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DANGER

This Tester generates high voltage!

Any incorrect handling may cause death.

Read Chapter 3 "Safety Precautions

during Testing"

in this manual to prevent accident.

Keep this manual near the tester for easy access

of the operator.

TOS7200

User’s Manual

Insulation Resistance Tester

1. Preface 11

2. Preparation 14

3. Safety Precautions

during Testing 19

4. Basic Operation 23

5. Using Terminals and

Connectors 39

6. Maintenance 49

7. Specifications 51

No. IB028912
Jul. 2018

Summary of Contents for TOS7200

Page 1: ...in this manual to prevent accident Ɣ Keep this manual near the tester for easy access of the operator TOS7200 User s Manual Insulation Resistance Tester 1 Preface 11 2 Preparation 14 3 Safety Precautions during Testing 19 4 Basic Operation 23 5 Using Terminals and Connectors 39 6 Maintenance 49 7 Specifications 51 No IB028912 Jul 2018 ...

Page 2: ...llowing information Model indicated at the top section on the front panel Firmware version p 15 Serial number indicated at the bottom section on the rear panel Copyrights Reproduction and reprinting of this manual whole or partially without our permission is prohibited Both unit specifications and manual contents are subject to change without notice Copyright 2016 Kikusui Electronics Corporation D...

Page 3: ...ss of the operator 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 ...

Page 4: ...ndensation 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 par...

Page 5: ...tions 22 Dangerous States of Failed Tester 22 4 Basic Operation 23 Setting the Test Voltage 23 Setting Limits 24 Setting a lower resistance LOWER 24 Setting the upper resistance UPPER 25 Turning the Judgment Function On and Off 26 Turning the lower judgment function on and off 26 Turning the upper judgment function on and off 27 Window comparator function 27 Setting the Timer Function 28 Turning t...

Page 6: ...6 TOS7200 Troubleshooting 50 7 Specifications 51 Basic performance 51 Interface and other functions 53 General specifications 55 Dimensions 56 Index 57 ...

Page 7: ...between ON and OFF for the test duration timer function TIMER ON LED p 28 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 REMO...

Page 8: ...or when the judgment result is UPPER FAIL p 25 LOWER LED Lights when the lower limit setting is displayed or when the judgment result is LOWER FAIL p 24 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...

Page 9: ...s the number of averaging times p 34 AUTO RANGE Shows the measurement range mode 1 auto range 0 fixed range p 35 LOWER ON Indicates the lower judgment function 1 ON 0 OFF p 35 SPEED Shows the communication rate for RS232C communications 0 9600 bps 1 19200 bps 2 38400 bps p 35 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 s...

Page 10: ...onnector 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 resistance value p 48 6 OUTPUT terminals These terminals output the test voltage They are connected in parallel to the OUTPUT terminals on the front panel p 16 1 For details see the communication interface manual ...

Page 11: ... can be conducted on a wide range of electric and electronic components and equipment 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 up...

Page 12: ...orporating 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 pa...

Page 13: ...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 ...

Page 14: ...ipment 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 th...

Page 15: ...rning 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 Firmware version Model When the power is turned on the tester lights up al...

Page 16: ...nal Connecting the high voltage side test leadwire Perform the following procedure after connecting the low voltage side test leadwire 1 Press the STOP switch 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 WARNING Insecure con...

Page 17: ...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 WARNING Risk of electric shock Never touch a test leadwire the DUT the HIGH terminal or the LOW terminal during a test or while the DANGER ...

Page 18: ...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 con...

Page 19: ...adwires 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 WARNING The tester derivers a 1000 Vdc test voltage which can cau...

Page 20: ...ol 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 MEMORY VOLTAGE RESISTANCE...

Page 21: ...ed 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 WARNING In Testing the test leadwire and DUT are charge...

Page 22: ...ch 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 i...

Page 23: ... digit at which a value is to be set 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 MEMORY VOLTAGE RESISTANCE TIMER MEMORY VOLTAGE RESISTANCE TIMER Voltmeter VOLT key For moving the cursor or changing a numerical value Whe...

Page 24: ...havalueistobeset 4 With the SHIFT key held down press the or key to change the value If necessary change the value at another digit to achieve the desired lower resistance MEMORY VOLTAGE RESISTANCE TIMER MEMORY VOLTAGE RESISTANCE TIMER Resistance meter UPPER LOWER key LOWER LED UPPER LED UPPER ON LED For moving the cursor or changing a numerical value Lower Resistance Resolution 0 01 MΩ to 9 99 MΩ...

Page 25: ...ain to light up the UPPER LED 3 Press the or key to move the cursor to the digit at which a value is to be set 4 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 upper resistance 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 When both the upper and lower ju...

Page 26: ...icating 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 MEMORY VOLTAGE RESISTANCE TIMER MEMORY VOLTAGE RESISTANCE TIMER Resistance meter UPP...

Page 27: ...en 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 fixe...

Page 28: ... range of 0 5 s to 999 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 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 or key to move the cursor to t...

Page 29: ...s 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 or key to move the cursor to the digit at which a valu...

Page 30: ...s 999 blinks The WAIT LED blinks during the wait time 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 p...

Page 31: ... 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 PASS lamp lit Measured resistance value To eliminate the effects of the charge current of a capaciti...

Page 32: ...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 sw...

Page 33: ...key held down press the SYSTEM key The TOS7200 enters system setting mode 4 Press the or key to move the cursor to the digit at which a value is to 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 5 With the SHIFT key held down press the or key to change the value To exit system setting 1 Press the STOP ...

Page 34: ...t 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 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 sto...

Page 35: ...e Communication rate SPEED This setting selects the RS232C communication rate 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 judgmen...

Page 36: ...n 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 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 ...

Page 37: ...e 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 s...

Page 38: ... contents of the panel settings stored in memory Before initializing make sure no data still required is contained in memory 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 Panel memory number Test volta...

Page 39: ...ured 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 WARNING The remote control uses an external signal to turn ON OFF the high voltage which may involve great danger Therefore thorough safety measures must be taken to ensu...

Page 40: ...N 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 o...

Page 41: ...m 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 a...

Page 42: ...e these components see the OMRON Corporation catalogs Wire and tool that are necessary to make the connection WARNING Possible electric shock Ensure that all devices are off before you connect or disconnect cables between them CAUTION Possible damage to the internal circuitry Keep the signal wire at least 50 cm away from the high voltage test lead and the DUT Do not short the output voltage circui...

Page 43: ...etween 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 resi...

Page 44: ...tion of the SIGNAL I O Connector Output signal controller Input signal controller COM Output signal 1 Output signal 2 Input signal 1 Input signal 2 15 V 15 V COM S1 Use a make contact such as a relay or switch to set the input terminal to the Low level Example of Control Using a Make Contact COM ic Use a logic element such as a transistor in place of a switch in the above example Consideration sho...

Page 45: ... 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...

Page 46: ...al 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 cance...

Page 47: ...n in Table below PM signals and memory numbers to be recalled Strobe Signal READY OUT PM0 PM3 IN STB IN 10 ms or more 10 ms or more 10 ms or more 5 ms or more The next signal input requires an interval of 10 ms or more The input terminal is pulled up to 12 V using a resistor Opening the input terminal effectively creates a high level input PM3 PM2 PM1 PM0 Memory number to be recalled H H H H 0 H H...

Page 48: ...0 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 Resistance measurement Output voltage Vo 1 1 Full scale is 5 V 0 Ω 0 V 1 MΩ 0 30 V 10 MΩ 1 04 V 100 MΩ 2 00 V 1000 MΩ 3 00 V 10000...

Page 49: ...fe 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 WARNING Any break or cr...

Page 50: ...he START switch or START signal of the SIGNAL I O does not work Confirm that no STOP signal of the SIGNAL I O is being input Using Terminals and Connectors p 39 Confirm that the tester is not in PASS or FAIL status The START switch does not function during output of a judgment result Press the STOP switch to cancel output Confirm that the tester is not currently storing panel settings to or recall...

Page 51: ... 1 V 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...

Page 52: ... s 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 Judgment Judgment method Indication Buzzer SIGNAL I O UPPER FAIL If a resistance value equal or higher than the upper resistance is detected the tester shuts off the output and returns an UPPER FAIL judgment FAIL lamp lights UP...

Page 53: ...tance value 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 ...

Page 54: ...s 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 resulti...

Page 55: ...sed 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 test leadwires 1 set 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...

Page 56: ...56 TOS7200 Specifications Dimensions Unit mm inch 215 8 46 230 9 06 MAX5 0 20 MAX85 3 35 66 2 60 MAX260 10 24 M A X 1 2 0 4 7 2 ...

Page 57: ...ving 4 O OUTPUT terminal 7 P panel memory 36 PASS HOLD 34 PASS judgment 31 PASS lamp 8 power cord connecting 14 power turning ON 15 prohibited operations 22 R RECALL key 7 remote control box 12 REMOTE LED 9 REMOTE terminal 40 RESISTANCE 8 S SIGNAL I O connector 42 SPEED 35 stand 4 START switch 7 starting the test 30 STOP switch 7 STORE key 7 SYSTEM key 7 system settings 33 T test ending 31 precaut...

Page 58: ...58 TOS7200 V version 15 VOLT key 7 W WAIT TIME setting 29 warning residual high voltages 21 ...

Page 59: ......

Page 60: ...se 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...

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