Kikusui TOS5200 User Manual
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TOS5200
DANGER
This product generates high voltage!
ż Improper operation can lead to serious accidents.
ż
To prevent accidents, be sure to read the section
“Safety Precautions during Testing” in this manual.
ż
Keep this manual close to the product so that the
operators can read the manual at any time.
General Description
Installation and
Preparation
Safety Precautions
during Testing
Panel Operation Basics
Withstanding Voltage Test
External Control
Maintenance
Specifications
App
User’s Manual
Withstanding Voltage Tester
PART NO. IB027962
Sep. 2014
These manuals are intended for users of the Withstanding
About the Manuals
Checking the Package Contents
or or
High-voltage test lead
(1 set)
[TL31-TOS]
Setup Guide (1 pc.)
[Z1-006-140]
Power cord (1 pc.)
Rating: 125 Vac, 10 A
Plug: NEMA5-15
[85-AA-0003]
Rating: 250 Vac, 10 A
Plug: GB1002
[85-10-0790]
Rating: 250 Vac, 10 A
Plug: CEE7/7
[85-AA-0005]
SIGNAL I/O
plug (1 set)
Assembly type
(D-sub plug unit)
High-voltage warning
sticker (1 pc.)
[A8-210-202]
CD-ROM (1 pc.)
[SA-6071]
Japanese (1 sheet): [Z1-006-150]
English (1 sheet): [Z1-006-152]
Quick Reference
Safety Information (1 pc.)
[Z1-005-040]
The power cord that is pr ovided varies depending o n the
destination for the product at the factory- shipment.
Voltage Tester and their instructors. Explanations are given
under the presumption that the reader has knowledge related
to electricity.
Trademarks
Microsoft, Windows, and Visual Basic are registered trademarks 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.
Manual construction
■ 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.
■ Quick Reference
The quick reference briefly explains the control panel and
the basic operation of it.
■ Safety Information
This document contains general safety precautions for this
product. Keep them in mind and make sure to observe
them.
■ 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 maintenance on the product, and so on.
■ 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.
Copyrights
The contents of this manual may not be reproduced, in whole
or in part, without the prior consent of the copyright holder.
The specifications of this product and the contents of this manual are subject to change without prior notice.
© 2014 Kikusui Electronics Corporation
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.
PDF files are included in the accompanying CD-ROM.
You can view the PDF files using Adobe Reader 6.0 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)
2 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 operators 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.
You will receive a potentially fatal electric shock if:
• You touch an output terminal while output is being generated.
• You touch a test lead that is connected to an output terminal while output is being
generated.
• You touch the device under test (DUT) while output is being generated.
• 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:
• You operate the tester without grounding it.
• You operate the tester without using rubber gloves for electrical work.
• You come close to a location that is electrically connected to an output terminal
while output is being generated.
Dangerous Operations
TOS5200 3
When using this product, be sure to observe the “Saf ety
Safety Precautions
Precautions Concerning Installation Location
Left panel inlet
holes
Right panel inlet holes
Notations Used in This Manual
WARNING
DESCRIPTION
See
Memo
Precautions” in the Safety information manual.
When installing this product, be sure to observe the “Precautions Concerning Installation Location” in the Safety
information manual. The following precautions pertain
only to this product.
• 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)
• 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)
• Do not use the product in 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 adequate 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 obstacles).
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.
• 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 person al
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.
CAUTION
Indicates a potentially hazardous situation which, if
ignored, may result in damage to the product or other
property.
Indicates information that you should know.
Explanation of terminology or operation principle.
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.
Indicates useful information.
• 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
4 TOS5200
corona discharge between its test lead clips. This will generate a significant amount of broadband RF emission. To minimize 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.
Contents
1
2
About the Manuals .................................................................................................. 2
Checking the Package Contents ............................................................................. 2
Notes to the supervisor ........................................................................................... 3
Dangerous Operations ............................................................................................3
Safety Precautions .................................................................................................. 4
Precautions Concerning Installation Location ......................................................... 4
Notations Used in This Manual ...............................................................................4
Search by Topic....................................................................................................... 8
Front Panel............................................................................................................. 10
Rear Panel ............................................................................................................. 12
General Description
Product Overview......................................................................................................................................................... 14
Features.............................................................................................................. 14
Options .............................................................................................................................................................................. 16
Installation and Preparation
Connecting the Power Cord.................................................................................................................................... 20
Using the Protection Cover..................................................................................................................................... 21
Turning the Power On................................................................................................................................................ 22
Checking indicators and the status of the interlock feature................................. 22
Turning the POWER switch on....................................................................................................... 23
Turning the POWER switch off............................................................................ 23
Connecting to the Device under Test (DUT) .................................................................................................. 24
Using test leads................................................................................................... 24
Using the optional high voltage test probe
(model HP01A-TOS/HP02A-TOS)...................................................................... 26
Disconnecting test leads from the DUT............................................................... 26
3
4
Safety Precautions for Testing
Pre-Test Inspection..................................................................................................................................................... 28
Testing Precautions.................................................................................................................................................... 28
Remote Control Precautions.................................................................................................................................. 29
Interrupting Testing or Operations....................................................................................................................... 29
Emergency Measures................................................................................................................................................ 29
Forbidden Actions........................................................................................................................................................ 30
Turning the power on and off repeatedly............................................................. 30
About Malfunctions...................................................................................................................................................... 30
To Use the Product for a Long Time Free of Malfunctions..................................................................... 30
Panel Operation Basics
Parts of the Screen...................................................................................................................................................... 32
Panel Operations.......................................................................................................................................................... 34
Switching screens ............................................................................................... 34
Selecting items....................................................................................................................................... 35
Entering values.................................................................................................... 35
Locking panel operations (key lock).................................................................... 36
Talk mode............................................................................................................ 36
TOS5200 5
5
Panel Memory................................................................................................................................................................. 37
Saving test conditions.......................................................................................................................... 37
Recalling test conditions..................................................................................................................... 38
Withstanding Voltage Test
About Judgment............................................................................................................................................................. 40
Effectiveness of the lower limit............................................................................ 40
Invalid Settings............................................................................................................................................................... 40
Setting Test Conditions.............................................................................................................................................. 41
Test conditions (basic items)............................................................................... 41
Test conditions (additional items)........................................................................ 42
CONFIG Settings.......................................................................................................................................................... 44
CONFIG 1 settings........................................................... ................................... 44
CONFIG 2 settings........................................................... ................................... 46
Starting a Test................................................................................................................................................................ 48
To start a test................................................ .................................... ... ............... 48
When a test starts............................................................................................... 48
To change the voltage setting during a test ........................................................ 49
If you cannot start testing.................................................................................... 49
Finishing a Test.............................................................................................................................................................. 51
To stop a test ............................... ... .................................... ... ............................. 51
When a test finishes............................................................................................ 51
To clear judgment results................................................................................................................... 52
6
7
8
External Control
SIGNAL I/O Connector............................................................................................................................................... 54
SIGNAL I/O specifications .................................................................................. 54
Internal construction............................................................................................................................. 56
Input signal usage example ................................................................................ 56
Output signal usage example ........................................................... ... ............... 56
Starting a Test................................................................................................................................................................ 57
Recalling Panel Memory and Test Modes ....................................................................................................... 57
Interlock Feature........................................................................................................................................................... 58
How to use the interlock feature ......................................................................... 59
STATUS OUT connector........................................................................................................................................... 59
Maintenance
Pre-Test Inspection...................................................................................................................................................... 62
Inspection of test leads and the judgment feature.............................................. 62
Calibration........................................................................................................... 62
Specifications
Withstanding voltage tester................................................................................. 64
Other features.......................................................................................................................................... 66
Interfaces.................................................................................................................................................... 67
General........................................................................................................................................................ 69
Outline drawing.................................................. ................................................. 70
Appendix
A List of Default Settings ............................................................72
Initializing the TOS5200...................................................................................... 72
B Protection Functions ...............................................................74
6 TOS5200
C Test Start Operat ion and Display............................................75
D Troubleshooting.......................................................................76
Index...........................................................79
TOS5200 7
Search by Topic
• What accessories are included in the
package?
➔ “Checking the Package Contents” p.2
• Before I start testing, I want to check
that the TOS5200 is operating safely.
➔ “Turning the Power On” p.22
• How do I use each of the two test leads?
➔ “Using test leads” p.24
• I want to check that measurements are
being performed correctly before I start
testing.
➔ “Pre-Test Inspection” p.62
• I want to know more about the interlock
feature.
➔ “Interlock Feature” p.58
Preparation
• Other than the basic settings that are
shown on the panel, what test
conditions can be set?
➔ “Test conditions (additional items)” p.42
➔ “CONFIG Settings” p.44
• How are measured values judged?
➔ “About Judgment” p.40
• How does the TOS5200 display the
judgment results?
➔ “When a test finishes” p.51
• How can I hold the PASS judgment
result?
➔ “Judgment result hold time (Pass Hold)” p.45
Setup
8 TOS5200
• How do I save the present test conditions
and use them later?
➔ “Panel Memory” p.37
• How do I start tests with a greater level of
safety?
➔ “Double action feature” p.45
• How do I prevent unintentional key
operations from changing the test
conditions?
➔ “Using the Protection Cover” p.21
➔ “Locking panel operations (key lock)” p.36
• How do I control the TOS5200 using
external signal input?
➔ “SIGNAL I/O Connector” p.54
• How do I release the interlock feature?
➔ “Turning the Power On” p.22
Operation
• How do I check that the test leads are
not damaged (for example, that they
have no breaks)?
➔ “Pre-Test Inspection” p.62
• What do I need to keep in mind to use
the TOS5200 for a long time without
malfunctions?
➔ “To Use the Product for a Long Time Free
of Malfunctions”
p.30
Maintenance
Troubleshooting
See “Troubleshooting” on page 76.
TOS5200 9
Front Panel
START
STOP
1
MEMORY
2
3
RECALL
RESET
POWER
OUTPUT
DANGER
HIGH VOLTAGE LOW
CONFIG LIMIT ON/OFF ON/OFF KEY LOCK
FUNCTION
SET
VOLTAGE
UPR/LWR
CURRENT
TEST/RISE
TIMER
MORE
REMOTE USB
LOCAL
S
HIFT
ACW
MAX5kV
READY
TEST
PASS
FAIL
Loosen the screw and pull this part towards you
to remove the cover.
READY
CONFIG
s
RISE TEST
RMS AVE MORE CAL RM T
MT
1
2
TEST
PAS S
FAIL
3
PROTECTION
A
LIMIT
50Hz 60Hz
kV
Mȍ
mA
UPPER
LOWER W COMP
T
OS5
200
ACW
AC WITHSTANDING
VOLTAGE TESTER
The protection cover is
attached to the TOS5200
when the product is
shipped from the factory.
19
20
1816
17
2
3
1
14
15
8
9
10
11
7
4
12513
6
Test conditions
operating unit
No. Name Function
1 DANGER LED Lights in red when a test is being performed. p.48
2 Status indicators
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
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
Press these keys to display the settings that are saved to memory.
When test conditions or configuration items are being set, these keys correspond to the menus displayed on the screen.
4 MEMORY keys
MEMORY 1 key: Displays the settings saved to MEMORY 1.
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.
1
+SHIFT key:
Saves the current settings to panel memory.
See
p.37 , p.44
10 TOS5200
No. Name Function
See
5 START switch Starts testing. p.48
6 STOP switch Stops testing and clears the current status. p.51 ,p.74
HIGH VOLTAGE
7
terminal
LOW VOLTAGE
8
terminal
FUNCTION key
(ACW key)
9
CONFIG key
10 Rotary knob Changes settings.
This terminal is for the high-voltage line of the tester output. p.24
This terminal is for the low-voltage line of the tester output (with cable lock). p.24
Does not use.
+SHIFT key:
1
Displays the CONFIG setup screen.
—
p.44
p.35 ,p.41
,p.44
1 1 Screw hole Fasten a screw to this hole to fix the protection cover in place. —
SET key Press to select the voltage setting.
12
LIMIT key
+SHIFT key:1 Selects the voltage limit setting.
p.35 ,p.41
UPR/ LWR key Press to alternately select the upper and lower current limits.
13
ON/ OFF key
14 REMOTE connector
+SHIFT key:1 Turns the lower limit judgment feature on and off.
Specialized connector for connecting the optional remote control box, RC01-
TOS/RC02-TOS, or the high voltage test probe, HP01A-TOS/HP02A-TOS.
p.35 ,p.41
p.16 , p.26
TEST/ RISE key Press to alternately select the test time and voltage rise time.
15
ON/ OFF key
+SHIFT key:
1
Turns the test time (Test Time) on and off.
16 USB port USB interface connector.
p.35 ,p.41
Communication interface
manual
LOCAL key Switches between local mode and remote mode. —
17
SHIFT key Press to access the features that are written in blue. —
MORE key
18
KEY LOCK key
Press to select additional test condition settings.
Frequency, start volt age, volt age fall time, and measurement mode
+SHIFT key:
1
Locks panel key operations (settings and changes).
p.41 ,p.42
p.36
19 POWER switch
Turns the power on [ ] and off [ ].
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 dow n SHIFT.
TOS5200 11
Rear Panel
xxxxxxx-x
SIGNAL I/ ORS232C
COM
STATUS OUT
+
KIKUSUI ELECTRONICS CORP.
STRIP-GAUGE
AWG
24-16
10 mm
AC INPUT
50-60Hz
800VA MAX
100-240V
DO NOT REMOVE COVERS. NO OPERATOR SERVICEABLE
PARTS INSIDE.
REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.
UNPLUG THE MAINS SUPPLY CORD BEFORE HANDLING
THE CORD OR LOAD WIRES.
WARNING
10
76
5
See
1 2
3
4
No. Name Function
Chassis terminal
1
Functional ground terminal
2 AC LINE connector AC inlet p.20
3 Air outlet Air outlet for cooling —
4 STATUS OUT connector Connector for connecting the optional warning light unit, PL02-TOS p.17 , p.59
5 Serial number The product’s serial number —
6 RS232C port RS232C interface connector
7 SIGNAL I/O connector External control signal connector p.54
1
—
Communication
interface
manual
1 A multipurpose ground termin al provided for the stable operation of the TOS5200. Use it if necessary.
12 TOS5200
General Description
This chapter gives an overview of the
TOS5200 and explains the options that are
available for it.
Product Overview
Features
The TOS5200 Withstanding Voltage Tester performs withstanding voltage tests, which is one
of the four types of tests
This product can perform AC withstanding voltage tests on electrical products and electrical
components in accordance with the requirements of safety and electric al standards and ordinances such as IEC, EN, UL, VDE, and JIS.
It is suited to (1) research and development installations, (2) test facilities for quality assurance testing and standard certification, and (3) manufacturing lines.
The withstanding voltage tester is easy to use, safe, and reliable.
● Newly developed constant-voltage output for stable testing
The TOS5200 is not affected by AC line interference. Because the output voltage is maintained at a fixed value even if the AC line voltage or frequency changes, 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 modification 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.
● 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.
1
that are required for ensuring the safety of electrical products.
● 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.
● Window comparator feature for setting upper and lower judgment limits
You can set not only the uppe r limit, but the lowe r limit as well. This i s useful in determining whether there are breaks in test leads or whether there was a mistake during operations. This leads to highly reliable tests.
● Ability to save three sets of test conditions
You can save three sets of test conditions.
● Improved 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.
● 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.
14 TOS5200
Product Overview
● Light-weight and easy to move
Even though the TOS5200 can generate 500 VA, which is sufficient for performing withstanding 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.
1
General Description
TOS5200 15
Options
KRA4-TOS
RC01-TOS (one hand)
RC02-TOS (two hands)
Rack mount option
The following options are available for the TOS5200.
For information about options, contact your Kikusui agent or distributor.
Name Model Note
Rack mount adapter
KRA4-TOS For EIA inch racks
KRA200-TOS For JIS millimeter racks
Model RC01-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.
Model DD-5P/9P remote control adapter cable
This is an adapter cable for connecting the product to a
remote control box.
16 TOS5200
Model HP01A-TOS/HP02A-TOS high voltage test probe
See
Options
p. 26
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.
AC 4 kV
DC 5 kV
Model PL02-TOS warning light unit
The warning light unit indicates th at the TOS5200 is performing a
test. This enables you to see that a test is in progress from a distance.
1
Rated voltage
General Description
TOS5200 17
18 TOS5200
This page is intentionally blank.
Installation and Preparation
This chapter describes how to prepare this
product for use.
Connecting the Power Cord
WARNING
• This product conforms to IEC Safety Class I (equipment that has a protective conductor terminal). Be sure to earth ground the product to prevent electric shock.
• The product is grounded through the power cord ground wire. Connect the protective conductor terminal to earth ground.
• 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 distributor.
• 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 adequate clearance around the
power outlet.
• Do not use the supplied power cord with other instruments.
This product confor ms t o IE C Over voltage Cate gory II ( energ y-co nsumi ng equip ment th at is supplied from a fixed installation ).
In addition to the supplied power cord, Kikusui also provides other 200 V power cords with
plugs (sold separately).
Check that the POWER switch is turned off.
1
Check that the AC power line meets the nomin al input rating of the prod-
2
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 frequency in the range of 47 Hz to 63 Hz.
Connect the power cord to the rear-panel AC inlet, and then connect the
3
power plug to an outlet that has a ground terminal.
20 TOS5200
Using the Protection Cover
OUTPUT
CONFIG LIMIT ON/OFF ON/OFF KEY LOCK
SET
VOLTAGE
UPR/LWR
CURRENT
R/T/F
TIMER
LOCAL
SSHIFT
Loosen the screw.
Pull the tab toward you.
TOS5200 bottom panel
Use the screw to fasten
the cover in place.
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 manufacturi ng lin e, at ta ch the protect ion 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.
■ Removing the protection cover
Loosen the screw, and then pull the
hook centered at the bottom of the
cover towards you to remove the protection cover from the panel.
2
Installation and Preparation
■ 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.
■ Storing the protection cover
When you want to use the
TOS5200 without the protection
cover attached, such as when you
will repeatedly perform tests with
frequently changed test conditions, you can store the protection
cover on the product’s 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.
TOS5200 21
Turning the Power On
See
See
See
A
kV
Mȍ
mA
CONFIG
RISE TEST
RMS AVE MORE CAL RMT
MT
LIMIT
50Hz 60Hz
UPPER
LOWER W COMP
s
1
2
3
READY
TEST
PAS S
FAIL
PROTECTION
A
kV
Mȍ
mA
CONFIG
RISE TEST
RMS AVE MORE CAL RMT
MT
LIMIT
50Hz 60Hz
UPPER
LOWER W COMP
s
1
2
3
READY
TEST
PAS S
FAIL
PROTECTION
Firmware version screen
Interlock protection mode
Checking indicators and the status of the interlock feature
p. 58
p. 58
p. 20
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 performed so that output is turned off whenever the fence is opened are both examples of effective safety measures.
When the TOS5200 is turned on, a self-test is run, and all the indicators on the front panel
light. To ensu re 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.
Check that the power cord and all cables are correct ly conn e ct ed .
1
Check that nothing is connected to the SIGNAL I/O connector.
2
Press the ( ) side of the front-panel POWER switch to turn the TOS5200
3
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.
Press the ( ) side of the front-panel POWER switch to turn the TOS5200
4
off.
22 TOS5200
Turning the POWER switch on
A
kV
Mȍ
mA
CONFIG
RISE TEST
RMS AVE MORE CAL RMT
MT
LIMIT
50Hz 60Hz
UPPER
LOWER W COMP
s
1
2
3
READY
TEST
PAS S
FAIL
PROTECTION
A
kV
Mȍ
mA
CONFIG
RISE TEST
RMS AVE MORE CAL RMT
MT
LIMIT
50Hz 60Hz
UPPER
LOWER W COMP
s
1
2
3
READY
TEST
PAS S
FAIL
PROTECTION
Firmware version 1.00 display example
See
WARNING
Connect the included SIGNAL I/O plug to the SIGNAL I/O connector.
1
Connecting the SIGNAL I/O plug will release the interlock feature.
Press the ( ) side of the POWER switch to turn the TOS5200 on.
2
Check the firmware version (Ver x.xx) that is displayed on the screen.
3
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).
Turning the Power On
2
Installation and Preparation
p. 72
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 displaye d (with
the factory 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
Press the ( ) 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 change d,
the last settings may not be stored.
Risk of electric shock.
• 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 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.
• Except in an emergency, do not turn the POWER switch off while output is being
generated.
TOS5200 23
Connecting to the Device under Test (DUT)
WARNING
WARNING
OUTPUT
DANGER
T
OS5
200
Off
Off
POWER
See
Low-voltage test lead (black)
Raise the cable lock.
Low-voltage test lead (black)
Lower the cable lock.
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
p. 62
Risk of electric shock.
• Parts of the included test leads near the alligator clips
protrude from the vinyl insulation when the wires are
connected. These parts are dangerous. Never come
close to these parts during testing.
• 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.
Check that the POWER switch is off and that the DANGER LED is off.
1
Check that there are no tears or breaks in the test lead insulation.
2
Raise the front-panel LOW VOLTAGE terminal’s cable lock, and then
3
connect the low-voltage test lead (black).
Never come close to this area
during testing.
Lower the cable lock to secure the lead in place.
4
24 TOS5200
Connecting to the Device under Test (DUT)
Low-voltage test lead (black)
High-voltage test lead (red)
OUTPUT
DANGER
T
OS5
200
Off
470 Ω, 3 W
470 Ω, 3 W
DUT
Toroidal core
Toroidal core
HIGH VOLTAGE
terminal
Connect the toroidal core or resistor as close to
the DUT as possible.
LOW terminal
TOS5200
HIGH VOLTAGE
terminal
LOW terminal
TOS5200
DUT
Connect the low-voltage test lead (black) to the DUT.
5
Connect the high-voltage test lead (red) to the DUT.
6
Connect the high-voltage test lead (red) to the front-panel HIGH VOLT-
7
AGE terminal.
Check that the DANGER LED is turned off.
8
2
Installation and Preparation
Reducing the effect of noise
Noise may be generated if the outputs are shorted or if the DUT insulation is damaged. Electronic 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 resistor of approximately 470 Ω
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 o n and tha t is often used with p ower cable s. Thi s
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 Ω (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.
TOS5200 25
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