Kikusui TOS8030 Operation Manual
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Kikusui TOS8030 Operation Manual

Ac withstanding voltage tester
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OPERATION MANUAL
AC Withstanding Voltage Tester
TOS8030
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.
Part No. Z1-AB0-072, IB008579
Sep. 2014

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  • Page 1 Part No. Z1-AB0-072, IB008579 Sep. 2014 OPERATION MANUAL AC Withstanding Voltage Tester TOS8030 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...
  • Page 2 If you find any incorrectly arranged or missing pages in this manual, they will be replaced. If the manual gets lost or soiled, a new copy can be provided for a fee. In either case, please contact Kikusui distributor/ agent, and provide the “Kikusui Part No.” given on the cover.

  • Page 3: Testing Cannot Be Performed At Unpacking

    Testing Cannot be Performed at Unpacking If the TOS8030’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 42) to operate the tester, taking advantage of the interlock function.

  • Page 4: To The Supervisor In Charge Of Operation

    • 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. TOS8030...

  • Page 5: Safety Symbols

    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 TOS8030 Safety Symbols 3...

  • Page 6: Safety Precautions

    Always ground the product’s protective conductor terminal to prevent electric shock. Installation • This product is designed for indoor use. Only use it indoors. • When installing products be sure to observe “2.2 Precautions for Installation” described in this manual. 4 Safety Precautions TOS8030...
  • Page 7 • To maintain performance and safe operation of the product, it is recommended that periodic maintenance, checking, cleaning, and calibration be performed. Service • Internal service is to be done by Kikusui service engineers. If the product must be adjusted or repaired, contact Kikusui distributor/agent. TOS8030...
  • Page 8 • The product carries a label providing important safety information. If this label is damaged or the information provided becomes illegible, replace it with a new label. To obtain a new label, please contact your Kikusui distributor or agent. 6 Safety Precautions...
  • Page 9 MIN position. Danger Set the TEST VOLTAGE High-voltage knob to the MIN position output terminal unless actually testing. INTERLOCK terminal MADE IN TAIWAN NC03368-1 Always connect the power cordʼs protective conductor terminal to ground. TOS8030 Safety Precautions 7...
  • Page 10 Precautions for Safe Testing Gives the precautions to be observed at all times to ensure safe testing. Chapter 4 Part Name’s and Functions Gives the names of switches, terminals, and other controls of the TOS8030. Chapter 5 Panel Operations Describes procedures for testing.

  • Page 11: Table Of Contents

    Five States - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32 TOS8030...
  • Page 12 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49 Appendix Improvements in Waveform Obtained Using a Zero-start Switch - - - - - - -50 Index ___________________________________________________ 51 10 Contents TOS8030...

  • Page 13: Chapter 1 General

    NOTE * The TOS8030 withstanding voltage tester was designed based on a product con- cept of lightweight portability. As such, please check the specification require- ments for the relevant standards when using the tester to test electronic devices based on JIS, UL, or other standards.

  • Page 14: Options

    This switch shuts off the output voltage or cancels a status (such as FAIL). It switch has the same function as the STOP switch on the tester. RC01-TOS RC02-TOS 200(W) x 70(H) x 39(D) mm 330(W) x 70(H) x 39(D) mm 12 General TOS8030...
  • Page 15 When ending the test, confirm that the LED on the probe is not lit, then disconnect the probe from the DUT. High-voltage test leads Model number Maximum usage voltage Cable length Remarks Equivalent of TOS8030 TL01-TOS Approx. 1.5 m 5 kVac (rms) 50 Hz/60 Hz accessory 5 kVdc TL02-TOS Approx.

  • Page 16: Chapter 2 Installation And Preparations For Use

    Describes how to unpack the tester for preparation before use. Unpacking Inspection Check the TOS8030 tester upon receipt for any damage that may have occurred dur- ing transit and to confirm that all accessories have been provided. If the product is damaged or if any accessories are missing, notify your Kikusui dis- tributor or agent.

  • Page 17: Precautions For Installation

    The tester may fall, resulting in damage or injury. ■ Do not use the tester in locations subject to strong magnetic or electric fields. Using the tester in such locations may result in malfunctions, leading to electric shock or fire. TOS8030 Installation and Preparations for Use 15...

  • Page 18: Moving Precautions

    fixed installation) of the IEC standards. Checking the supply voltage Before connecting the power cord, check the tester’s supply voltage (100 V or 200 V). The tester’s nominal input rating is indicated on the rear panel. 16 Installation and Preparations for Use TOS8030...
  • Page 19 Check that the power supply meets the nominal input rating for the tester. Turn the POWER switch off. Connect the power cord to the AC INPUT connector on the tester’s rear panel. Insert the power cord plug into an electrical outlet. TOS8030 Installation and Preparations for Use 17...

  • Page 20: Grounding

    * An AC power line is generally a power line connected to an electrical outlet to which the tester’s power cord is connected. Here, it also refers to an AC line con- nected to a privately-owned electrical power generation device. 18 Installation and Preparations for Use TOS8030...

  • Page 21: Chapter 3 Precautions For Safe Testing

    Wearing Rubber Gloves • When using the tester, always wear rubber gloves intended for electrical WARNING work to prevent electric shock. If you have difficulty obtaining proper rubber gloves, consult your Kikusui distribu- tor or agent. TOS8030 Precautions for Safe Testing 19...

  • Page 22: Operating Precautions

    Insert the black test lead into the LOW terminal and attach an extraction prevention guard to the terminal, as shown in Fig. 3-2. LOW-side test lead (black) Attach the extraction prevention guard to the terminal and fasten securely. Fig. 3-2 Connecting the LOW-side Test Lead 20 Precautions for Safe Testing TOS8030...
  • Page 23 Connecting the HIGH VOLTAGE-side test lead ■ To disconnect the test leads from the DUT Disconnect the red test lead from the HIGH VOLTAGE terminal. You do not need to disconnect the black test lead from the LOW terminal. TOS8030 Precautions for Safe Testing 21...

  • Page 24: For High Voltage Output

    POWER switch off. ■ Do not turn the POWER switch off. Except in emergencies, do not turn the POWER switch off while output is being generated. 22 Precautions for Safe Testing TOS8030...

  • Page 25: Checking Safety After Shutting Off The Output

    Disconnect the red test lead from the HIGH VOLTAGE terminal. You do not need to disconnect the black test lead from the LOW terminal. HIGH VOLTAGE-side test lead (red) Fig. 3-8 Disconnecting the HIGH VOLTAGE-side Test Lead TOS8030 Precautions for Safe Testing 23...

  • Page 26: When Interrupting Operations

    DUT, or other components, take the following two steps. Both must be performed, although either may be performed first. Turn the POWER Disconnect the power plug switch off. from the electrical outlet. Fig. 3-10 Response to Emergencies 24 Precautions for Safe Testing TOS8030...

  • Page 27: Stop Using The Tester In The Event Of A Malfunction

    • Implement safeguards so that no one will attempt to use the tester before WARNING it has been sent for repair. • Always contact your Kikusui distributor or agent to request repairs. To ensure safety, never attempt to repair the product yourself. TOS8030...

  • Page 28: Chapter 4 Part Name's And Functions

    Chapter 4 Part Name’s and Functions Gives the names of switches, terminals, and other controls of the TOS8030. Front Panel Fig.4-1 TOS8030 Front Panel [1] POWER switch Turns the tester power on/off. Depressing the switch turns power on ( | ).
  • Page 29 This voltmeter displays the output voltage, indicating the voltage at the HIGH VOLTAGE terminal. If the tester enters the PROTECTION state, the voltmeter displays the reason for protective function activation by a code ranging from P01 to P12 (7 events). TOS8030 Part Name’s and Functions 27...
  • Page 30 When the TIMER switch is turned ON, test time can be set. Select the range (x0.1 or x1) and set test time in the range of 0.5 s to 99 s. For more information, see item “Test time” (page 35). 28 Part Name’s and Functions TOS8030...

  • Page 31: Rear Panel

    Rear Panel MADE IN TAIWAN NC03368-1 Fig. 4-2 TOS8030 Rear Panel [1] REMOTE connector Used to start or stop testing from a remote location. For more information, see “Using the REMOTE Connector” (page 38). [2] SIGNAL OUT terminal Used to monitor the tester status externally.

  • Page 32: Chapter 5 Panel Operations

    After all the display units and indications light, the tester changes to display the test conditions currently set. Lit (8.8.8.) Fig. 5-2 Indications Displayed After POWER Switch is Turned On 30 Panel Operations TOS8030...

  • Page 33: Tester States And Indications

    When lit, this lamp indicates When lit, this lamp indicates that that the test result has been the protection circuit has been determined to be FAIL. activated. (FAIL state) (PROTECTION state) Fig. 5-4 Indicators on the Front Panel TOS8030 Panel Operations 31...

  • Page 34: Five States

    STOP signal), after which the tester transitions to a READY state. ■ READY state A READY signal is generated in this state. All four lamps (TEST, PASS, FAIL, and PROTECTION) remain unlit. Press the START switch in this state to start testing. 32 Panel Operations TOS8030...

  • Page 35: Events Or Conditions That Can Activate The Protection Function - -33

    Adjust the output voltage to 3.0 kV or less using the A voltage of 3.6 kV or higher was output. TEST VOLTAGE knob. To cancel the PROTECTION state, press the STOP switch. Fig. 5-5 Example of Display of Code “P06” TOS8030 Panel Operations 33...

  • Page 36: Procedure For Test

    Setting a Current Detection Reference Limit NOTE • If the operator sets a current value exceeding 5 mA, testing is subject to output time limitations. For more information, see “Footnote *1” in “9.1 Basic Specifica- tions” (page 46). 34 Panel Operations TOS8030...
  • Page 37 • The maximum output voltage of the tester at no-load rises above 3 kV. This value rises higher in proportion to power supply fluctuations, but it should always be set to a value ranging from 0.05 kV to 3.00 kV. TOS8030 Panel Operations 35...
  • Page 38 Adjust the voltage to a desired value (from 0.05 kV to 3.00 kV). Press the START switch to start test voltage setting. Press the STOP switch to finish test voltage setting. Turn the knob slowly clockwise. Fig. 5-9 Setting the Test Voltage 36 Panel Operations TOS8030...

  • Page 39: Connection To The Dut

    START switch. ■ Before disconnecting the test leads from the DUT Confirm that high voltage is not being output, referring to “3.3.3 Checking Safety after Shutting off the Output” (page 23). TOS8030 Panel Operations 37...

  • Page 40: Chapter 6 Remote Control

    6.1.1 Remote Control with the Optional Remote Control Box The TOS8030 can be controlled from a remote location using an optional remote control box to start or stop testing. Connecting the remote control box to the REMOTE connector on the front panel switches the tester from front panel control to remote control.

  • Page 41: Remote Control Using A Control Device

    Press the STOP switch. switch on the front panel. Connecting a control device to the REMOTE connector requires a 5-pin, DIN Stan- dard-based connector. Contact your Kikusui distributor or agent if you have diffi- culty obtaining a 5-pin DIN connector. TOS8030...
  • Page 42 Configure the control circuits so that pins 2 and 3 connect externally. Control circuit example REMOTE connector TOS8030 In this example, controlling the START and STOP con- tacts lets you operate the tester in the same way as from...
  • Page 43 REMOTE connector TOS8030 Photocoupler iʼ Icʼ turned on STOP START 20 ms or more 20 ms or more Fig. 6-4 Example: Circuit 3 REMOTE Connector Input Conditions H-level input voltage 11 V to 15 V L-level input voltage 0 V to 4 V...

  • Page 44: Using The Interlock Terminal

    For safety, always enable the interlock function when perform- ing actual testing. To ensure user safety, the TOS8030 interlock function interlocks with external equipment to shut down output. When this function is activated, a PROTECTION state is invoked and output is shut off, preventing further testing. When this function...

  • Page 45: Chapter 7 Status Signal Output

    Turn the POWER switch terminals, pressing on off before connecting this part using a a wire to the SIGNAL screwdriver or the like. TOS8030 OUT terminals. Rating of make Internal circuit of contact signal: each pair of terminals 1 A/30 Vdc Fig.

  • Page 46: Example: Use Of Signals

    7.2.2 Example: Use of Signals ■ Driving a DC buzzer using a FAIL signal Closed at FAIL judgment TOS8030 Buzzer 30 V or less FAIL 1 A or less Fig. 7-2 Example: Use of FAIL Signal ■ Driving a lamp using an H.V ON signal...

  • Page 47: Chapter 8 Maintenance And Calibration

    Please contact your Kikusui distributor or agent to purchase accessories. Calibration The TOS8030 tester is calibrated appropriately on shipment from the factory. How- ever, the tester should be calibrated after long-term usage. • The tester generates voltages as high as 3 kV. Because internal inspec-...

  • Page 48: Chapter 9 Specifications

    Chapter 9 Specifications Provides the electrical and mechanical specifications for the TOS8030. The specifications are based on the following conditions and settings, unless other- wise specified. • Warm-up time: 30 minutes ° ° • Temperature: 5 C to 35 •...
  • Page 49 When the provided TL01-TOS lead wires are used (typical val- 20 μA 40 μA 60 μA ues) *6 Voltage required to make FAIL judgment with the output terminals short-circuited due to internal resistance in the output circuit. TOS8030 Specifications 47...

  • Page 50: Other Functions

    160 (170) W x 132 (155) H x 230 (270) D mm Weight Approx. 6 kg • High-voltage test leads TL01-TOS (approx. 1.5 m): 1 set • Power cord: 1 Accessories • INTERLOCK jumper: 1 • Operation Manual: 1 copy 48 Specifications TOS8030...

  • Page 51: Dimensions

    Dimensions MAX270 (10.63) MAX30 230 (9.05) (1.18) MAX170 (6.69) 160 (6.30) Unit: mm (inch) TOS8030 Specifications 49...

  • Page 52: Appendix

    DUT, potentially damaging the DUT or resulting in a FAIL assess- ment for a good DUT. To reduce distortion of test voltage waveforms, the TOS8030 tester uses a zero-start switch semiconductor to open or close a circuit when the supply voltage is near 0 V.

  • Page 53: Index

    HP01A-TOS 13 SIGNAL OUT terminal 43 HP02A-TOS 13 START switch 26 starting the test 37 startup inspection 19 indicators 27 status signal output 43 inspection 45 STOP switch 26 installation 15 stray capacity 47 interlock function 42 TOS8030 Index 51...
  • Page 54 TEST state 32 test time 35 test voltage 35 TEST VOLTAGE knob 28 test voltage waveform 46 time limitations 46 TIMER 28 TL01-TOS 13 TL02-TOS 13 upper reference limit 34 voltmeter 27 window comparator 11 zero-start switch 50 52 Index TOS8030...
  • Page 56 KIKUSUI ELECTRONICS CORP. 1-1-3 Higashiyamata, Tsuzuki-ku, Yokohama, 224-0023, Japan Tel: +81-45-593-7570 Fax: +81-45-593-7571 http://www.kikusui.co.jp/en Website...

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