User's Manual: Insulation Resistance Tester

No.
IB028912
Jul. 2018
User’s Manual
1. Preface 11
Insulation Resistance Tester
2. Preparation 14
TOS7200 3. Safety Precautions
during Testing 19
4. Basic Operation 23
5. Using Terminals and

Connectors 39
6. Maintenance 49
7. Specifications 51
DANGER
This Tester generates high voltage!
Ɣ Any incorrect handling may cause death.
Ɣ Read Chapter 3 "Safety Precautions during Testing"
in this manual to prevent accident.
Ɣ Keep this manual near the tester for easy access
of the operator.
About the TOS7200 Manuals Notations Used in the Manual
There are five TOS7200 Manuals listed as follows.

• Device under test is also referred to as DUT.
• Setup Guide
• The term “PC” is used to refer generally to both personal
Setup Guide is intended for first-time users of this product. It
computers and workstations.
provides an overview of the product and notes on usage. It also
explains how to set up the product for testing the DUT. Always • The following markings are used in the explanations in the
read this manual before using the product. manual.
• Quick Reference
WARNING
Quick Reference explains Panel description and operation
briefly. Indicates a potentially hazardous situation which, if ig-nored,
could result in death or serious injury.
• Safety Information
Safety information contains general safety precautions for this
CAUTION
product. Keep them in mind and make sure to observe them.
Indicates a potentially hazardous situation which, if ignored,
• User’s Manual (this manual)
may result in damage to the product or other property.
This manual is intended for first-time users of this product. It
provides an overview of the product and notes on usage. It also
explains how to configure the product, operate the product,
perform maintenance on the product, and so on. Indicates information that you should know.
• Communication Interface Manual

Interface Manual contains details about remote control. The
DESCRIPTION
manual is provided on the accompanying CD-ROM. Explanation of terminology or operation principle.
Interface manual is written for readers with sufficient basic
knowledge of how to control instruments using a personal
computer. Unpacking
TOS7200 Manuals are intended for users of the Insulation Upon receiving the product, confirm that the necessary
Resistance Tester and their instructors. Explanations are given accessories are included and have not been damaged in transit.
under the presumption that the reader has knowledge about the Should any damage or shortage be found, please contact Kikusui
electrical aspects of electrical safety testing. distributor/agent.
Retain the packing material for future transport.
Firmware version of the product to which this
manual applies Accessory
This manual applies to TOS7200 with firmware version 1.0x.
When making an inquiry about the product, please provide us The power cord that is provided varies depending on
with the following information. the destination for the product at the factory-shipment.
Model (indicated at the top section on the front panel)
Firmware version (p.15)
Serial number (indicated at the bottom section on the rear or or
panel)
Plug: NEMA5-15 Plug: CEE7/7 Plug: GB1002
Copyrights Rating: 125 Vac/10 A Rating: 250 Vac/10 A Rating: 250 Vac/10 A
Reproduction and reprinting of this manual, whole or partially, [85-AA-0003] [85-10-1070] [85-10-0791]
without our permission is prohibited. Power cord (1 pc., Aprox. 2.5 m)
Both unit specifications and manual contents are subject to
change without notice.
Copyright © 2016 Kikusui Electronics Corporation.
TL08-TOS High-voltage test lead

(1 set, 1.5 m)
Quick Reference Safety information

(English: 1 pc., Japanese: 1 pc.) (1 pc.)
Setup guide (1 pc.) CD-ROM (1 pc.)
2 TOS7200
To supervisor in charge of operation
• If the operator does not read the language used in this manual, translate the manual into
appropriate language.
• Help the operator in understanding this manual before operation.
• Keep this manual near the Tester for easy access of the operator.
For your own safety (to avoid electrification)
While the Tester is delivering its test voltage, never touch the following areas, or else, you will be
electrified, and run the risk of death by electric shock.
• the output terminal
• the test leadwires connected to the output terminal
• the Device Under Test (DUT)
• any part of the Tester, which is electrically connected to the output terminal, and
• the same part as above immediately after the output has been cut off.
TOS7200 3
Safety Precautions
When using this product, be sure to observe the “Safety

Precautions” in the Safety information manual.
Precautions Concerning
Installation Location
When installing this product, be sure to observe the “Precautions
Concerning Installation Location” in the Safety information
manual.
Items specific to this product are given below.
• When you install the product, be sure to observe the
temperature 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 you store the product, be sure to observe the
temperature 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)
• Use the product in an industrial environment.
Use the product 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 emissions to prevent
interference to the reception of radio and television broadcasts
• Use of the legs
These legs are used to raise the front part of the tester so that
the screen on the front panel is easier to see and the keys are
easier to operate.
To use the legs, pull them toward the front until you hear a click.
Moving the Product
When moving or transporting the product to the installation

location, be sure to observe the “Precautions to Be Taken When
Moving the Product” in the Safety information manual.
Item specific to this product are given below.
• Retract the legs.
4 TOS7200
Contents
About the TOS7200 Manuals ................2
4 Basic Operation . . . . . . . . 23
Setting the Test Voltage. . . . . . . . . . . . 23
Setting Limits . . . . . . . . . . . . . . . . . . . . 24
Notations Used in the Manual ................2 Setting a lower resistance (LOWER) . . . 24
Unpacking ..............................................2 Setting the upper resistance (UPPER) . . 25
To supervisor in charge of operation .....3 Turning the Judgment Function On and Off
For your own safety (to avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
electrification) ......................................3 Turning the lower judgment function on and
off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety Precautions .................................4
Turning the upper judgment function on and
Precautions Concerning Installation off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Location ...............................................4 Window comparator function . . . . . . . 27
Moving the Product ................................4 Setting the Timer Function. . . . . . . . . . 28
Contents .................................................5
Turning the timer function on and off . . . 28
Front Panel .............................................7
Setting the test time (TEST TIME) . . . . . 28
Display ....................................................8
Setting the wait time (WAIT TIME) . . . . . 29
Rear Panel............................................10
Starting and Ending a Test . . . . . . . . . 30
1 Preface . . . . . . . . . . . . . . . 11
Outline of the TOS7200 . . . . . . . . . . . . . 11
Features . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starting the test. . . . . . . . . . . . . . . . . . . . 30
Ending the test . . . . . . . . . . . . . . . . . . . 31
PASS judgment . . . . . . . . . . . . . . . . . 31
FAIL judgment . . . . . . . . . . . . . . . . . . 32
Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RC01-TOS/RC02-TOS remote-control System Setting. . . . . . . . . . . . . . . . . . . 33
boxes . . . . . . . . . . . . . . . . . . . . . . . . 12 Controlling the system settings . . . . . . . . 33
To exit system setting. . . . . . . . . . . . . 33
2 Preparation . . . . . . . . . . . . 14
Connecting the Power Cord. . . . . . . . . 14
Description of each item . . . . . . . . . . . . . 34
Panel Memory . . . . . . . . . . . . . . . . . . . 36
Storing in panel memory . . . . . . . . . . 36
Turning ON the Power . . . . . . . . . . . . . 15 Recalling a panel memory . . . . . . . . . 36
Turning the POWER switch off. . . . . . 15
Key Lock . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting the Test leadwires . . . . . . 16
Connecting to the OUTPUT terminals . . 16 Invalid Settings. . . . . . . . . . . . . . . . . . . 37
Connecting to the DUT . . . . . . . . . . . . . 17 Initialize . . . . . . . . . . . . . . . . . . . . . . . . 38
Connecting to a grounded DUT . . . . . 17 Settings for test conditions . . . . . . . . . 38
Connecting to an ungrounded DUT . . 18 System setting . . . . . . . . . . . . . . . . . . 38
5
Disconnecting Test Leads from the
DUT . . . . . . . . . . . . . . . . . . . . . . . . 18 Using Terminals and
Connectors . . . . . . . . . . . . 39
3 Safety Precautions during

Testing . . . . . . . . . . . . . . . 19
REMOTE Terminal. . . . . . . . . . . . . . . . 40
Performing remote control . . . . . . . . . 41
Daily Checking. . . . . . . . . . . . . . . . . . . 19 SIGNAL I/O Connector . . . . . . . . . . . . 42
Wire and tool that are necessary to make
Precautions on Testing . . . . . . . . . . . . 20
the connection . . . . . . . . . . . . . . . . . 42
Precautions for pausing tests. . . . . . . 20
Items charged up to dangerous high Specifications for the SIGNAL I/O connector
voltages . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Matters to be sure of after turning-off Example of use . . . . . . . . . . . . . . . . . . . . 44
power . . . . . . . . . . . . . . . . . . . . . . . . 20 Starting a test . . . . . . . . . . . . . . . . . . . . 46
Warnings for remote control. . . . . . . . 20 Controlling signals . . . . . . . . . . . . . . . 46
Recalling the panel memory. . . . . . . . 47
Warning for Residual High Voltages . . 21
Discharge time . . . . . . . . . . . . . . . . . . 21 ANALOG OUT Terminals. . . . . . . . . . . 48
6
Action When in Emergency . . . . . . . . . 21
Maintenance . . . . . . . . . . . 49
Prohibited Operations . . . . . . . . . . . . . 22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 49
Dangerous States of Failed Tester . . . 22 Maintenance . . . . . . . . . . . . . . . . . . . . . . 49
Calibration. . . . . . . . . . . . . . . . . . . . . . . . 49
TOS7200 5
Troubleshooting . . . . . . . . . . . . . . . . . . . 50
7 Specifications . . . . . . . . . . 51
Basic performance . . . . . . . . . . . . . . . . .
Interface and other functions . . . . . . . . .
51
53
General specifications . . . . . . . . . . . . . . 55
Dimensions. . . . . . . . . . . . . . . . . . . . . . . 56
Index..................................57
6 TOS7200
Front Panel
10 Display 1
OUTPUT
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
11 9 8 7 6 5 4 3 2
No. Name Description See

1 START switch Starts testing. p. 30
2 STOP switch Stops testing and clears the current status. Cancels a PASS or FAIL judgment. p. 31
3 LOCAL key Switches RS232C remote mode (REMOTE LED lit) to local mode. —
SHIFT key Used to access the features that are written in blue. —
4 and keys Moves the cursor when setting test conditions or the like.*1
Pressing them both at the same time locks the keys and turns on the KEYLOCK —
LED.
and keys Increases or decreases the numerical value of the digit at which the cursor is
—
located.
5 TEST/WAIT key Sets the test duration or wait time. p. 28
TIMER ON key Switches between ON and OFF for the test-duration timer function (TIMER ON
p. 28
LED).
6 UPPER/LOWER key Sets the upper or lower resistance p. 24
UPPER ON key Switches between ON and OFF for the upper judgment p. 27
7 VOLT key Sets the test voltage p. 23
SYSTEM key Switches to the system setting display. p. 33
8 RECALL key Recalls panel settings from memory p. 36
STORE key Stores panel settings to memory p. 36
9 REMOTE terminal This dedicated terminal is used to connect the optional remote control box
p. 40
RC01-TOS or RC02-TOS.
10 OUTPUT terminal Test voltage output terminals
p. 16
Connected in parallel with the OUTPUT terminals on the rear panel.
11 Legs These legs are provided to raise the front part of the tester to make it easier to
p. 4
view the front panel screen and operate the keys.
*1. The location of the cursor is indicated by a blinking 7-segment LED on the display unit. This blinking will stop if no
keystroke is entered for 5 seconds or more.
TOS7200 7
Display
1 2 3 4 5 6
10 9 8 7

1 DANGER lamp On (red) during testing and while voltage resides across the output
p. 30
terminals.
2 MEMORY Indicates panel memory settings. p. 36
STORE LED Lights when settings can be stored to panel memory. —
7-segment LED Indicates the number of a memory into or from which panel settings
—
are stored or recalled
3 VOLTAGE Indicates the test voltage. p. 23
7-segment LED Indicates the output voltage (during testing).
—
Indicates the test voltage setting (not during testing).
4 RESISTANCE Indicates the resistance (during testing).
p. 24
Indicates the upper limit or lower limit setting (not during testing).
UPPER ON LED Lights when the upper judgment is enabled. p. 27
UPPER LED Lights when the upper limit setting is displayed or when the
p. 25
judgment result is UPPER FAIL.
LOWER LED Lights when the lower limit setting is displayed or when the
p. 24
judgment result is LOWER FAIL.
7-segment LED Indicates the resistance measurement during testing (blinks when
the measurement range is exceeded) or indicates the upper or lower —
limit setting otherwise.
5 TIMER Indicates the test time (during testing).
Indicates the judgment wait time or test time setting (not during p. 28
testing).
WAIT LED Lit: The 7-segment LED displays the judgment wait time.
p. 29
Not lit: The 7-segment LED displays the test time.
TIMER ON LED Lights when the timer function is on.
p. 28
Blinks when the judgment wait time is set longer than the test time.
7-segment LED Indicates the countdown time when the timer is on and the elapsed
—
time when the timer is off (during testing).
6 PASS lamp When the result of a pass/fail judgment is PASS, this LED lights. p. 31
7 FAIL lamp When the result of a pass/fail judgment is FAIL, this LED lights. p. 32
8 TOS7200
8 System setting display Indicates the selected function when system settings are being
p. 33
configured.
DOUBLE ACTION Indicates the setting for the DOUBLE ACTION function.
p. 34
1: ON, 0: OFF
MOMENTARY Indicates the setting for the MOMENTARY function.
p. 34
1: ON, 0: OFF
FAIL MODE Indicates the setting for the FAIL MODE function.
p. 34
1: ON, 0: OFF
PASS HOLD Indicates the setting for the PASS HOLD function.
p. 34
1: ON, 0: OFF
AVG Shows the number of averaging times. p. 34
AUTO RANGE Shows the measurement range mode.
p. 35
1: auto-range, 0:fixed range
LOWER ON Indicates the lower judgment function
p. 35
1: ON, 0: OFF
SPEED Shows the communication rate for RS232C communications.
p. 35
0: 9600 bps, 1: 19200 bps, 2: 38400 bps
BUZZER Indicates the buzzer volume level (10 levels from 0 to 9) p. 35
9 KEYLOCK LED Lights up when the tester is in KEYLOCK state. p. 37
10 REMOTE LED*1 Lights up when the tester is remotely controlled through the RS232C
—
interface.
*1. When lit, all inputs except the STOP switch are not accepted. To return to local mode, press LOCAL (SHIFT).
TOS7200 9
Rear Panel
1 6
2 3 4 5

1 POWER switch Turns the power on [ ] and off [ ]. p. 15
2 AC LINE connector AC inlet. p. 14
3 SIGNAL I/O connector External control signal connector. p. 42
4 RS232C connector*1 This is the RS232C interface. —
5 ANALOG OUT terminals Analog output terminal
This terminal outputs the voltage that corresponds to the measured p. 48
resistance value.
6 OUTPUT terminals These terminals output the test voltage.
They are connected in parallel to the OUTPUT terminals on the front p. 16
panel.
*1. For details, see the communication interface manual.
10 TOS7200
1 Preface
Outline of the TOS7200
The TOS7200 is an insulation resistance tester that is available in a wide range of electric and
electronic components and equipment, and allows any test voltage to be set. Because it
features the window comparator and timer function, the tester is capable of efficiently
conducting insulation resistance tests based on various safety standards. Moreover, with the
panel memory, which can be recalled externally and the RS232C interface provided as
standard equipment, the tester can flexibly handle automated systems.
Features
 Arbitrary setting of the output voltage

The output voltage may be set to between 25 V and 1000 V. Thus, insulation resistance
tests can be conducted on a wide range of electric and electronic components and
equipment.
Test voltage Resistance measurement range

25 V 0.03 MΩ to 250 MΩ
50 V 0.05 MΩ to 500 MΩ
100 V 0.10 MΩ to 1000 MΩ
125 V 0.13 MΩ to 1250 MΩ
250 V 0.25 MΩ to 2500 MΩ
500 V 0.50 MΩ to 5000 MΩ
1000 V 1.00 MΩ to 5000 MΩ
 Equipped with a discharge function

The tester features a discharge function, which discharges the electric charge in the device
under test (DUT.) This allows tests to be conducted more safely.
 Equipped with a window comparator

The tester has adopted a window comparator system capable of making judgments on
both the upper and lower limits. This prevents non-contact-caused judgment errors and
other errors.
 Equipped with a timer function

The tester features a timer function that allows the test time to be set. It also enables
setting of the wait time, allowing more secure measurements and evaluation.
TOS7200 11
Preface
 Output terminals on the rear panel

Output terminals on the rear panel improve wiring workability in an automated
production line or other workshops.
 Analog output
The rear panel is provided with an analog output section for measured resistance values.
 Equipped with a panel memory

As the TOS7210A can store up to 10 types of panel settings, settings complying with
various standards can easily be invoked to conduct tests.
 Provided with a SIGNAL I/O connector and remote-control terminal

Equipped with a SIGNAL I/O connector as standard equipment, to output the test status as
an external I/O and handle starting/stopping of tests and recalling of panel memory. In
addition, the front panel has a remote-control terminal that allows tests to be started/
stopped remotely.
 Incorporating the RS232C interface as standard equipment

The tester features an RS232C interface as standard equipment for easy connection to a
PC, allowing measured data to be obtained.
Option
This Tester features the following options:
RC01-TOS/RC02-TOS remote-control boxes

These remote-control boxes remotely control starting/stopping of the tester when
connected to the REMOTE terminal on the front panel.
The RC01-TOS has one START switch, while the RC02-TOS has two.
For the RC02-TOS, a test starts only when both switches are pressed simultaneously.
 Functions
• OPERATE switch
The TEST switch can be operated only when this switch is set to ON. When it is turned OFF,
a test in progress will be stopped forcibly.
• START switch
When the OPERATE switch is ON and the tester is in ready status, pressing this switch starts
testing.
• STOP switch
This switch is used to shut off the output voltage or cancel a FAIL judgment. It serves the
same function as the STOP switch on the front panel of the tester.
12 TOS7200
Preface
RC01-TOS: 200 mm (W)×70 mm(H)×39 mm (D)
RC02-TOS: 330 mm (W)×70 mm (H)×39 mm (D)
Connection of a remote-control box to the tester requires the use of a DIN-Mini DIN adapter.
For DD-5P/6P DIN-Mini DIN adapter [84250], contact your Kikusui distributor/agent.
TOS7200 13
2 Preparation
This chapter describes the procedures from installation to operation checking.
Connecting the Power Cord
WARNING • This product is a piece of equipment that 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 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 for other devices.
This product is a piece of equipment that conforms to IEC Overvoltage Category II (energy-
consuming equipment that is supplied from a fixed installation).
1 Check that the POWER switch is turned off.
2 Check whether the AC power line is compatible with the input rating of
the product.
The product can receive a nominal power supply voltage in the range of 100 Vac
to 240 Vac (85 Vac to 250 Vac) that has a frequency 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.
14 TOS7200
Turning ON the Power
WARNING • Before turning ON the power, always confirm that the AC power is within the
allowable line-voltage range indicated on the rear panel of the tester. For more
information, see “Connecting the Power Cord” (p.14).
• To prevent electric shock, be sure to turn OFF the POWER switch before disconnecting
the cable for the SIGNAL I/O or RS232C connector.
1 Confirm that the AC power is within the allowable line voltage range
indicated on the rear panel of the tester.
2 Confirm that the AC power cord is properly connected to the AC LINE

connector on the rear panel of the tester.
3 Connect the other plug of the AC power cord to an electrical outlet.
4 Turn ON the POWER switch of the tester.

The voltmeter displays the installed firmware version number, and the resistance
meter displays “7200,” which is the product model.
Following these displays, the voltmeter and resistance/current meter change to
the displays status when the POWER switch was last turned off.
Firmware version Model
When the power is turned on, the tester lights up all LEDs on the front panel to perform self-
testing. To ensure safety, be sure to confirm that all LEDs is lit before operating the tester. It is
especially dangerous to use the tester if its DANGER lamp is broken.
When the power is turned on, the DANGER lamp lights, but no voltage is generated.
Turning the POWER switch off.
The POWER switch to turn the TOS7200 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.
Possible electric shock.

WARNING
• 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.
TOS7200 15
Connecting the Test leadwires
Test leadwires connect the product to the DUT.
Insecure connection of a test leadwire may cause the entire DUT to be charged to high
WARNING
voltage, posing a danger. Take care to connect the test leadwires securely.
Connecting to the OUTPUT terminals
 Connecting the low voltage side test leadwire
1 Press the STOP switch.
2 Check that the DANGER lamp is off.
3 Check that there is no breakage in the test leadwires.
4 Connect the low voltage side test leadwire to the LOW terminal.
 Connecting the high voltage side test leadwire

Perform the following procedure after connecting the low voltage side test leadwire:
2 Confirm that the DANGER lamp is off.
3 Connect the high voltage side test leadwire to the HIGH terminal.
4 Short-circuit the low voltage side and high voltage side test leadwires to
confirm that no high voltage is output.
16 TOS7200
Connecting the Test leadwires
Connecting to the DUT
Connect the test leadwires to the DUT after connecting the low voltage side and high
voltage side test leadwires to the tester.
2 Confirm that the DANGER lamp is off.
3 Short-circuit the high voltage side test leadwire using the low voltage side
test leadwire to confirm that no high voltage is applied.
4 Connect the low voltage side test leadwire to the DUT.
5 Connect the high voltage side test leadwire to the DUT.
Risk of electric shock. Never touch a test leadwire, the DUT, the HIGH terminal, or the
WARNING
LOW terminal during a test (or while the DANGER lamp is lit).
The polarity of the output terminal of the tester is negative. The HIGH terminal has negative (-)
polarity, while the LOW terminal has positive (+) polarity.
Connecting to a grounded DUT

When conducting an insulation resistance test on a DUT with one terminal grounded, connect
the LOW terminal of the tester to the grounding terminal of the DUT.
For example, to conduct an insulation resistance test across the AC LINE and grounding
terminal of the grounded DUT, connect the LOW terminal of the tester to the grounding
terminal of the DUT and the HIGH terminal of the tester to the AC LINE of the DUT.
OUTPUT
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
TOS7200
L AC LINE
N
Grounded DUT
Insulation resistance test across
the AC LINE and chassis of the DUT
Risk of electric shock. Never touch a test leadwire, the DUT, the HIGH terminal, or the
WARNING
LOW terminal during a test (or while the DANGER lamp is lit).
TOS7200 17
Disconnecting Test Leads from the DUT .
DESCRIPTION ● Reason that the LOW terminal of the tester is connected to the grounding terminal of
the DUT that has been grounded:
It is appropriate to connect the line terminal (LINE) to the negative (-) side of the power
source and the grounding terminal (EARTH) to the positive (+) side. When testing the
insulation of insulation wires or cables with respect to ground for direct current, connecting
the negative polarity of the power source to the core and the positive polarity to ground will
generally provide smaller measured values than when the reverse polarities are connected.
Thus, the above-noted connection is considered appropriate for the detection of insulation
failures.
For the above reason, the tester connects the negative polarity of the power source to the
HIGH terminal and the positive polarity of the power source to the LOW terminal. Thus, for
insulation resistance testing involving a DUT with one grounded terminal, it is appropriate to
connect the LOW terminal of the tester to the grounding terminal of the DUT, and the HIGH
terminal of the tester to the LIVE terminal of the DUT.
Connecting to an ungrounded DUT

When conducting insulation resistance testing on a DUT that has not been grounded, connect
the HIGH and LOW terminals of the tester to any two points of the DUT.
OUTPUT
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
TOS7200
Ungrounded DUT
Disconnecting Test Leads from the DUT .
1 Check that the DANGER lamp is off.
2 Remove the high voltage side test leadwire from the TOS7200 HIGH
terminal.
3 Remove the high voltage side test leadwire from the DUT.
4 Remove the low voltage side test leadwire.

You can remove either end of this test leadwire first: the DUT end or the OUTPUT
terminal end.
18 TOS7200
3 Safety Precautions during Testing
This chapter describes the precautions to be followed in the handling of this tester. When
using the tester, take utmost care to ensure safety.
The tester derivers a 1000 Vdc test voltage which can cause human injury or death.
WARNING
When operating the tester, be extremely careful and observe the cautions, warnings,
and other instructions given in this chapter.
Daily Checking
To avoid accidents, confirm at least the following before starting operation:

• The tester is connected to an earth ground.
• The coating of the test leadwires are free from cracks, fissures, and breakage.
• The test leadwires are not broken.
• When a test is started without the test leadwires connected to each other in the UPPER
OFF condition, a FAIL judgment must not be made.
• When a test is started with the test leadwires short-circuited in a LOWER ON condition, a
FAIL judgment must be made.
TOS7200 19
Precautions on Testing
Precautions for pausing tests

When changing test conditions, press the STOP switch once to take precautions. If you are
not going to resume the test soon or if you are leaving the Test area, be sure to turn-OFF
the POWER switch.
OUTPUT
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
STOP
switch
POWER
switch
Items charged up to dangerous high voltages
WARNING • Possible electric shock. Never touch a test leadwire, the DUT, the HIGH terminal, or the
LOW terminal during a test.
• The vinyl sheaths of the alligator clips of the test leadwires which are supplied
accompanying the Tester have no sufficient insulation for the high test voltages.
Never touch them when in test.
Alligator clip
Never touch this part.
Matters to be sure of after turning-off power

If you have to touch the DUT, test leadwires, HIGH terminal, and/or LOW terminal for re-
connections or other reasons, be sure of the following matter.
The DANGER lamp has gone out.
Warnings for remote control

Be extremely careful when operating the Tester in the remote control mode in which the
dangerous high test voltage is ON/OFF-controlled remotely. Provide protective means as
follows:
• Provide means to assure that the test setup does not become the test voltage is being
delivered by inadvertent operation.
• Provide means to assure that none can touch the DUT, test leadwires, HIGH terminal, and
LOW terminal when the test voltage is being delivered.
20 TOS7200
Warning for Residual High Voltages
WARNING • In Testing, the test leadwire, and DUT are charged to a high voltage. The tester is
equipped with a discharge circuit, but some time is nonetheless required to discharge
them after the output is cut off. There is a danger of electric shock during discharge.
To avoid electric shock, take the utmost care to ensure that the DUT, test leadwire, and
highly charged parts around the output terminal are not touched. If it is necessary to
touch them, be sure to confirm the following:
The DANGER lamp has gone out.
• As soon as the output is cut off, the tester’s discharge circuit starts forced discharging
(discharge function). Do not disconnect the DUT during a test or prior to completion
of discharging.
The discharger function operates until the DUT voltage (or output terminal voltage) becomes
approximately 30 V.
Discharge time
The length of the discharge time varies according to the properties of the DUT and the test
voltage.
Discharge is conducted at a resistance of approximately 25 kΩ in testing.
When no DUT is connected, the tester itself requires this following lengths of time to reduce
the internal capacitor voltage to 30 V.
Test voltage 1000 V: Approximately 0.5 ms
Assuming that a 0.05 μF capacitor is tested, the following lengths of time are required to
reduce the charge to 30 V.
Test voltage 1000 V: Approximately 5 ms
If the DUT is disconnected during a test or before the completion of discharging, assuming
that the DUT has a capacity of 0.01 μF and a parallel resistance of 100 MΩ, approximately 3.5
seconds at 1000 V is required for the DUT to discharge to 30 V.
When the approximate time constant of the DUT is known, the time required for discharging
to 30 V after the output is cut off is calculated as the time constant times the value given
above.
Action When in Emergency
In case of an emergency (such as electric shock hazard or burning of DUT), take the following
actions. You may do either (a) or (b) first. But be sure to do both.
(a) Turn OFF the power switch of the Tester.
(b) Disconnect the AC power cord of the Tester from the AC line receptacle.
TOS7200 21
Prohibited Operations
 Do not turn on/off the power repeatedly

After turning OFF the power switch, be sure to allow 10 seconds or more before turning it
ON again. Do not repeat turning ON/OFF the power switch rapidly –if you do this, the
protectors of the Tester may not be able to render their protective functions properly.
Do not turn OFF the power switch when the tester is delivering its test voltage–you may
do this only in case of emergency.
Dangerous States of Failed Tester
Typical possible dangerous states of the Tester are as shown below and in which cases the
most dangerous situation that “the high test voltage remains delivered and won't be turned off!”
may occur. When this situation has occurred, immediately turn OFF the power switch and
disconnect the AC power cable from the AC line receptacle.
The DANGER lamp does not go out despite you have pressed the STOP switch.
Also when the Tester is in other malfunctioning states than the above, there is a possibility
that the output voltage is delivered irrespective of your proper operating procedure. Never
use the Tester when it has failed.
WARNING • Keep the Tester away of other people until you call our service engineer for help.
• Immediately call your Kikusui distributor/agent. It is hazardous for an unqualified
person to attempt to troubleshoot any Tester problem.
22 TOS7200
4 Basic Operation
This chapter describes basic panel operations such as how to set test conditions and system
settings.
Setting the Test Voltage
The tester enables setting of the test voltage to be applied to the DUT in the range of -10 Vdc
to -1020 Vdc (resolution: 1 V). (Note that the minus sign “-” is not indicated.)
Voltmeter
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
VOLT key For moving the cursor or

changing a numerical value
1 Press the VOLT key.

This causes the rightmost digit of the voltmeter LED to blink, indicating that the
cursor is positioned at this digit.
2 Press the
be set.
or key to move the cursor to the digit at which a value is to
3 With the SHIFT key held down, press the or key to change the value.
If necessary, change the value at another digit to reach the desired test-voltage
value. When the blinking of the changed value stops, the setting takes effect.
When the lower judgment is activated, making settings such that the value obtained by
dividing the test voltage by the lower resistance exceeds 1.1 mA causes the LOWER LED to
blink, notifying the operator that a test cannot be conducted. In such cases, lower the test
voltage or raise the lower resistance. (p.24)
TOS7200 23
Setting Limits
Set the limits for making pass/fail judgments on the DUT. There is a lower limit (LOWER) and an
upper limit (UPPER).
UPPER LED LOWER LED

UPPER ON LED Resistance meter
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
UPPER/LOWER key For moving the cursor or

Setting a lower resistance (LOWER)
The lower resistance can be set in the range of 0.01 MΩ to 5000 MΩ (provided that the current
is within the maximum rated current).
Lower Resistance Resolution

0.01 MΩ to 9.99 MΩ 0.01 MΩ
10.0 MΩ to 99.9 MΩ 0.1 MΩ
100 MΩ to 5000 MΩ 1 MΩ
When the wait time elapses following the start of a test, if an insulation resistance value below
the lower resistance is detected, the tester makes a FAIL judgment and ends the test.
1 Press the UPPER/LOWER key.

This causes the rightmost digit of the resistance meter LED to blink, indicating
that the cursor is positioned at this digit.
2 Check whether the LOWER LED is lit.

If it is, the lower resistance is displayed. If the UPPER LED is lit, the value
displayed is the upper resistance. In such cases, press the UPPER/LOWER key
again to light up the LOWER LED.
3 Press the or key to move the cursor to the digit at which a value is to be set.
If necessary, change the value at another digit to achieve the desired lower resistance.
• When both the upper and lower judgments are activated, setting the lower resistance to a
value higher than the upper resistance causes the UPPER LED to blink, notifying the
operator that a test cannot be conducted. (The lower resistance is set to 1.00 MΩ at factory
shipment.) In such cases, lower the lower resistance or raise the upper resistance.
• When the lower judgment is activated, making settings such that the value obtained by
dividing the test voltage by the lower resistance exceeds 1.1 mA causes the LOWER LED to
blink, notifying the operator that a test cannot be conducted. In such a case, lower the test
voltage or raise the lower resistance.
24 TOS7200
Setting Limits
Setting the upper resistance (UPPER)
The upper resistance can be set in the range of 0.01 MΩ to 5000 MΩ (provided that the current
is within the maximum rated current).
Upper Resistance Resolution

0.01 MΩ to 9.99 MΩ 0.01 MΩ
10.0 MΩ to 99.9 MΩ 0.1 MΩ
100 MΩ to 5000 MΩ 1 MΩ
1 Press the UPPER/LOWER key.

This causes the rightmost digit of the resistance meter LED to blink, indicating
that the cursor is positioned at this digit.
2 Check whether the UPPER LED is lit.

If it is, the upper resistance is displayed. If the LOWER LED is lit, the value
displayed is the lower resistance. In such a case, press the UPPER/LOWER key
again to light up the UPPER LED.
3 Press the
be set.
If necessary, change the value at another digit to reach the desired upper
resistance.
When both the upper and lower judgments are activated, setting the upper resistance to a
value below the lower resistance causes the UPPER LED to blink, notifying the operator that
the test cannot be conducted. (The upper resistance is set to 100 MΩ at factory shipment.)
In such cases, raise the upper resistance, lower the lower resistance, or set the lower
judgment to OFF.
TOS7200 25
Turning the Judgment Function On and Off
The lower limit (LOWER) and upper limit (UPPER) are used to make pass/fail judgment on the
DUT. You can set the lower and upper judgment functions separately. If both judgment
functions are ON, they function as a window comparator.
UPPER LED LOWER LED

UPPER ON LED Resistance meter
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
UPPER/LOWER key For moving the cursor or

If the upper or lower judgment function is OFF, no FAIL judgment is made. However, if the timer
is on, a PASS judgment will be made after the test time elapses, so you need to be careful.
Turning the lower judgment function on and off
When the lower judgment is set to ON, if the resistance value falls below the lower resistance”,
the tester makes a FAIL judgment and ends the test.
Setting the lower judgment to OFF causes the tester not to return a FAIL judgment, even if the
insulation resistance falls below the lower resistance.
You can turn on or off the lower judgment function with judgment mode (LOWER ON) (p.35) in
the system settings.
1 With the SHIFT key held down, press the VOLT key to enter the system setting.
This causes the leftmost digit of the voltmeter (digit indicated as DOUBLE
ACTION) to blink, indicating that the cursor is positioned at this digit.
2 Press the or key to move the cursor to the LOWER ON position.
3 With the SHIFT key held down, press the or key to change the setting.
The display shows 0 when the lower judgment function is off and 1 when it is on.
4 Press the STOP switch to exit the system setting.
• To measure the resistance value despite the fact that it causes a drop in the test voltage, use
a tester with the lower judgment set to OFF. In such a case, if the output voltage exceeds the
range of ±(2 % of setting + 2 V), the measured voltage value displayed on the voltmeter
blinks, notifying the operator of a drop in the test voltage.
• A lower judgment cannot be made until the wait time has elapsed since the start of a test.
26 TOS7200
Turning the Judgment Function On and Off
Turning the upper judgment function on and off
If the upper judgment is set to ON, when the resistance reaches or exceeds the upper limit, a
FAIL judgment is made, and the test is ended.
To turn on the upper judgment function, hold down SHIFT and press UPPER/LOWER (UPPER
ON). The function toggles between ON and OFF each time you press the key. When set to ON,
the UPPER ON LED lights.
Window comparator function

If both the lower and upper judgment functions are ON, they function as a window
comparator. When the resistance reaches or exceeds the upper limit or reaches or goes lower
than the lower limit, a FAIL judgment is made, and the test is ended.
If you turn on the upper judgment function when a fixed range is selected, the UPPER ON LED
blinks to indicate that you cannot start the test. Set the range to auto, or turn off the upper
judgment function.
TOS7200 27
Setting the Timer Function
When the timer function is set to ON, the duration of testing can be controlled. When the set
test time elapses with the resistance value within the upper and lower resistances during
testing, the tester makes a PASS judgment and ends the test.
WAIT LED TIMER ON LED
Timer
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
TEST/WAIT key For moving the cursor or

Turning the timer function on and off
ON and OFF of the timer function can be alternately selected by pressing the TEST/WAIT
(TIMER ON) key with the SHIFT key held down. When the timer function has been activated,
the TIMER ON LED lights up.
If the upper or lower judgment function is OFF, no FAIL judgment is made. However, if the timer
is on, a PASS judgment will be made after the test time elapses, so you need to be careful.
Setting the test time (TEST TIME)
The test duration during which the set test voltage is applied to the DUT can be set in the
range of 0.5 s to 999 s.
Test Time Resolution
0.5 s to 99.9 s 0.1 s
100 s to 999 s 1s
1 Press the TEST/WAIT key.

This causes the rightmost digit of the LED to blink, indicating that the cursor is
positioned at this digit.
2 Check whether the WAIT LED is lit.

If it is not lit, the test time is displayed. If it is lit, the value displayed is the wait
time. In such a case, press the TEST/WAIT key again to turn off the WAIT LED.
3 Press the
be set.
28 TOS7200
Setting the Timer Function
If necessary, change the value at another digit to reach the desired test time.
Setting the test time shorter than the wait time with the timer function set to ON causes the
TIMER ON LED to blink, notifying the operator that the test cannot be conducted.
Setting the wait time (WAIT TIME)
In insulation resistance testing, application of the test voltage to the DUT, including a
capacitive DUT, results in a lower insulation resistance measurement than expected until
completion of charge, due to the charge current. To eliminate the effects of the charge current
during lower judgment, the tester provides a wait time extending from the application of the
test voltage to the start of lower judgment.
The wait time can be set in the range of 0.3 s to 10 s (resolution of 0.1 s).
1 Press the TEST/WAIT key.

This causes the rightmost digit of the LED to blink, indicating that the cursor is
positioned at this digit.
2 Check whether the WAIT LED is lit.

If it is, the wait time is displayed. If the WAIT LED is not lit, the value displayed is
the test time. In such cases, press the TEST/WAIT key again to make the WAIT
LED light.
3 Press the
be set.
If necessary, change the value of another digit to set the desired wait time.
Setting the test time shorter than the wait time with the timer function set to ON causes the
TIMER ON LED to blink, notifying the operator that the test cannot be conducted.
TOS7200 29
Starting and Ending a Test
• If a setting is invalid (p.37), the tester cannot start a test.

• When a PASS/FAIL judgment result is being output, the tester cannot start a test.
• If the STOP switch has been pressed, the tester cannot start a test. (This includes a stop
signal from the remote control.)
• When DOUBLE ACTION in the system setting (p.33) is activated, the test can be started by
pressing the STOP switch, then pressing the START switch within approximately a half-
second. Otherwise, the test cannot be started.
• When MOMENTARY in the system setting (p.33) is activated, the tester performs the test
only while the START switch is being held down.
Starting the test
• To start the test, press the START switch.

• When the test starts, the DANGER lamp lights up, the voltmeter and resistance meter
indicate the measured values, and the timer indicates the time.
• The time indicated after the start of the test differs depending on whether the timer
function is set to ON or OFF.
When the timer is ON: The time remaining of the set time is indicated.
When the timer is OFF: The elapsed test duration is indicated.
(Note that if the test time exceeds 999 seconds, “999” blinks.)
• The WAIT LED blinks during the wait time.
DANGER lamp lit Measured resistance value
Example of Display during a Test
30 TOS7200
Ending the test
PASS judgment
Measured resistance value
PASS lamp lit
 When the timer is ON:

• When the test time elapses without a FAIL judgment during testing, the tester makes a
PASS judgment and ends the test.
• When a PASS judgment is made, the PASS lamp lights up and the buzzer sounds. The
PASS judgment is indicated for approx. 0.2 seconds. The display of a PASS judgment may
be set to HOLD. (p.33) The buzzer is also linked to the “PASS” display time.
• The measurement results will be displayed while the PASS lamp is lit.
 When the timer is OFF:

• If the FAIL conditions are not met, the test will continue.
• To interrupt the test, press the STOP switch. When the STOP switch has been pressed to
stop the test, no judgment is made and “PASS” is not displayed.
• To eliminate the effects of the charge current of a capacitive DUT, a lower judgment will not
be made until the wait time (p.29) elapses from the start of a test.
• During the wait time, the WAIT LED blinks.
START
HV ON
TEST
Test Time
Output voltage
PASS
READY
Example of the Timing Chart of PASS Judgment
TOS7200 31
FAIL judgment
Measured resistance value
FAIL lamp lit
• When the upper judgment is activated, detection of a resistance value greater than the
upper resistance during a test causes the tester to make a FAIL judgment, shut off the
output, and end the test.
• When the lower judgment is activated, detection of a resistance value below the lower
resistance during a test causes the tester to make a FAIL judgment, shut off the output,
and end the test.
• The tester lights up the LOWER LED for lower judgment or the UPPER LED for upper
judgment, lights up the FAIL lamp, and sounds the buzzer.
• To stop a FAIL judgment, press the STOP switch. (The tester continues to output a FAIL
judgment indication until the STOP switch is pressed.)
• The measurement results will be displayed until the STOP switch is pressed.
START
HV ON
TEST
Output voltage
FAIL
STOP
READY
Example of a Timing Chart of Output Shutoff Caused by FAIL Judgment
32 TOS7200
System Setting
In addition to test conditions such as the test voltage, this product has settings related to the
system.
In system setting, the following items can be set:
• Double action
• Momentary
• Fail mode
• Pass hold
• Average count (AVG)
• Auto-range
• Lower judgment (LOWER ON)
• Communication rate (SPEED)
• Buzzer volume (BUZZER)
Controlling the system settings
2 Check that the DANGER lamp is turned off.
3 With the SHIFT key held down, press the SYSTEM key.
The TOS7200 enters system setting mode.
4 Press the
be set.
The 7-segment LED corresponding to the system setting function display turns
on to indicate that a system setting item has been selected.
To exit system setting

The display returns to the previous status before the tester entered system
setting.
System setting display
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
For moving the

cursor or changing
a numerical value
SYSTEM key
TOS7200 33
System Setting
Description of each item
 Double action (DOUBLE ACTION)

When DOUBLE ACTION is set to ON, the START switch must be pressed within
approximately a half-second after the STOP switch is pressed to start testing. Pressing only
the START switch does not start a test; this function requires pressing both the STOP and
START switches, making the procedure more complicated. Nevertheless, this method
offers greater safety.
When operating the tester through the RS232C interface, set this feature to OFF.
7-segment LED Setting
0 DOUBLE ACTION is OFF ← At initialization
1 DOUBLE ACTION is ON
 Momentary (MOMENTARY)
When MOMENTARY is set to ON, the tester performs a test only for as long as the START
switch remains pressed.
Since this operation keeps the operator’s hands confined to the front panel of the tester or
the optional remote control box during a test, it increases the safety of operations. Use of
this function together with the optional RC02-TOS (a remote control box operated using
both hands) further increases safety.
When controlling the tester via the RS232C interface, set this feature to OFF.
0 MOMENTARY is OFF ← At initialization
1 MOMENTARY is ON
 Fail mode (FAIL MODE)

With FAIL MODE set to ON, a FAIL judgment can only be canceled using the STOP switch
on the front panel. It cannot be cancelled by a stop signal from the remote control.
0 FAIL MODE is OFF ← At initialization
1 FAIL MODE is ON
 Pass hold (PASS HOLD)

When PASS HOLD is set to ON, a PASS judgment is held until the STOP switch is pressed.
0 PASS HOLD is OFF ← At initialization
1 PASS HOLD is ON
 Average count (AVG)

The number of averaging times is fixed to “100”.
1 Number of averaging times: 100 (Fixed)
34 TOS7200
System Setting
 Auto-range (AUTO RANGE)

This setting selects auto-range or fixed range for measurements.
When AUTO RANGE is selected, the tester automatically selects the optimum range for
measurements. When fixed range is selected, the range is selected based on output
voltage and lower resistance.
0 Fixed range
1 Auto-range ← At initialization
When the fixed range is selected with the upper judgment set to ON, the UPPER ON LED
blinks, notifying the operator that a test cannot be performed. In such cases, select auto-
range or set the upper judgment to OFF.
 Lower judgment (LOWER ON)

When the lower judgment function is set to ON, if the resistance value falls below the
lower resistance, the tester returns a FAIL judgment and ends the test.
When the lower judgment function is set to OFF, the tester does not return a FAIL
judgment, even if the insulation resistance falls below the lower resistance.
0 Lower judgment is OFF
1 Lower judgment is ON ← At initialization
 Communication rate (SPEED)

This setting selects the RS232C communication rate.
0 9600 bps
1 19200 bps ← At initialization
2 38400 bps
 Buzzer volume (BUZZER)

The system mode allows the volume of the buzzer sounded in the event of a FAIL
judgment to be set in 10 steps of 0 to 9. The buzzer volume is set to “5” at initialization.
The volume of the buzzer sounded in the event of a PASS judgment is approximately half
of that sounded in the event of a FAIL judgment.
TOS7200 35
Panel Memory
This tester allows a maximum of 10 types of panel settings to be stored in internal memory
and recalled if necessary.
Storing in panel memory
1 With the SHIFT key held down, press the STORE key to enter the store
mode.
The STORE LED lights up and the memory number’s 7-segment LED blinks.
2 With the SHIFT key held down, press the or key to select the memory
number at which the panel settings are to be stored.
3 With the SHIFT key held down, press the STOP switch.
The STORE LED goes off and the tester exits store mode.
If only the STOP switch is pressed, the STORE LED goes off and the tester exits
store mode, but panel settings are not stored.
STORE LED Memory number
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
STORE key For selection of

a memory number
Recalling a panel memory
1 Press the RECALL key to move the cursor to the memory number’s 7-
segment LED.
The memory number LED blinks, indicating that the cursor is positioned at that
LED.
2 With the SHIFT key held down, press the

number.
or key to select a memory
The panel settings stored in that memory location will then appear.
36 TOS7200
Key Lock
The key lock prevents accidental changing of the test conditions.

Press the and keys simultaneously to involve key-locked status, causing the KEYLOCK
LED to light up. In the key-locked status, only the START and STOP switches are valid.
To cancel key lock, press the and keys simultaneously once again.
KEYLOCK
LED
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
Press simultaneously
Invalid Settings
If any of the invalid settings specified below are made, the tester causes the associated LED to
blink, notifying the operator that an invalid setting has been made. While that LED is blinking,
a test cannot be conducted.
 OVER 1.1 mA
If the value obtained by dividing the test voltage by the lower resistance exceeds 1.1 mA,
the LOWER LED blinks.
 UPPER ≤ LOWER
When both the upper and lower judgments are set to ON, setting the upper resistance to a
value equal to or less than the lower resistance causes the UPPER LED to blink.
 TEST ≤ WAIT
When the timer function is activated, setting the test duration to a value equal to or less
than the wait time causes the TIMER ON LED to blink.
 FIX ∩ UPPER ON
If the fixed range is selected with upper judgment is activated, the UPPER ON LED blinks.
TOS7200 37
Initialize
Initializing clears the contents of the panel settings stored in memory. Before initializing,
make sure no data still required is contained in memory.
To initialize, turn ON the POWER switch with the SHIFT key held down. This clears the contents
of memory and restores tester settings to the factory default settings. (Press the SHIFT key
until the timer’s 7-segment LED starts to blink.)
The panel settings restored following initialization are given in Table below. For settings for test
conditions aside from the test-voltage set value, the same value is stored in panel memories 0 to 9.
Settings for test conditions

Item Set value
Test voltage (VOLTAGE) See 「Test voltage settings」in the
following table.
Lower resistance (LOWER) 1.00 MΩ
Upper judgment (UPPER ON) ON
Upper resistance (UPPER) 100 MΩ
Timer (TIMER ON) ON
Timer set value (TIMER) 0.5 s
Wait time (WAIT TIME) 0.3 s
 Test voltage settings
Panel memory number Test voltage set value

0 10 V
1 25 V
2 50 V
3 100 V
4 125 V
5 250 V
6 500 V
7 to 9 1000 V
System setting
Item Set value
Double action (DOUBLE ACTION) OFF
Momentary (MOMENTARY) OFF
Fail mode (FAIL MODE) OFF
Pass hold (PASS HOLD) OFF
Average count (AVG) 1 (fixed)
Auto-range (AUTO RANGE) ON
Lower judgment function (LOWER ON) ON
Communications rate (SPEED) 19200 bps
Buzzer volume (BUZZER) 5
38 TOS7200
5 Using Terminals and Connectors
This chapter describes use of the terminals and connectors on the front and rear panels of the
tester.
The remote control uses an external signal to turn ON/OFF the high voltage, which may
WARNING
involve great danger. Therefore, thorough safety measures must be taken to ensure
that a high voltage is not accidentally generated and that no one touches the DUT,
high-voltage test leadwire, output terminals, or other parts while high voltage is being
generated. If such measures cannot be taken, do not perform remote control.
When a START signal at the SIGNAL I/O connector is enabled, the START signal has priority
over a START signal at the REMOTE terminal.
A STOP signal through the SIGNAL I/O connector and that through the REMOTE terminal are
accepted equally.
 REMOTE terminal on the front panel

This terminal allows the starting and stopping of a test to be controlled using the optional
remote-control box RC01-TOS or RC02-TOS.
 SIGNAL I/O connector on the rear panel

Inputting a signal to this connector allows a test to be started or stopped and the panel
memory to be recalled. Moreover, output signals through the SIGNAL I/O connector allow
the condition of the tester to be checked.
 ANALOG OUT terminals

This connector outputs a voltage compressed logarithmically that corresponds to the
measured resistance value, in the range of 0 V to 4 V.
 RS232C communication interface connector

You can remotely control the TOS7200 through the RS232C interface. For details, see the
communication interface manual on the included CD-ROM.
TOS7200 39
REMOTE Terminal
The REMOTE terminal is a 6-pin mini-DIN connector on the front panel designed to allow
connection of an optional remote control box RC01-TOS or RC02-TOS.
Connecting a remote control box disables the START switch on the front panel.
OUTPUT
MEMORY
MEMORY VOLTAGE
VOLTAGE RESISTANCE
RESISTANCE TIMER
TIMER
REMOTE terminal
(6-pin mini-DIN connector)
CAUTION • To prevent damage to the tester, do not connect any component other than the dedicated
remote control boxes to the REMOTE terminal.
• Install signal wires more than 50 cm from the high voltage test leadwire or DUT. Avoid short-
circuiting the test voltage to a signal wire. If the test voltage is short-circuited to a signal
wire, the entire internal circuit may be destroyed.
Connection of a remote-control box to the tester requires the use of a DIN-Mini DIN adapter.
For DD-5P/6P DIN-Mini DIN adapters [84250], contact your Kikusui distributor/agent.
40 TOS7200
REMOTE Terminal
Performing remote control
1 Turn OFF the POWER switch.
2 Connect the REMOTE terminal and the remote-control box using the
dedicated connection cable (5-pin DIN cable) via the DIN-mini DIN
adaptor.
3 Turn ON the POWER switch.

This allows the input of a start signal from the remote control box and disables the
START switch on the front panel. Note that stop operations may be performed
both by using the STOP switch on the front panel and by transmitting a stop
signal from the remote control box. For more information, see the operation
manual for the optional remote control box.
4 To restore control from the front panel, turn OFF the POWER switch.
5 Remove the dedicated connection cable (6-pin DIN cable) from the
REMOTE terminal on the front panel.
6 Turn ON the POWER switch.

This enables the START switch on the front panel.
• When a START signal at the SIGNAL I/O connector is enabled, the START signal has priority
over a START signal at the REMOTE terminal. A STOP signal through the SIGNAL I/O
connector and that through the REMOTE terminal are accepted equally.
• Connecting or disconnecting a remote control box to or from the REMOTE terminal with the
POWER switch turned ON interrupts high-voltage output.
• When FAIL MODE in the system setting (p.33) has been activated, a FAIL judgment cannot
be canceled by the input of a stop signal via the REMOTE terminal. In such cases, use the
STOP switch on the front panel to cancel the judgment.
TOS7200 41
SIGNAL I/O Connector
Possible electric shock. Ensure that all devices are off before you connect or disconnect
WARNING
cables between them.
Possible damage to the internal circuitry.

CAUTION
• Keep the signal wire at least 50 cm away from the high-voltage test lead and the DUT.
• Do not short the output voltage circuit.
• If you use the TOS7200 with incomplete connections, burn outs caused by heating may
occur when the output is turned on.
• Do not touch the contacts or attach insulators to them. Doing so may reduce the quality of
the contacts or cause other problems.
The SIGNAL I/O connector is a D-SUB 25-pin connector on the rear panel.
This connector is used to start and stop tests, recall panel memory entries, and monitor the
status of the TOS7200.
• Connector on the tester side SIGNAL I/O connector

XM3B-2522 D-sub 25-pin female connector (socket) ; SIGNAL I/O RS232C
manufactured by OMRON Corporation, Screw M2.6 x 0.45

• Complies connector (plug)
D-sub 25-pin male (with fix screw M2.6)
To avoid malfunctions caused by noise, use shielded-type D-sub 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
distributor.
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: Φ0.32 mm (AWG28) to 0.65 mm (AWG22) in diameter

Twisted wire: Φ0.32 mm2 (AWG22) to 0.08 mm2 (AWG28)
Wire stripper A wire stripper that matches the wires listed above
42 TOS7200
Specifications for the SIGNAL I/O connector
 Input signal
Low-active control input
Active LOW control input: 11 V to 15 V
High-level input voltage: 0 V to 4 V
Low-level input voltage: -5 mA maximum
Input time width: 5 ms minimum
 Output signal
Open drain output
Output withstand voltage: 30 Vdc
Output saturation voltage: Approx. 0.7 V (25 °C)
Maximum output current: 400 mA (TOTAL)
 Pin assignment
No. Signal name I/O Description of signal
1 PM0 I LSB 1-digit BCD active LOW input
N.C 2 PM1 I Panel memory’s selection signal input terminal
N.C 3 PM2 I
N.C
STB 4 PM3 I MSB
N.C
N.C PM3 5 N.C
N.C PM2 6 N.C
N.C PM1 7 N.C
COM PM0
8 N.C
9 STB I Input terminal for the strobe signal of the panel
13 12 11 10 9 8 7 6 5 4 3 2 1
memory
25 24 23 22 21 20 19 18 17 16 15 14
10 N.C
11 N.C
COM H.V ON
N.C TEST 12 N.C
ENABLE PASS 13 COM Circuit common (chassis potential)
STOP U FAIL 14 HV ON O ON during a test or while a voltage remains between
START L FAIL the output terminals
N.C READY
15 TEST O ON during a test
16 PASS O ON for approx. 0.2 seconds when PASS judgment is
Pin Configuration for the SIGNAL I/O Connector
made, or continuously ON while PASS HOLD is activated
17 U FAIL O Continuously ON if an insulation resistance equal to or
exceeding the upper resistance is detected, resulting in
FAIL judgment
18 L FAIL O Continuously ON if an insulation resistance equal to or
falling below the lower resistance is detected, resulting
in FAIL judgment
19 READY O ON during standby
20 N.C
21 START I Input terminal for the START signal
22 STOP I Input terminal for the STOP signal
23 ENABLE I Remote control enable signal input terminal
24 N.C
25 COM Circuit common (chassis potential)
Input signals cannot be directly controlled using logic IC such as HC.
TOS7200 43
 Internal configuration
Common of the input signal control block is connected to common of the output signal
control block.
Because the input signal circuit is pulled up to +12 V, opening the input terminal
effectively creates a high-level input.
Output signal 1
Output
signal
controller Output signal 2
• +15 V
•
•
Input signal 1
Input +15 V
signal
controller
Input signal 2
•
•
• COM
Internal Configuration of the SIGNAL I/O Connector
Example of use
 Input signal
S1
Use a make contact such as a relay or
switch to set the input terminal to the Low
level.
COM
Example of Control Using a Make Contact
ic
Use a logic element such as a transistor in
place of a switch in the above example.
Consideration should be given to pulling
up the transistor’s collector current, ic, by
COM 5 mA or more.
Example of Control Using a Logic Element
44 TOS7200
 Output signal
Install signal wires more than 50 cm from the high voltage test leadwire, DUT, and the like.
CAUTION
Avoid short-circuiting the test voltage to a signal wire. If the test voltage is short-circuited to a
signal wire, the entire internal circuit may be destroyed.
• When a load is short-circuited, the open-collector output causes the burning of an

output element or printed circuit board. We recommend inserting a protection fuse into
the output.
• When driving an inductive load such as a relay, be sure to connect a diode in parallel with
the coil.
• The tester’s internal control circuit is designed to prevent malfunctions caused by noise
generated by the tester or peripheral equipment. However, connected equipments may
malfunction if bare (unshielded) cables are connected to SIGNAL I/O terminals, because
such cables would make a sort of “antenna” to pick up external noise. Therefore, for
connectors, cables, and the external circuit, use a shielded metal connector, a shielded
cable, and an external circuit provided in a shielded enclosure, respectively. Moreover,
connect each to the cabinet of the tester. This isolates the circuits related to the SIGNAL I/
O connector from the external environment and reduces noise-induced malfunctions.
Relay The relay is driven

by an output
400 mA or less
30 V or less
COM
Example of Driving the Relay
R Obtains a Low-level digital

A signal using an output signal
30 V or less
Low upon
signal output
COM
Example of Obtaining a Low-level Digital Signal
TOS7200 45
Starting a test
To start a test by using the SIGNAL I/O connector, set the ENABLE signal to a low level first.
After a lapse of 10 ms, set the START signal to a low level for 5 ms or more. The READY signal
turns to a high level after the effective START signal has been detected.
When the ENABLE signal is the low level, the START signal of the SIGNAL I/O connector is
enabled. This disables START input via the REMOTE terminal and the START switch on the front
panel. But, stopping is possible using any of the available methods: the STOP switch on the
panel, STOP input via the REMOTE terminal, or the STOP signal.
ENABLE (IN)
READY (OUT)
5 ms or more
START (IN)
10 ms
or more
START Signal
Controlling signals
1 Short-circuit from pin 23 (ENABLE) to pin 13 or pin 25 (COM) to set that

signal to the low level.
This disables the START switch on the front panel and START input via the
REMOTE terminal. Note that stop operations may be performed via the STOP
switch on the front panel, the STOP input from the remote control, or the STOP
signal via the SIGNAL I/O connector.
2 Short-circuit from pin 21 (STOP) to pin 13 or pin 25 (COM) to set that signal
to the low level.
This starts a test.
3 Short-circuit pin 22 (STOP) to pin 13 or pin 25 (COM) to set that signal to

the low level.
This stops a test.
4 To cancel remote control, set ENABLE of the start signal to the high level.
This enables the START switch on the front panel and disables the START signal
of the SIGNAL I/O connector.
• Changing the ENABLE level of a start signal shuts off high-voltage output.
• When FAIL MODE is activated in the system settings (p.33), a FAIL judgment cannot be
canceled by stop input from the remote control. In such cases, use the STOP switch on the
front panel to cancel judgment.
• The input terminal is pulled up to +12 V using a resistor. Opening the input terminal
46 TOS7200
Recalling the panel memory

A PM signal and STB signal are processed with the timing specified below (make sure the
READY signal is at the Low level).
The relationship between the PM0 to PM3 signals and the memory numbers actually to be
recalled is as shown in Table below.
READY (OUT)
PM0-PM3 (IN)
5 ms
or more
STB (IN)
10 ms 10 ms
or more 10 ms or more or more
The next signal input

requires an interval
of 10 ms or more.
Strobe Signal
The input terminal is pulled up to +12 V using a resistor. Opening the input terminal
 PM signals and memory numbers to be recalled
PM3 PM2 PM1 PM0 Memory number to

be recalled
H H H H 0
H H H L 1
H H L H 2
H H L L 3
H L H H 4
H L H L 5
H L L H 6
H L L L 7
L H H H 8
L H H L 9
TOS7200 47
ANALOG OUT Terminals
As shown below, the ANALOG OUT terminals output a logarithmically compressed voltage
corresponding to a measured resistance value, in the range of 0 V to 4 V.
Vo = log ( 1 + Rx )
0ȍ Rx: Resistance measurement
Resistance measurement Output voltage (Vo)*1

0Ω 0V
1 MΩ 0.30 V
10 MΩ 1.04 V
100 MΩ 2.00 V
1000 MΩ 3.00 V
10000 MΩ or more 4.00 V
*1. Full scale is 5 V.
J1 outputs 4 V when a test is not in progress.
Compatible wire material:

• Solid wire of Φ0.65 mm (AWG22)
• Twisted wire of 0.32 mm2 (AWG22), single wire diameter of Φ0.18 mm or more
 Connection to the connector
1 Strip approx. 10 mm of the covering from the end of each wire.
2 Insert the end of a flat-head screw driver into opening A to open port B.
3 Insert the signal wire into B, making sure the covering is not caught in
port B.
4 Gently pull the wire to confirm that it does not come off easily.
Shaft diameter: ø3 mm; width of the tip: 2.6 mm
mB
10 m
48 TOS7200
6 Maintenance
This chapter describes the maintenance and inspection of the tester. To maintain the tester’s
original performance for as long as possible, conduct periodic inspection and maintenance.
Inspection
 AC power cord
Confirm that the covering is free of breaks and cracks, that the plug is free of looseness and
cracks, and that the cord does not contain a broken wire.
 High-voltage test leadwires

Confirm that the covering is free of breaks and cracks and that there is no break in the
leads.
Any break or crack in the covering greatly increases the risk of electric shock or fire. If
WARNING
you find any breaks or cracks, immediately discontinue use of the tester.
To purchase accessories, contact your Kikusui distributor/agent.
Maintenance
The tester generates voltages as high as 1000 Vdc. Never attempt to maintain the
WARNING
Tester including overhauls for yourself, as such tasks entail great danger. For such
service, contact your Kikusui distributor/agent.
 Backup battery
The tester uses a lithium battery for memory backup.
If the battery is exhausted, the memory will not retain stored test conditions or other data.
Although the service life depends on the usage environment, we generally recommend that
the battery be replaced every three years. We also recommend that regular internal
inspections and cleaning be conducted at the same intervals.
Calibration
Regular calibration is required to maintain the accuracy of measuring instruments over

extended periods. For calibration, contact your Kikusui distributor/agent.
The tester generates voltages as high as 1000 Vdc. Never attempt to calibrate the Tester
WARNING
for yourself, as such tasks entail great danger. For such service, contact your Kikusui
distributor/agent.
TOS7200 49
Maintenance
Troubleshooting
The problems specified below do not necessarily indicate failures. Please perform the
following checks before requesting repairs. If the remedy does not solve the problem or if your
case does not match any of the items, contact your Kikusui distributor/agent.
Symptom Check Item Reference, Description

The tester does not Confirm that the AC power cord is “Connecting the Power Cord” (p.14)
start when the connected.
POWER switch is
pressed.
The keys on the Confirm that the KEYLOCK function is off. “Key Lock” (p.37)
front panel do not Confirm that the tester is not being “REMOTE Terminal” (p.40)
work. remotely controlled via the REMOTE “SIGNAL I/O Connector” (p.42)
terminal or SIGNAL I/O connector.
Confirm that the tester is not being “LOCAL key” (p.7)
remotely controlled via the RS232C
interface.
The START switch or Confirm that no STOP signal of the SIGNAL “Using Terminals and Connectors”
START signal of the I/O is being input. (p.39)
SIGNAL I/O does not Confirm that the tester is not in PASS or The START switch does not function
work. FAIL status. during output of a judgment result.
Press the STOP switch to cancel
output.
Confirm that the tester is not currently “Panel Memory” (p.36)
storing panel settings to or recalling panel
settings from panel memory.
Confirm that the double-action function is “Double action (DOUBLE ACTION)”
off. (p.34)
Confirm that the ENABLE signal of the “SIGNAL I/O Connector” (p.42)
SIGNAL I/O is at the high level.
Confirm that the tester is not in the midst “System Setting” (p.33)
of making system settings.
Confirm that the LOWER LED is not
blinking.
Confirm that the UPPER LED is not
blinking.
“Invalid Settings” (p.37)
Confirm that the TIMER ON LED is not
blinking.
Confirm that the UPPER ON LED is not
blinking.
Confirm that the tester is not being “LOCAL key” (p.7)
remotely controlled via the RS232C
interface.
50 TOS7200
7 Specifications
Basic performance
Output section
Output voltage range -25 V to -1000 V
Resolution 1V
Accuracy ±(1.5 % of setting +2 V)
Maximum rated output 1 W (1000 V/1 mA)
Maximum rated current 1 mA
Output Output type Floating
terminals Isolation voltage ±1000 Vdc
Ripple 1000 V 2 Vp-p or less
under no load
Maximum rated 10 Vp-p or less
load
Voltage regulation 1 % or less (maximum rated load → no load)
Short-circuiting current 12 mA or less
Output rise time 50 ms or less (10 % to 90 %, no load)
Discharge function Forced discharge at the end of test (discharge resistance: 25 kΩ)
Voltmeter
Measurement range 0 V to -1200 V
Resolution 1V
Accuracy ±(1 % of reading +1 V)
Resistance meter
Measurement range 0.01 MΩ to 5000 MΩ
(In the range of over 100 nA to a maximum rated current of 1 mA)
Display □ . □□ MΩ [R < 10.0 MΩ]
□□ . □ MΩ [10.0 MΩ ≤ R < 100.0 MΩ]
□□□ MΩ [100.0 MΩ ≤ R < 1000 MΩ]
□□□□ MΩ [1000 MΩ ≤ R ≤ 5000 MΩ]
(R = measured insulation resistance)
Accuracy *1 ±(10 % of reading) [100 nA < i ≤ 200 nA]
±(5 % of reading) [200 nA < i ≤ 1 μA]
±(2 % of reading) [1 μA < i ≤ 1 mA]
(i = measured output-voltage value/measured resistance value)
Range selection The current measurement range is selectable between AUTO and FIX.
AUTO Automatically changes the current measurement range according to the measured
current value.
FIX Fixes the current measurement range based on the output voltage set value and
LOWER set value (in UPPER OFF status)
Holding function Holds the resistance value obtained at the end of testing while a PASS judgment is
being output.
TOS7200 51
Specifications
Judgment function
Judgment method/action See Separate Table 1.
Setting range for the upper 0.01 MΩ to 5000 MΩ
resistance (UPPER) [In the range of the maximum rated current or less]
Setting range for the lower 0.01 MΩ to 5000 MΩ
resistance (LOWER) [In the range of the maximum rated current or less]
Judgment accuracy See Separate Table 2.
Time
Setting range for the test 0.5 s to 999 s
duration (TEST TIME) (TIMER OFF function provided)
Setting range for the wait time 0.3 s to 10 s
(WAIT TIME) (TEST TIME > WAIT TIME)
Accuracy ±(100 ppm +20 ms)
*1. In the humidity range of 20 %rh to 70 % rh (no condensation permitted), with no disturbance such as swinging of
the test leadwires
Table.1 Judgment method/action of the judgment function

Judgment Judgment method Indication Buzzer SIGNAL I/O
UPPER If a resistance value equal or higher than the upper resistance FAIL lamp lights. Outputs an
FAIL is detected, the tester shuts off the output and returns an UPPER LED lights. ON UPPER FAIL
UPPER FAIL judgment. signal.
LOWER If a resistance value equal or less than the lower resistance is FAIL lamp lights. Outputs a
FAIL detected, the tester shuts off the output and returns a LOWER LOWER LED lights. LOWER FAIL
ON
FAIL judgment. Note that no judgment is made within the signal.
judgment wait time (WAIT TIME) after the start of the test.
PASS If no abnormality is found when the set test time has elapsed, PASS lamp lights. Outputs a PASS
ON
the tester shuts off the output and returns a PASS judgment. signal.
• A PASS signal is output for approx. 200 ms. However, if the PASS HOLD function is set to “HOLD,” the signal is
continuously output until a STOP signal is input.
• An UPPER FAIL or LOWER FAIL signal is continuously output until a STOP signal is input.
• The buzzer volume for FAIL or PASS judgment is adjustable. However, it cannot be individually adjusted for PASS and FAIL
judgments, as they use common settings.
Table.2 Judgment accuracy of the upper/lower judgment function

i = test/(UPPER, LOWER)
UPPER, LOWER
100 nA < i ≤ 200 nA 200 nA < i ≤ 1 μA 1 μA < i ≤ 1 mA
0.01 MΩ ≤ R < 10.0 MΩ − − ±(2 % of setting+3 digits)
10.0 MΩ ≤ R< 50.0 MΩ − ±(5 % of setting+5 digits) ±(2 % of setting+3 digits)
50.0 MΩ ≤ R< 100 MΩ − ±(5 % of setting+5 digits) ±(2 % of setting+3 digits)
100 MΩ ≤ R< 200 MΩ ±(10 % of setting+5 digits) ±(5 % of setting+5 digits) ±(2 % of setting+3 digits)
1000 MΩ ≤ R< 2000 MΩ ±(10 % of setting+50 digits) ±(5 % of setting+50 digits) −
2000 MΩ ≤ R ≤ 5000 MΩ ±(10 % of setting +100 digits) ±(5 % of setting+50 digits) −
• The humidity must be in the range of 20 % to 70 %rh (no condensation permitted), and there must be no
disturbance such as swinging of the test leadwires.
• The lower judgment requires a test duration of 0.5 s or more after the wait time has expired. It also requires a wait
time of 1.0 s or more for a lower judgment of 200 nA or less.
52 TOS7200
Specifications
Interface and other functions
REMOTE 6-pin mini-DIN connector on the front panel

The optional remote controller RC01-TOS or RC02-TOS is connected to remotely
control starting/stopping of a test (note that a DIN-mini DIN adapter is required).
SIGNAL I/O D-SUB 25-pin connector on the rear panel
For names and descriptions of connector signals, see Separate Table 3.
Input High-level 11 V to 5 V All input signals are active Low controlled.
input voltage The input terminal is pulled up to +12 V using a resistor.
Low-level 0 V to 4 V Opening the input terminal is equivalent to inputting a
input voltage high-level signal.
Low-level -5 mA maximum
input current
Input time width 5 ms minimum
Output Output method Open drain output (4.5 Vdc to 30 Vdc)
Output 30 Vdc
withstand
voltage
Output Approx. 0.7 V (25 ℃ )
saturation
voltage
Maximum output 400 mA (TOTAL)
current
ANALOG OUT Outputs a logarithmically compressed voltage corresponding to the measured
resistance value
+
Vo = log ( 1 + Rx )
0ȍ Rx: Resistance measurement
Rx (1 MΩ: 0.30 V, 10 MΩ: 1.04 V, 100 MΩ: 2.00 V, 1000 MΩ: 3.00 V, 10000 MΩ or
more: 4.00 V)
Output impedance: 1 kΩ
COM Analog output-circuit common
Accuracy ± (2% of full scale)
RS232C D-SUB 9-pin connector on the rear panel (compliant with EIA-232-D)
All functions other than the POWER switch and KEYLOCK function are remotely
controllable.
Baud rate 9600/19200/38400 bps
(data: 8 bits; parity: none; stop bit: 2 bits fixed)
Display 7-segment LED, 4-digit voltage display, 4-digit insulation resistance display,
and 3-digit time display
Memory function A maximum of 10 types of test conditions can be stored in memory.
Backup battery life 3 years or more (at 25 °C)
TEST MODE MOMENTARY A test is conducted only when the START switch is pressed.
FAIL MODE Disables cancellation of FAIL judgment using a stop signal via remote control.
DOUBLE ACTION Starts a test only when the STOP switch is pressed and the START switch is pressed
within approximately a half-second.
PASS HOLD Allows the time of holding PASS judgment to be set to 0.2 s or HOLD.
KEYLOCK Places the tester in a state in which no keystroke other than the START/STOP switch
is accepted.
TOS7200 53
Specifications
 Table.3 SIGNAL I/O pin assignment

No. Signal name I/O Description of signal
1 PM0 I LSB 1-digit BCD active LOW input
2 PM1 I Panel memory’s selection signal input terminal
3 PM2 I
4 PM3 I MSB
5 N.C
6 N.C
7 N.C
8 N.C
9 STB I Input terminal for the strobe signal of the panel memory
10 N.C
11 N.C
12 N.C
14 HV ON O ON during a test or while a voltage remains between the output terminals
15 TEST O ON during a test
16 PASS O ON for approx. 0.2 seconds when PASS judgment is made, or continuously ON
while PASS HOLD is activated
17 U FAIL O Continuously ON if an insulation resistance equal to or exceeding the upper
resistance is detected, resulting in FAIL judgment
18 L FAIL O Continuously ON if an insulation resistance equal to or falling below the lower
resistance is detected, resulting in FAIL judgment
19 READY O ON during standby
20 N.C
21 START I Input terminal for the START signal
22 STOP I Input terminal for the STOP signal
23 ENABLE I Remote control enable signal input terminal
24 N.C
54 TOS7200
Specifications
General specifications
Environment
Installation location Indoors and at altitudes up to 2000 m
Warranty Temperature 5 °C to 35 °C (41 °F to 95 °F)
range Humidity 20 %rh to 80 %rh (no condensation)
Operating Temperature 0 °C to 40 °C (32 °F to 104 °F)
range Humidity 20 %rh to 80 %rh (no condensation)
Storage Temperature -20 °C to 70 °C (-4 °F to 158 °F)
range Humidity 90 %rh or less (no condensation)
Power requirements
Nominal voltage range 100 Vac to 240 Vac
(allowable voltage range) (85 Vac to 250 Vac)
Power At rated load 30 VA maximum
consumption
Allowable frequency range 47 Hz to 63 Hz
Insulation resistance 30 MΩ or more (500 Vdc) [between AC LINE and the chassis]
Withstand voltage 1390 V AC for 2 seconds, 10 mA or less [AC LINE to chassis]
Earth continuity 25 Aac/0.1 Ω or less
Safety *1 Conforms to the requirements of the following directive and standard.
Low Voltage Directive 2014/35/EU
EN 61010-1 (Class I*2 , Pollution degree 2*3 )
Electromagnetic compatibility Conforms to the requirements of the following directive and standard.
(EMC)*1 EMC Directive 2014/30/EU
EN 61326-1 (Class A*4 )
EN 55011 (Class A*4, Group 1*5 )
EN 61000-3-2
EN 61000-3-3
Under following conditions
1. Used HV test leadwires TL08-TOS which is supplied.
2. No discharge occurs at outside of the tester.
3. Used the shielded cable which length is less than three meters
when the SIGNAL I/O is used.
Dimensions See Dimensions.
Weight Approx. 2 kg (4.4 lb)
Accessories
AC power cord 1 pc.
TL08-TOS high-voltage 1 set
test leadwires
Setup guide 1 pc.
Quick reference English: 1pc., Japanese: 1pc.
Safety information 1 pc.
CD-ROM 1 pc.
*1. Only on models that have CE marking on the panel. Not applicable to custom order models.
*2. This instrument is a Class I equipment. Be sure to ground the protective conductor terminal of the instrument.
The safety of the instrument is not guaranteed unless the instrument is grounded properly.
*3. Pollution is addition of foreign matter (solid, liquid or gaseous) that may produce a reduction of dielectric
strength or surface resistivity. Pollution Degree 2 assumes that only non-conductive pollution will occur except
for an occasional temporary conductivity caused by condensation
*4. This is a Class A equipment. 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 emissions to prevent interference to the reception of radio and television broadcasts.
*5. This is a Group I equipment. This product does not generate and/or use intentionally radio-frequency energy, in
the form of electromagnetic radiation, inductive and/or capacitive coupling, for the treatment of material or
inspection/analysis purpose.
TOS7200 55
56
Specifications
Dimensions
MAX85 (3.35)
66 (2.60)
215 (8.46)
MAX5 230 (9.06)
) (0.20) MAX260 (10.24)
0 (4.72
MAX12
Unit: mm (inch)
TOS7200
Index
A O
ANALOG OUT terminals ............................................................. 48 OUTPUT terminal ............................................................................ 7
AUTO RANGE ................................................................................. 35
AVG ................................................................................................... 34 P
panel memory ............................................................................... 36
B PASS HOLD ..................................................................................... 34
BUZZER ............................................................................................ 35 PASS judgment ............................................................................. 31
volume .............................................................................. 35 PASS lamp ......................................................................................... 8
power cord, connecting ............................................................. 14
C power, turning ON ....................................................................... 15
calibration ....................................................................................... 49 prohibited operations ................................................................. 22
checking .......................................................................................... 19
R
D RECALL key ....................................................................................... 7
DANGER lamp ...................................................................................8 remote control box ...................................................................... 12
discharge time ............................................................................... 21 REMOTE LED ..................................................................................... 9
DOUBLE ACTION ........................................................................... 34 REMOTE terminal .......................................................................... 40
RESISTANCE ...................................................................................... 8
E
S
emergency, action ....................................................................... 21
ending the test .............................................................................. 31 SIGNAL I/O connector ................................................................. 42
SPEED ............................................................................................... 35
F stand ................................................................................................... 4
START switch .................................................................................... 7
FAIL judgment ............................................................................... 32
starting the test ............................................................................. 30
FAIL lamp ...........................................................................................8
STOP switch ...................................................................................... 7
FAIL MODE ...................................................................................... 34
STORE key ......................................................................................... 7
failed Tester .................................................................................... 22
SYSTEM key ...................................................................................... 7
firmware version ........................................................................... 15
system settings ............................................................................. 33
I
T
initialize ........................................................................................... 38
test
installation location, precaution ................................................4
ending ............................................................................... 31
invalid settings .............................................................................. 37
precaution ....................................................................... 20
starting .............................................................................. 30
K
test leadwires, connecting ........................................................ 16
key lock ............................................................................................ 37 TEST TIME, setting ........................................................................ 28
KEYLOCK LED ....................................................................................9 test voltage, setting ..................................................................... 23
TEST/WAIT key ................................................................................. 7
L timer function, setting ................................................................ 28
LOWER LED ................................................................................ 8, 37 TIMER key .......................................................................................... 7
LOWER, setting .............................................................................. 24 TIMER ON LED ........................................................................... 8, 37
troubleshooting ............................................................................ 50
M
maintenance .................................................................................. 49 U
memory ........................................................................................... 36 UPPER LED ...................................................................................... 37
backup .............................................................................. 49 UPPER ON key .................................................................................. 7
MOMENTARY ................................................................................. 34 UPPER ON LED ................................................................................. 8
moving ................................................................................................4 UPPER, setting ............................................................................... 25
UPPER/LOWER key ......................................................................... 7
TOS7200 57
V
version ..............................................................................................15
VOLT key ............................................................................................ 7
W
WAIT TIME, setting .......................................................................29
warning, residual high voltages ...............................................21
58 TOS7200
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 distrib-
utor of the “Part No.” written on the front cover of this manual.
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.
After you have finished reading this manual, store it so that you can use it for reference
at any time.
KIKUSUI ELECTRONICS CORP.

1-1-3 Higashiyamata, Tsuzuki-ku, Yokohama,
224-0023, Japan
Tel: +81-45-482-6353 Fax: +81-45-482-6261
Website http://www.kikusui.co.jp/en

User's Manual: Insulation Resistance Tester

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No.

5. Using Terminals and

There are five TOS7200 Manuals listed as follows.

• Communication Interface Manual

TL08-TOS High-voltage test lead

Quick Reference Safety information

Setup guide (1 pc.) CD-ROM (1 pc.)

For your own safety (to avoid electrification)

When using this product, be sure to observe the “Safety

Moving the Product

When moving or transporting the product to the installation

3 Safety Precautions during

No. Name Description See

No. Name Description See

No. Name Description See

Outline of the TOS7200

 Arbitrary setting of the output voltage

Test voltage Resistance measurement range

 Equipped with a discharge function

 Equipped with a window comparator

 Equipped with a timer function

 Output terminals on the rear panel

 Equipped with a panel memory

 Provided with a SIGNAL I/O connector and remote-control terminal

 Incorporating the RS232C interface as standard equipment

This Tester features the following options:

RC01-TOS/RC02-TOS remote-control boxes

RC01-TOS: 200 mm (W)×70 mm(H)×39 mm (D)

RC02-TOS: 330 mm (W)×70 mm (H)×39 mm (D)

Connecting the Power Cord

• Use the supplied power cord to connect to the AC line.

1 Check that the POWER switch is turned off.

2 Confirm that the AC power cord is properly connected to the AC LINE

3 Connect the other plug of the AC power cord to an electrical outlet.

4 Turn ON the POWER switch of the tester.

Firmware version Model

Turning the POWER switch off.

The POWER switch to turn the TOS7200 off.

Possible electric shock.

Test leadwires connect the product to the DUT.

Connecting to the OUTPUT terminals

 Connecting the low voltage side test leadwire

1 Press the STOP switch.

2 Check that the DANGER lamp is off.

3 Check that there is no breakage in the test leadwires.

 Connecting the high voltage side test leadwire

1 Press the STOP switch.

2 Confirm that the DANGER lamp is off.

Connecting to the DUT

1 Press the STOP switch.

2 Confirm that the DANGER lamp is off.

4 Connect the low voltage side test leadwire to the DUT.

5 Connect the high voltage side test leadwire to the DUT.

Connecting to a grounded DUT

Connecting to an ungrounded DUT

Disconnecting Test Leads from the DUT .

1 Check that the DANGER lamp is off.

4 Remove the low voltage side test leadwire.

To avoid accidents, confirm at least the following before starting operation: