judgment is cleared TOS5200 Specifications TOS5200 Judgment Judgment method and feature judgment operation Judgment Judgment method Display Buzzer poe Y If a current that is greater than or equal to FAIL LED and Generates UPPER the upper limit is detected the outp
65. r of approximately 470 Q between the tips of the high and low voltage test leads and the DUT Connect the toroidal core or resistor as close to the DUT as possible If you are connecting a toroidal core it is effective to wrap the test leads two to three times around a type of core that can be snapped on and that is often used with power cables This type of core is usually approximately 20 mm in diameter If you are connecting a resistor pay close attention to the power rating of the resistor When the upper limit is 10 mA or less connect a resistor of approximately 470 A 3 W 30 kV impulse withstanding voltage Because this resistor causes the voltage to fall the voltage that is actually applied to the DUT is slightly lower than the voltage that is generated from the product s output terminals when a 10 mA current flows the voltage falls approximately 10 V These methods are extremely useful in reducing the effect of noise Connect the toroidal core or resistor as close to the DUT as possible Toroidal core 470 2 3 W HIGH VOLTAGE HIGH VOLTAGE Oww terminal terminal DUT DUT LOW terminal LOW terminal 5 ml Toroidal core 4702 3W TOS5200 TOS5200 Installation and Preparation 26 Connecting to the Device under Test DUT Using the optional high voltage test probe model HP01A TOS HP02A TOS If you use the optional test probe instead of the test leads you can use hands on cont
66. r outlet Air outlet for cooling 4 STATUS OUT connector Connector for connecting the optional warning light unit PLO2 TOS p 17 p 59 5 Serial number The product s serial number Communication 6 RS232C port RS232C interface connector interface manual 7 SIGNAL I O connector External control signal connector p 54 1 A multipurpose ground terminal provided for the stable operation of the TOS5200 Use it if necessary TOS5200 General Description This chapter gives an overview of the TOS5200 and explains the options that are available for it 14 Product Overview The TOS5200 Withstanding Voltage Tester performs withstanding voltage tests which is one of the four types of tests that are required for ensuring the safety of electrical products This product can perform AC withstanding voltage tests on electrical products and electrical components in accordance with the requirements of safety and electrical standards and ordi nances such as IEC EN UL VDE and JIS It is suited to 1 research and development installations 2 test facilities for quality assur ance testing and standard certification and 3 manufacturing lines The withstanding voltage tester is easy to use safe and reliable Features e Newly developed constant voltage output for stable testing The TOS5200 is not affected by AC line interference Because the output voltage is main tained at a fixed value even if the AC line voltage or frequency cha
67. re enables you to send test results and the like from the product through the RS232C interface without using commands from a PC It can reduce processing on the PC If you turn talk mode on you cannot control the product from a PC To control the product from a PC turn talk mode off off 0 Talk mode is not used factory default setting on 1 Talk mode is used CONFIG 2 settings On the CONFIG 0 setup screen you can set the output conditions when using the optional warning light unit PLO2 TOS Example Selecting H V ON blinking Wd l EE Power ON setting 0 off 1 on Protection setting 0 off 1 on Ready setting 0 off 1 on Lower Fail setting 0 off 1 on Upper Fail setting 0 off 1 on Pass setting 0 off 1 on v Test setting 0 off 1 on v H V ON setting 0 off 1 on H V ON Sets whether the 24 Vdc output is generated while there is a residual voltage and during test ing off 0 The 24 Vdc output is turned off while there is a residual voltage and during testing factory default setting on 1 The 24 Vdc output is turned on while there is a residual voltage and during testing 46 TOS5200 CONFIG Settings Test Sets whether the 24 Vdc output is generated while tests are being performed with the test voltage at the specified voltage value The 24 Vdc output is not generated during voltage rise
68. rol to start tests For details see the OPERATION MANUAL HIGH VOLTAGE TEST PROBE HP01A TOS HP02A TOS Disconnecting test leads from the DUT Check that the POWER switch is off and that the DANGER LED is off Disconnect the high voltage test lead red from the front panel HIGH VOLTAGE terminal Disconnect the low voltage test lead black You can disconnect the low voltage test lead black first from either the DUT or the TOS5200 3 Disconnect the high voltage test lead red from the DUT TOS5200 Safety Precautions for Testing This chapter describes the precautions that must be followed to perform tests safely 28 Pre Test Inspection Z N WARNING Risk of electric shock e During testing this product supplies a voltage of at least 5 kVac to an external device Handling this tester improperly may lead to a fatal accident To prevent acci dents strictly follow the precautions and always pay the utmost attention to safety concerns when you operate the TOS5200 e This product conforms to IEC Safety Class equipment that has a protective con ductor terminal Be sure to earth ground the product to prevent electric shock e The product is grounded through the power cord ground wire Connect the protec tive conductor terminal to earth ground e During testing be sure to wear rubber gloves for electrical work Check the following items before you start testing and always follow the precautions e Th
69. s is 1 KQ or less 14 HV ON O On during testing and when a voltage remains across the output terminals E 15 TEST O On during testing excluding when voltage is rising or falling O 16 PASS o On for at least 0 2 seconds the PASS HOLD time when a PASS judgment occurs o On continuously when the PASS HOLD time is set to HOLD E On continuously when an UPPER FAIL judgment occurs because a value greater than or 2 17 U FAIL O eech x lt equal to the upper limit is detected UU On continuously when LOWER FAIL results from judgment because a value less than or 18 L FAIL O EE equal to the lower limit is detected 19 READY O On when the TOS5200 is waiting when it is in the READY state 20 PROTECTION O On when protective features have been activated 21 START l Start signal input terminal 22 STOP l Stop signal input terminal 23 ENABLE Input terminal for the start signal s ENABLE signal If the ENABLE signal changes the TOS5200 is switched to Protection mode 24 24 V 24 V internal power supply output terminal maximum output current 100 mA 25 COM Circuit common terminal NC NC NC STB m NC TEST SEL _ NCC AITO SEL po PM1 COM PMO INTERLOCK m INTERLOCK I ta 12 11 10 9 8 zels lalale 28 4l bal bol bi 20 19 hal 17 16 hs 14 COM HV ON 24V TEST ENABLE _ i PASS STOP _ i J FAIL START L L FAIL PROTECTION READY e TOS5200 S 55 9 SIGNAL I O Connector
70. sults 52 External Control SIGNA VO eeler SIGNAL I O specifications inreenensnnenenenaenenannennnneannaeaneennnnat Internal construction Input signal usage example Output signal usage example s sssesseeeeeeesekesitsiteekeetrsttstrtknstnntnntnnstnntnnenneennee 56 Starting ECK EE 57 Recalling Panel Memory and Test Modes EENEG 57 Interlock TE 58 How to use the interlock feature A 59 STATUS e Ria 59 Maintenance Pre Test 1151 072707 9 6 SAHA 62 Inspection of test leads and the judgment feature s es 62 GC IAT ON ai aa eege 62 Specifications Withstanding voltage Tester 64 Other FEALUFSS sieniin a rni ai rA a EEE avai eiS nS ul ENEE Outline drawing Appendix A Listof Default Settings sesiiesiscrsscceccrsssssessensiesasisdenastacsiseciaacnsscas 72 Initializing the TOS5200 strnnensnnenenenennenannnnananannananneannananenananee 72 B Protection Functions eebe 74 TOS5200 TOS5200 C Test Start Operation and Display ccccssssssseeeeesssseeeeees 75 D TROUDIGSIOOUIING scciccsascsnadhncrescccaseanasanccistonssccccuaebenetsoommacananananins 76 1470 EN 79 Search by Topic Preparation What accessories are included in the package gt Checking the Package Contents Before start testing want to check that the TOS5200 is operating safely gt Turning the Power On p 22 Other than the basi
71. tection mode factory default setting on 1 The 24 Vdc output is turned on when the TOS5200 is in protection mode Power ON Sets whether the 24 Vdc output is generated while the POWER switch is on off 0 The 24 Vdc output is turned off when the POWER switch is turned on fac tory default setting on 1 The 24 Vdc output is turned on when the POWER switch is turned on TOS5200 Withstanding Voltage Test Q 47 OW Starting a Test Risk of electric shock During testing do not touch the test leads and the DUT N WARNING To start a test 1 Check that the TOS5200 is correctly connected to the DUT 2 When the READY LED lights in white press START PROTECTION FMS READY E If the test does not start see If you cannot start testing If you want to start another test after testing finishes set a wait time between tests as neces sary When atest starts The TEST and DANGER LEDs light The TEST LED lights in red a Lit ad m lt e ZO O ii oe Lit The TEST and DANGER LEDs light Dancer id A Sr AR The TEST LED lights in red If the start voltage and the voltage rise time have been set After the voltage rises to the start voltage or after the voltage rise time elapses the TEST LED lights in red and the test starts While the voltage is rising the TEST LED blinks in red and the display counts up to the set rise time Blinking
72. time Rise Time and voltage fall time Fall Time off 0 The 24 Vdc output is turned off during testing factory default setting on 1 The 24 Vdc output is turned on during testing Pass Sets whether the 24 Vdc output is generated after a PASS judgment has occurred off 0 The 24 Vdc output is turned off during testing factory default setting on 1 The 24 Vdc output is turned on during testing Upper Fail Sets whether the 24 Vdc output is generated after an upper limit FAIL judgment has occurred off 0 The 24 Vdc output is turned off after an upper limit FAIL judgment occurs factory default setting on 1 The 24 Vdc output is turned on after an upper limit FAIL judgment occurs Lower Fail Sets whether the 24 Vdc output is generated after a lower limit FAIL judgment has occurred off 0 The 24 Vdc output is turned off after an lower limit FAIL judgment occurs factory default setting on 1 The 24 Vdc output is turned on after a lower limit FAIL judgment occurs Ready Sets whether the 24 Vdc output is generated while the READY LED is lit off 0 The 24 Vdc output is turned off while the READY LED is lit factory default setting on 1 The 24 Vdc output is turned on while the READY LED is lit Protection Sets whether the 24 Vdc output is generated while the TOS5200 is in protection mode off 0 The 24 Vdc output is turned off when the TOS5200 is in pro
73. tors understand the information in this manual before they operate this product Keep this manual close to the product so that the operators can read the manual at any time If the tester will be used to repeatedly perform tests with fixed conditions such as when being used as part of a manufacturing line attach the protection cover to ensure safe operation of the tester This is useful in preventing incorrect operation of the tester Dangerous Operations You will receive a potentially fatal electric shock if e You touch an output terminal while output is being generated e You touch a test lead that is connected to an output terminal while output is being generated e You touch the device under test DUT while output is being generated e You touch a location that is electrically connected to an output terminal while output is being generated You may receive a potentially fatal electric shock if e You operate the tester without grounding it e You operate the tester without using rubber gloves for electrical work e You come close to a location that is electrically connected to an output terminal while output is being generated TOS5200 AN Safety Precautions When using this product be sure to observe the Safety Precautions in the Safety information manual N Precautions Concerning Installa tion Location When installing this product be sure to observe the Pre cautions Concerning Installation
74. ulated time Remote Protection A connection to or disconnection from the front panel REMOTE connector was detected SIGNAL I O Protection The rear panel SIGNAL I O connector s ENABLE signal has changed USB Protection The USB connector has been disconnected or a defect was detected during remote con trol operation TOS5200 Specifications Interfaces 0000000000000000000000000000000000000000000000000000000000000000000 TOS5200 USB USB Specification 2 0 Standard type B socket RS232C Hardware D SUB 9 pin connector EIA 232 D compliant All functions except the POWER switch and key lock Baudrate 9600 19200 38400 57600 115200 bps Transmission system Start stop synchronization Data length 8 bits Stop bits 1 bit Parity bit None Program message CR LF during transmission CR LF or CR LF during reception terminator REMOTE Front panel 9 pin MINI DIN connector By connecting an optional device to this connector you can control the starting and stopping of tests remotely SIGNAL UO Rear panel D sub 25 pin connector Output Output method Open collector output 4 5 Vdc to 30 Vdc specifications Output withstanding 30 Vdc voltage Output saturation volt Approx 1 1 V 25 C age Maximum output current 400 MA TOTAL Input High level input voltage 11 Vto 15 V specifications Low level input voltage 0 Vto4 V Low level input current 5 MA max
75. ut is UPPER ON a U FAIL FAIL turned off and an UPPER FAIL judgment lights i signal occurs If a current that is less than or equal to the FAIL LED and lower limit is detected the output is LOWER LOWER turned off and a LOWER FAIL judgment lights Generates occurs This judgment is not performed ON an L FAIL FAIL A SE i 3 during voltage rise time Rise Time of all signal tests and during the voltage fall time Fall Time of withstanding voltage tests If the specified time elapses without any PASS LED Generates PASS problems the output is turned off and a lights ON a PASS PASS judgment occurs gnis signal If PASS HOLD is enabled the PASS signal is generated continuously until the TOS5200 receives a STOP signal The UPPER FAIL and LOWER FAIL signals are generated continuously until the TOS5200 receives a STOP signal The FAIL and PASS buzzer volume levels can be changed For PASS judgments the length of time that the buzzer sounds for is fixed to 0 2 seconds Even if PASS HOLD is enabled the buzzer turns off after 0 2 seconds Upper limit setting 0 01 mA to 110 mA Lower limit setting 0 01 mA to 110 mA OFF Judgment accuracy 1 00 mA si 1 5 of set i lt 1 00 MA 1 5 of set 30 JA Current detection method Calculates the current s true rms value or mean value value and compares this value with the reference value Calibration Calibrated with the rms of a sine wave using a pure resistive load Time
76. ved safety In addition to having features that enable you to view the output voltage the TOS5200 also enables you to set the voltage limits so you can prevent a voltage greater than what is necessary from being generated unintentionally This provides protection for the DUT e Standard equipped USB port The TOS5200 is standard equipped with a USB interface You can use a PC or sequencer to control test conditions and read measured values and test results 1 The four tests are the withstanding voltage insulation resistance earth continuity and leakage current tests TOS5200 Product Overview TOS5200 Light weight and easy to move Even though the TOS5200 can generate 500 VA which is sufficient for performing with standing voltage tests it only weighs 15 kg or less so it can be moved by even a single person Protection against incorrect operations In addition to the key lock feature the TOS5200 has a protection cover for the part of its panel that is used to change test conditions This cover is useful in preventing incorrect operations when you want to perform tests with fixed conditions General Description E 15 Options The following options are available for the TOS5200 For information about options contact your Kikusui agent or distributor Rack mount option Name Model Note KRA4 TOS For EIA inch racks KRA200 TOS For JIS millimeter racks Rack mount adapter KRA4 TOS Model RC0
77. xed while panel settings are being recalled from or See poe saved to memory See p 51 54 e STOP is being pressed including when a STOP signal is being applied to the SIG bay Peoh es NAL UO connector e mA is blinking See p 40 p The lower or upper limit is turned on and the upper limit has been set lower than the lower limit Specify a valid value e kV and mA are blinking simultaneously When the test voltage and the upper limit are set in the withstanding voltage test settings such that their product exceeds 550 VA Specify a valid value e TOS5200 ku Withstanding Voltage Test Q 50 Starting a Test PASS or FAIL is lit You cannot start testing while a judgment result is displayed Press STOP to switch the TOS5200 to the READY state PROTECTION is lit If PROTECTION is lit the TOS5200 has switched to protection mode and will not allow you to start testing Resolve the issues causing the PROTECTION mode to be on The double action feature has been turned on When the double action feature is turned on you cannot start tests just by pressing START Press STOP and then press START within 0 5 seconds TOS5200 Finishing a Test To stop a test STOP K Press STOP When a test finishes See p 41 p 42 TOS5200 A test will stop under one of the following conditions a If the test time el
78. y Remote control is not possible Is the baudrate set correctly p 46 through the RS232C interface Check the value TOS5200 77 78 This page is intentionally blank TOS5200 Index A accessories nnnennnnnnnnnnnnnneene ne enneenena 2 B Buzzer Volume Elle eebe ee 46 PASS ren ee 45 c CONFIG setup screen sssssesssnssssissrnsinsrrennernrerreenne 44 connection DUT E A E aie eee 24 D default settings list mrnnnene 72 Double Action 45 DUT E t E EEE 24 F Fail 4 0 e MESA 45 IC UNN Le 43 fall time control rerreneenneeeeeeneeeenee 43 firmware version mmrennnnennnnnnnannnannanne 2 ee Ee 43 H HPOTA TOS ou ccccccccccccccceceeeeeeeeeeeessensssesseuseaeeeeneeeeeers 26 HPO2ART EG 26 I initialization 72 10551210 17970 EPEE SEAD 62 judgment feature 62 test leads ennminenneeeeeea een 62 Interlock Protection 74 K KEYLOCK orriei ta kii aint aeii 36 key ek 25454 1330 ama ee a 36 L EA eieiei 40 Lower Fall EE 47 lower limit judgment 00 ee eee eeeteeeeeneeeteneeees 32 40 M measurement EE 43 measurement check ou ceeeeeecseceseceseseseeeesesentesseeaees 62 message invalid setting ismenamv 40 TOS5200 Mesuremerit uk case siruina iiai 43 Momentary geck magaja aema aa aada Desk 45 O elei IC 16 outline drawing miausereenansen
79. y the CONFIG setup screen ACW coun Press once to show the CONFIG screen and twice to show the CONFIG screen es en d Press MEMORY 2 or MEMORY 3 to move to the CONFIG item that you want to set and then use the rotary knob to set the value To exit from the CONFIG setup screen and return to the basic setup screen press STOP Memo The first screen that is dis played when you perform viously were viewing will be displayed configuration settings is called CONFIG setup screen CONFIG 1 settings If you enter CONFIG settings again without first turning the power off the screen that you pre On the CONFIG setup screen you can set the test mode and buzzer volume level Example Selecting the double action feature blinking 0 to 9 10 setting levels v Double action feature setting 0 off 1 on A Fail mode function setting 0 off 1 Momentary function setting 0 off 1 on eee ny ID Talk mode setting 0 off 1 on RS232C baud rate setting 0 9 600 1 19 200 2 38 400 3 57 600 4 115 200 FAIL judgment buzzer volume level setting 0 to 9 10 setting levels PASS judgment buzzer volume level setting Judgment result hold time setting 0 50 ms 1 100 ms 2 200 ms 3 1 s 4 2 s 5 5 s 6 HOLD on TOS5200 CONFIG Settings Double action feature This feature enables you to start a test by first pressing STOP and then pressing START within

TOS5200 User`s Manual - Kikusui Electronics Corp.

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