Kikusui TOS8040 User manual

Part No. Z1-AB0-082, IB008603
Oct. 2007
OPERATION MANUAL
AC Withstanding Voltage Tester
TOS8040
DANGER
This instrument generates high voltage.
• Any incorrect handling may cause death.
• Read “Precautions for Safe Testing” in this manual
to prevent accident.
• Keep this manual near the instrument for easy
access of the operator.

Use of Operation Manual
Please read through and understand this Operation Manual before operating the product. Afterreading,
always keep the manual nearby sothat you may referto itas needed.When moving the product to another
location,be sure to bring the manual as well.
If you find any incorrectly arranged or missing pages in this manual,they will be replaced.If the manual
gets lostor soiled,anew copy can be provided for afee.In eithercase,please contact Kikusui distributor/
agent, and provide the “Kikusui Part No.” given on the cover.
This manual has been prepared with the utmostcare; however, if you have any questions,or note any errors
or omissions,please contact Kikusui distributor/agent.
Reproduction and reprinting of this operation manual,whole or partially,withoutourpermission is prohib-
ited.
Both unitspecifications and manual contents are subject to change withoutnotice.
Copyright© 2005-2007 Kikusui Electronics Corporation

TOS8040 1
■ About this manual
This documentation is the Operation Manual for the TOS8040AC Withstanding
Voltage Tester.
Firmware version of the product to be used:
This Operation Manual applies to products incorporating firmware of:
Version 1.0x
The firmware version is indicated on the testtime indicator when the POWER
switch is turned on.For more information,see “5.1 Turning the POWER Switch
On” (page 32).
When inquiring aboutthe product, please provide this version numberand the serial
numberindicated on the rear of the product.
Testing Cannot be Performed at Unpacking
If the TOS8040’s power is turned on in the condition in which the tester has
been simply unpacked upon receipt, the interlock function will be acti-
vated, preventing performance of testing as-is.
See “6.2 Using the INTERLOCK Terminal” (page 45) to operate the tester,
taking advantage of the interlock function.

2TOS8040
To the Supervisor in Charge of Operation
•If the operator does not read the language used in this manual, translate the manual into
the appropriate language.
• Help the operator in understanding this manual before operation.
• Keep this manual near the instrument for easy access by the operator.
Hazardous Operations
Any of the following operations will result in electric shock, which may lead to serious
injury or death.
•Touching the output terminal while output is being generated.
•Touching a test lead connected to the output terminal while output is being generated.
•Touching the DUT while output is being generated.
•Touching a part electrically connected to the output terminal while output is being gener-
ated.
Any of the following actions may result in electric shock leading to serious injury or
death.
•Operating the tester without connecting the grounding wire to ground.
•Operating the tester without wearing rubber gloves intended for electrical work.
•Approaching a section electrically connected to the output terminal while output is being
generated.

TOS8040 Safety Symbols 3
or
Indicates that a high voltage (over 1000 V) is used here. Touching
the part causes a possibly fatal electric shock. If physical contact
is required by your work, start work only after you make sure that
no voltage is output here.
DANGER
Indicates an imminently hazardous situation which, if ignored,
will result in death or serious injury.
Indicates a potentially hazardous situation which, if ignored,
could result in death or serious injury.
Indicates a potentially hazardous situation which, if ignored, may
result in damage to the product and other property.
Shows that the act indicated is prohibited.
Is placed before the sign “DANGER,” “ WARNING,” or “CAUTION”
to emphasize these. When this symbol is marked on the product,
see the relevant sections in this manual.
Protective conductor terminal.
Chassis (frame) terminal.
On (supply)
Off (supply)
In position of a bi-stable push control
Out position of a bi-stable push control
WARNING
CAUTION
Safety Symbols
For the safe use and safe maintenance of this product, the following
symbols are used throughout this manual and on the product. Under-
stand the meanings of the symbols and observe the instructions they
indicate (the choice of symbols used depends on the products).

4 Safety Precautions TOS8040
Safety Precautions
The following safety precautions are intended to avoid fire hazard, electrical
shock, and other accidents or failures. Use of the product in a method not spec-
ified in this manual may impair the effectiveness of built-in protective functions.
Users
•This product must beused only byqualified personnel who understand the con-
tents of this Operation Manual.
•Ifthis product is handled byunqualified personnel, personal injury may result.
Ensure that the product is handled under the supervision of qualified personnel
(i.e., those experienced in electrical applications).
Purposes of use
•Donot use the product for any purpose other than those specified.
• This product is not designed or manufactured for home use or for general consumers.
Input power
•Always connect the product to apower supply in line with the product’sinput rating.
•Use the provided power cord to supply input power.
• This product is designed as equipment falling under Overvoltage Category II of the
IECStandards (energy-consuming equipment to besupplied from fixed installation).
Cover
• Components inside the instrument may present physical hazards. Donot remove
the external cover.
Grounding
• The product is equipment falling under Safety Class I of the IECStandards (equip-
ment with aprotective conductor terminal).Always ground the product’sprotective
conductor terminal to prevent electric shock.
Installation
• This product is designed for indoor use. Only use it indoors.
• When installing products besure to observe “2.2 Precautions for Installation”
described in this manual.
Operation
Manual
Line
Voltage
GNL

TOS8040 Safety Precautions 5
Relocation
•Turnoff the POWERswitch and disconnect all cables before relocating the product.
•Besure the operation manual beincluded when the product is relocated.
Operation
•Before using the tester, check that there are no abnormalities on the surface of
the power cord. (Before doing this, always disconnect the power cord from the
electrical outlet.)
•Ifany abnormality or failure is detected in the products, stop using it immediately.
Unplug the power cord. Becareful not to allow the product to beused before it is
completely repaired.
•Donot disassemble or modify the product. Ifit must bemodified, contact Kikusui
distributor/agent.
Maintenance and checking
•Toavoid electrical shock, beabsolutely sure to unplug the power cord before per-
forming maintenance or checking.
•Donot remove the cover when performing maintenance or checking.
•Tomaintain performance and safe operation of the product, it is recommended
that periodic maintenance, checking, cleaning, and calibration beperformed.
Service
•Internal service is to bedone byKikusui service engineers. Ifthe product must be
adjusted or repaired, contact Kikusui distributor/agent.
Check?

6 Safety Precautions TOS8040
Label
• The product carries alabel providing important safety information. Ifthis label is
damaged or the information provided becomes illegible, replace it with anew
label. To obtain anew label, please contact your Kikusui distributor or agent.

TOS8040 Safety Precautions 7
Front and rear panels
•Before using the tester, makesure you read and understand Chapter 3, “Precau-
tions for Safe Testing.”
SETTING SUPPLY
STANDARD
LINEVOLTAGEFREQUENCY VA MAX
220V
65050 60Hz
100V
120V
IF THIS COLUMN BLANK,THEUNIT IS WIRED IN 220V.
When connecting test
leads, connect the LOW
voltage terminalfirst.
When the voltage is
displayed here,
hazardous high
voltage is present.
Press STOP before
changing test
conditions.
Set the TEST VOLTAGE
knobto the MIN position
unless actually testing.
Danger
High-voltage
output terminal
Beforeturning the POWER
switchon, confirmthat the
TEST VOLTAGEknobis set
to the MIN position.
Always connect the power
cordʼsprotective conductor
terminalto ground.
Ifthis lamp goes on,
hazardous high voltage
is present.

8 Overvoltage Category TOS8040
Organization of the Operation Manual
The information in this manual is organized into the following chapters:
Chapter 1 General
Provides aproduct overview and describes features and options.
Chapter 2 Installation and Preparations for Use
Describes how to unpack the testerfor preparation before use.
Chapter 3 Precautions for Safe Testing
Gives the precautions to be observed at all times to ensure safe testing.
Chapter 4Part Name’s and Functions
Gives the names of switches,terminals,and othercontrols of the TOS8040.
Chapter 5 Panel Operations
Describes procedures for testing.
Chapter 6 Remote Control
Gives the procedure for operating the testerfrom aremote location using the
REMOTE connector and the INTERLOCK terminal.
Chapter 7 Status Signal Output
Describes the status signal outputs (SIGNAL OUT).
Chapter 8Special Test Modes
Explains the special testmodes.
Chapter 9 Maintenance and Calibration
Describes the maintenance and calibration of the tester. The testermustbe periodi-
cally inspected,maintained,and calibrated to maintain performance.
Chapter 10Specifications
Provides the electrical and mechanical specifications for the TOS8040.
Appendix
Provides guidelines for currentdetection lowerreference limitand zero-start switch.

TOS8040 Contents 9
Contents
Testing Cannot bePerformed at Unpacking - - - - - - - - - - - - - - - - - - - - - - - 1
To the Supervisor in Charge of Operation - - - - - - - - - - - - - - - - - - - - - - - - 2
Hazardous Operations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
Safety Symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Safety Precautions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Chapter 1 General
1.1 Product Overview ---------------------------------------12
1.2 Features ----------------------------------------------12
1.3 Options ----------------------------------------------14
Chapter 2 Installation and Preparations for Use
2.1 Unpacking Inspection ------------------------------------16
2.2 Precautions for Installation ---------------------------------17
2.3 Moving Precautions --------------------------------------18
2.4Connecting the PowerCord --------------------------------18
2.5Grounding --------------------------------------------20
Chapter 3 Precautions for Safe Testing
3.1 Startup Inspection ---------------------------------------21
3.2 Preparations Before Testing --------------------------------21
3.2.1 Checking the TestLeads -----------------------------21
3.2.2 Wearing RubberGloves -----------------------------21
3.3 Operating Precautions ------------------------------------22
3.3.1 Connecting the TestLeads ---------------------------22
3.3.2 For High Voltage Output-----------------------------24
3.3.3 Checking Safety afterShutting off the Output---------------25
3.4When Interrupting Operations -------------------------------26
3.5 Response to Emergencies ----------------------------------26
3.6 Stop Using the Testerin the Eventof aMalfunction ----------------27
Chapter 4 Part Name’sand Functions
4.1 FrontPanel --------------------------------------------28
4.2 Rear Panel --------------------------------------------31
Chapter 5 Panel Operations
5.1 Turning the POWER Switch On -----------------------------32
5.2 TesterStates and Indications --------------------------------33

10 Contents TOS8040
5.2.1 Five States --------------------------------------34
5.2.2 Events or Conditions That Can Activate the Protection Function -35
5.3 Procedure for Test--------------------------------------36
5.3.1 TestParameters -----------------------------------36
5.3.2 Connection to the DUT -----------------------------40
5.3.3 Starting the Testand Making Judgments ------------------40
Chapter 6 Remote Control
6.1 Using the REMOTE Connector -----------------------------41
6.1.1 Remote Control with the Optional Remote Control Box --------41
6.1.2 Remote Control Using aControl Device ------------------42
6.2 Using the INTERLOCK Terminal ---------------------------45
Chapter 7 Status Signal Output
7.1 Five Signal Outputs -------------------------------------46
7.2 Using the SIGNAL OUT Terminals --------------------------47
7.2.1 Description of the Terminals --------------------------47
7.2.2 Example: Use of Signals ----------------------------48
Chapter 8 Special Test Modes
8.1 FourTestModes ---------------------------------------49
8.1.1 DOUBLE ACTION --------------------------------49
8.1.2 PASS HOLD ------------------------------------50
8.1.3 MOMENTARY -----------------------------------50
8.1.4FAIL MODE ------------------------------------51
Chapter 9 Maintenance and Calibration
9.1 Cleaning the Tester-------------------------------------52
9.2 Inspection --------------------------------------------52
9.3 Calibration -------------------------------------------52
Chapter 10 Specifications
10.1 BasicSpecifications -------------------------------------53
10.2 OtherFunctions ----------------------------------------55
10.3 General Specifications -----------------------------------55
10.4Dimensions -------------------------------------------56
Appendix
A.1 Setting the CurrentDetection LowerReference Limit--------------57
A.2 Improvements in Waveform Obtained Using aZero-start Switch ------59

TOS8040 Contents 11
Index ___________________________________________________ 60

12 General TOS8040
Chapter 1 General
Provides aproduct overview and describes features and options.
1.1 Product Overview
This instrumentis awithstanding voltage testerwith amaximum outputof
4 kV/100 mA. It is capable of performing withstanding voltage (dielectricstrength)
tests for any electronicdevice or componentaccording with JIS,UL, CSA, BS,or
othervarious standards.
• Note to the supervisor in charge of operation, and operator
The utmost care has been devoted to making this tester as safe as possible.
However, accidental contact with the device under testing (DUT), test lead,
test probe, or the periphery of the output terminals may result in electric
shock, since high voltage is applied to the DUTduring tester operations.
Thus, use of the tester requires thorough safety measures, including provi-
sion of fences at the peripheries of the tester and DUTto prevent personnel
from approaching without good reason and to maintain safety.
1.2 Features
■AC withstanding voltage tests of up to 4kV/100 mA
The TOS8040has a500 VAhigh-voltage transformerin the high-voltage powersupply
section for tests involving amaximum outputof 4 kV/100 mA(for 10 minutes maxi-
mum).For testvoltages of 1kV or higher, the testercan perform tests that meetthe
requirements (short-circuitcurrentof 200 mAor more *) of the IEC standards.
*Continuous outputis not available,since the outputshuts off when an overcur-
rentis detected.
■Test time of 0.5 s to 99 s (x0.1 / x1 range)
The testtime can be setto aduration in the range from 0.5 s to 99 s,and in 0.1 s
intervals in the range from 0.5 s to 9.9 s (x0.1 range).
WARNING

TOS8040 General 13
■PASS — FAIL judgment using the window comparator
The testresults are determined using the window comparator. The window compar-
ator indicates aPASS judgmentif the measured value is between the upperand
lowerreference limitvalues and indicates FAIL in any othercase.
The testeris capable of issuing aFAIL judgmentnot only when itdetects leakage
currents above the presetupperreference limit, butalsoif aleakage currentbelow
the lowerreference limit(which can be adjusted continuously up to 1/2the upper
reference limit).This allows the testerto provide PASS—FAIL judgments of test
results even in cases involving broken wires in the testleads or contact failure.(This
function does have limits and will not work pastcertain values.)
■Displaying the cause of activation of the protective function as
a code number
If the protective function is activated,the cause is given as acode numberviathe
voltmeter. Acode numberis alsoindicated if there are discrepancies in setting test
conditions,allowing you to promptly correct the setting based on the code number
displayed.
■Remote control
The optional remote control box or testprobe allows testing to be started or stopped
remotely.
■Status signal output
The testerhas outputterminals for READY,H.V ON, PASS,FAIL, and PROTEC-
TION signals to enable external monitoring of testerstatus.
Use this function with the remote control function to automate functions or to
reduce actual hands-on testing requirements.
■Sequence circuit with noise reduction features
For reliability,the sequence circuitincorporates thorough noise reduction features
to preventnoise-induced malfunctions.

14 General TOS8040
1.3 Options
Remote Control Boxes
Connecting aremote control box to the REMOTE connector of ourWithstanding
Voltage Testers,Insulation Resistance Testers,or Withstanding Voltage Insulation
Resistance Testers,enables remote starting or stopping of testing.
The RC01-TOS has one START switch; the RC02-TOS has twoSTART switches.
With the RC02-TOS remote control box,testing can be started only when both
START switches are pressed simultaneously.
High-voltage test probes
The HP01A-TOS and HP02A-TOS are testvoltage output
probes designed to be connected to ourwithstanding volt-
age tester.
The testprobes are constructed sothat atestvoltage is
outputonly when the slide leverat the grip of atestprobe
is held and the triggeris activated with one hand,and a
switch on the upperpart of the probe is pressed with the
other; that is,operation requires twohands.Releasing
eitherhand outputs aSTOP signal,shutting off the tester’s
testvoltage.
This features are intended to preventinadvertentoutputof
testvoltages when using these probes.
Description of RC01-TOS/RC02-TOS
OPERATE
switch
The START switch is enabled only when this switch is ON. Turning this
OFF halts testing.
START
switch
When the OPERATE switch is ON and the testeris in aREADY state,press
this switch to begin testing.
STOP
switch
This switch shuts off the outputvoltage or cancels astatus (such as FAIL).It
has the same function as the STOP switch on the tester.
RC01-TOS
200(W) x 70(H) x 39(D) mm
RC02-TOS
330(W) x 70(H) x 39(D) mm
HP01A-TOS

TOS8040 General 15
• When using atest probe, do not connect it to the DUTwhile atest voltage
is being output from the probe. Also, do not disconnect the probefrom the
DUTwhile atest voltage is being output from the probe.
Disconnecting the probefrom the DUTwhile high voltage is being output
from the probemay result in damage to the DUT. Additionally, disconnect-
ing the probefrom the DUTin the middle of testing may result in aresidual
electrical charge in the DUT, posing asignificant hazard.
For these reasons, the probemust beconnected to the DUTbefore testing
begins. When ending the test, confirm that the LED on the probeis not lit,
then disconnect the probefrom the DUT.
•Touse atestprobe,activate the FAIL MODE special testmode.
With FAIL MODE activated,even releasing yourhand from the probe when the
testhas ended in aFAIL judgmentwill not clear the FAIL state,thus allowing for
secure identification of FAIL judgments.For more information,see “8.1.4 FAIL
MODE” (page 51).
High-voltage test leads
Model numberMaximum usage voltage Cable length
HP01A-TOS4 kVac (rms) 50Hz/60 Hz
5 kVdc
Approx.1.8 m
HP02A-TOSApprox.3.5 m
Model numberMaximum usage voltage Cable length Remarks
TL01-TOS5 kVac (rms) 50Hz/60 Hz
5 kVdc
Approx.1.5 m Equivalentof TOS8040
accessory
TL02-TOSApprox.3.0 m
WARNING
NOTE

16 Installation and Preparations for Use TOS8040
Chapter 2 Installation and Preparations for Use
Describes how to unpack the testerfor preparation before use.
2.1 Unpacking Inspection
Check the TOS8040testerupon receiptfor any damage that may have occurred dur-
ing transitand to confirm that all accessories have been provided.
If the product is damaged or if any accessories are missing,notify yourKikusui dis-
tributor or agent.
Fig.2-1 Accessories
•Werecommend retaining all packing materials in case the product needs to be
transported at alaterdate.
High-voltage test leads, 1 set
TL01C-TOS, 1.5m
Power cord, 1
OperationManual, 1 copy
［Z1-AB0-082］
INTERLOCK terminaljumper, 1
or
For 200-Vac system
(Rated voltage: 250 Vac)
Plug: CEE7/7
[85-AB-0005]
For 100-Vac system
(Rated voltage: 125Vac)
Plug: NEMA5-15
[85-AB-0006]
NOTE

TOS8040 Installation and Preparations for Use 17
2.2 Precautions for Installation
Always observe the following precautions and conditions when installing the tester
indoors:
■Do not use the tester in a flammable atmosphere.
Topreventexplosions or fires,neveruse the testernear combustible materials such
as alcohol or thinneror in an atmosphere containing such vapors.
■Avoid locations subject to high temperatures or exposed to
direct sunlight.
Donot locate the testernear aheateror in areas subject to drastictemperature fluctuations.
Operating temperature range: 0°C to +40°C
Storage temperature range: -40°C to +70°C
■Avoid humid locations.
Donot install the testerin high-humidity locations,including near boilers,humidifi-
ers,or watersupply.
Operating relative humidity range: 20% to 80% (with nodew condensation)
Storage relative humidity range: 90% or less (with nodew condensation)
Condensation may occureven within the operating humidity range.If so, donot use
the testeruntil itis completely dry.
■Do not install the tester in a corrosive atmosphere.
Donot install the testerin acorrosive atmosphere or in an atmosphere containing
sulfuricacid mistor the like.Doing somay resultin corrosion of conductors or
improperconnector contacts in the tester, resulting in malfunctions or failures and
leading to potential fires.
■Do not install the tester in locations with excessive dust.
Excessive dirt and dustmay resultin electricshock or fire.
■Do not use the tester in areas with poor ventilation.
The testeruses an unforced aircooling system.Provide adequate space around the
tester.
■Do not place any objects on the tester.
In particular, heavy objects placed on the testermay lead to malfunctions.
■Do not install the tester on tilted surfaces or in locations sub-
ject to vibration.
The testermay fall,resulting in damage or injury.
■Do not use the tester in locations subject to strong magnetic
or electric fields.
Using the testerin such locations may resultin malfunctions,leading to electric
shock or fire.

18 Installation and Preparations for Use TOS8040
■Do not use the tester in locations where sensitive measuring
instruments or receivers are also being used.
Use of the testermay affect the reliability or accuracy of such instruments or
devices.
At atestvoltage of more than 3kV,coronadischarges may occurthat resultin sig-
nificantwide-range RF emissions between the clips of the testleads.Tominimize
these effects,keep the alligator clips as far apart as possible.Neverallow an alliga-
tor clip or testlead to contact or approach the conductor surface (especially sharp
metal ends).
■Provide sufficient space around the power plug.
Donot use excessive force to insert the powerplug into an electrical outletthat
resists insertion/extraction.Donot install objects near the plug that make plug inser-
tion/extraction difficult.
2.3 Moving Precautions
When moving or transporting the testerto anotherinstallation site,observe the fol-
lowing precautions:
■Turn the POWER switch off.
Moving the testerwith the powerturned on may resultin electricshock or damage.
■Disconnect all wiring.
Moving the testerwith cables connected may resultin breaks in the cables or may
cause the testerto fall,which could resultin injury.
■When transporting the tester, always use the dedicated pack-
ing materials.
Failure to use the dedicated packing materials may resultin damage to the testerin
the eventof afall or due to vibrations during transport.
2.4Connecting the Power Cord
This product is designed to meetthe standards for Overvoltage Category II (energy-
consuming equipmentto be supplied from fixed installation) of the IEC standards.
Checking the supply voltage
Before connecting the powercord,check the tester’s supply voltage.
The tester’s nominal inputrating is indicated on the rear panel.The tester’s standard
specifications specify asupply voltage of 220 V.