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Hipot ( Withstanding Voltage) &Insulation Resistance Tester

S !
imple
ecure
afety
Short-circuit current:
Max rated output:

200 mAor more!*
500VA* When the output voltage is 1.0 kV or greater

Hipot (Withstanding Voltage) & Insulation Resistance Tester

TOS5300 Series
The PWM amp system provides highly-stable output
5 kV/100 mA (500 VA) AC Hipot (withstanding voltage) test
6 kV/maximum output 50 W DC Hipot (withstanding voltage) tester (TOS5301)
25 V-1000 V (7 steps), 500 V or greater, up to 5.00 GΩ Insulation Resistance test
High-precision measurement ±1.5 % of reading (with voltmeter 500 V or higher, Ammeter 1 mA or higher)
Rise time/Fall time control
Key lock function and Protection cover for key operation
Equipped with USB interface

Highly stable
Newly developed, high-efficiency
PWM switching amplifier !
Providing a stable output of highvoltage without being affected by
AC line variation. Ensure the user
to perform highly reliable testingwith confidence, even in regionswith large voltage variations. (Input
voltage fluctuation rate: ±0.3%)

Reducing
the tact time
Increasing the productivity!
Capable of setting
the test time from 0.1s

S !
▲Output voltage wave form

imple
ecure
afety

Supporting the
A new standard for
Hipot (Withstanding voltage) &World-wide
input voltage Insulation resistance testing
Usable globally !
Usable in any country without changing the
input power supply.

Selectable output frequency !
The instrument not rely on the input powerenv ironm ent . Supp l y ing th e s t ab le tes t
voltage with 50/60 Hz frequencies.

Applied to World-Wideinput voltage

Max rated output:

200 mAor more!*
500VA

Equipped with a Rise time/
Fall time control function
Prevents from an excessive stress applied to the
EUT or for standard tests.

▲Rise time control waveform(example)▲Fall time control waveform(example)Pursuing usability
and safety
All new design of the control
panel and output terminals!
Eliminates the projected components of output
terminals, and equips with a new type of the LOW
terminal. Pursuing the improvement of safety
and a convenience in production line, such asproviding the protection cover for the front panel.

Lightweight &Compact design
Increasing your work efficiency!

Short-circuit current:

Rise/Fall Time
control function of
the applied voltage

Weighs Approx. 15 kg
40% lighter than conventional models*Compared to TOS5300 and TOS8870A* When the output voltage is 1.0 kV or greater▲Output terminal
Left : HIGH (red)Right : LOW(black, with lock function)▲View with the protection cover
removed from front panel

The "TOS5300 Series" is a series of test instruments used in Hipot (withstanding
voltage) tests and insulation resistance tests, two of the four tests regarded
as necessary for ensuring the safety of electrical products. With an output
of 5 kV/100 mA (AC) and 6 kV/10 mA (DC), the series can be used in Hipot(withstanding voltage) & insulation resistance testing of electronic equipment
and electronic parts, based on the requirements of IEC, EN, UL, VDE, JIS, andother international safety standards and the Electrical Appliance and Material
Safety Law. Also, the test voltage stability is improved with the adoption of a
newly developed switching amplifier. Since the output voltage can be kept
constant even when the AC line voltage or frequency changes, consistenttesting can be performed, even when the power supply environment is in an
unstable region. The TOS5300 is also equipped with a number of features thatare capable of meeting a variety of test needs. It is low-cost standard modelthat provides thorough operability, reliability and safety.

H i p o t ( W i t h s t a n d - Vo l t a g e ) & I n s u l a t i o n R e s i s t a n c e Te s t e r

TOS5300Series
3 modelFeaturesandFunctions
2

Applied test / Model
AC Hipot (Withstanding voltage) test (ACW)DC Hipot (Withstanding voltage) test (DCW)
Insulation Resistance test (IR)TOS5300

TOS5301

TOS5302

✔

✔

✔

✔
✔

●ACW: 5 kV/100 mA; DCW: 6 kV/50 W ●IR: 25-1000 V (7 steps)/500 V or greater, up to 5.00 GΩ ●High-precision measurement ±1.5 % of reading (Voltage:
500 V or greater ; Current: 1 mA or more) ●Rise time / Fall time control function ●Discharge function ●World-wide input voltage ●AUTO function●USB interface ●Panel memory function (3 sets) ●Key lock and Protection cover for panel operation

Basic performance ensure the reliable testing

The achievement of AC Hipot (Withstanding voltage) testing with a constant stable output!
[ Input voltage variation : ± 0.3 %]The output waveform isessential factor in Hipot(Withstanding voltage) testing!
A conventional Hipot (Withstanding voltage)tester boosts and outputs the AC line's input
voltage through the use of a slide transformer.
With this slide transformer system, input voltage
fluctuations will affect the output, preventing
tests from being performed properly. At times,
the application of distortion voltage applied
to the EUT may cause a failure of new product(accelerating a deterioration of components).
Since the TOS5300 Series equips with a highefficient PWM amplifier that can output a stablehigh-voltage without being affected by thevariation of AC power line, users can perform"safe", "stable", and highly "reliable" tests withconfidence, even in regions with large voltage
variations.

▲AC output waveform of the
TOS5300 Series▲AC output waveform of the slide
transformer system

Realizing high-precision measurement withhigh-resolution and high-speed judgement

Supporting the World-wide
input voltage

Equipped with a high-accuracy, high-resolution of True RMS measurement circuit, including a Voltmeter with ±1.5 % of reading (500 V or
greater) / minimum resolution of 1V, and an Ammeter with ±1.5 %of reading (1 mA or more) / minimum resolution of 1 µA. In addition,
it is also equipped with an Auto range function. The Lower limit
judgment accuracy achieves a level of performance equivalent to theUpper limit judgment accuracy that enables to detect for such a poor
contact or disconnections of test leads. Moreover, it realizes the fast
judgment by the test time of 0.1 second, while reliable testing canbe performed, thanks to high-precision, high-resolution, high-speed
measurement and the judgment functions.

Usable globally !

This isdifferent,
too!

Usable in any country, without changing
the input power supply.

Selectable output frequency !
The instrument not rely on the input power environment.
Supplying the stable test voltage with 50/60 Hz frequencies.

Reducing the tact time
Reduction of the tact time leads to improve the productivity.
However, it has been an issue that reducing the tact time may
cause to worsen the measurement accuracy when the test time
is faster than the measuring response speed. The TOS5300 series
has been achieved to set the test time from 0.1 s.
(Model TOS5301)

6 kV/50 WDC Hipot (Withstanding voltage) test
Capable to perform DC Hipot (Withstanding voltage) test up to
6 kV. (Model TOS5301) Equipped with a stable DC/DC converterwith a low-ripple and the load variation of 3 % or less.

Insulation resistance test for 25 V to 1000 V*
Capable of precision
measurement from 0.00 mA▲ AC Hipot (Withstanding voltage) test settings display (example)

The TOS5302 is equipped with an insulation resistance tester. The
test voltages can be set from 25 V, 50 V, 100 V, 125 V, 250 V, 500 V
and 1000 V. And for setting at 500 V and above, it can perform theinsulation resistance test up to 5.00 GΩ.
*At 500 V and above, measurements up to 5.00 GΩ are possible.

3Functions and Safety that focus in the production site

Protection cover prevents physical operation error in the production site
Prevents a physical operation
error by installing the protection
cover on the control keys.

In many cases, workers on electronic equipment production lines and inspection lines
are not technical experts. Therefore, it ispossible that the operators may change
setting conditions and make operation
errors. In order to prevent from such cases,
the TOS5300 is equipped with a key lockfunction and a protection cover to disable aphysical key operation from the front panel.

▲View with the protection cover removed

Storing the protection cover for the key operation to the base of unit. ►During the periods of operation with the protection cover removed, such as
when the test conditions are frequently changed and tests are performed
repeatedly, the protection cover can be stored at the base.

New design of output terminal improves safety and functionality
Eliminates the projected components from thefront panel. The new design of LOW terminal.
In consideration of safety for the operator and the environment, theoutput terminal of HIGH-side has been placed in the most distantlocation from the control area. The free rotation machanisim protectsfrom twisting (or breaking) of the cable. Also, with having the lockfunction for the LOW terminal on the main unit, the metal plate is nolonger attached to the test lead of LOW-side, and it makes to resist
damage to the test lead. Because of elimination of these projectedcomponents, the TOS5300 can avoid from unexpected accidents
such as when the unit travels to other location. And also when thetest lead is snagged on something, or unexpected stress is appliedon the test lead, the High (High-voltage) test lead is designed to
disconnect easily, but the Low (ground) test lead is designed to resist
disconnection.
In order to prevent the insertion error, the color coding of the cable
are classified to HIGH (red) and LOW (black) , and the plug shape ofterminal are also different design.

▲Flat surface design of the HIGH terminal with free rotation mechanism,and the LOW terminal with lock function

It could be a cause of defect if the cable are incorrectly wired for
the HIGH (High-voltage) side and LOW (Low-voltage) side. In orderto prevent the insertion error, the protection plate is attached to
the Low-voltage (Black) test lead.

Monitoring the output voltage and protection when applying an overvoltage
by the operation error
LIMIT VOLTAGE function

Monitoring output voltage function

Prevents the user from setting a test voltage that exceeds thepreset voltage.

If the output voltage exceeds the setting voltage of (± 350 V), it turns
off the output and the system switches to PROTECTION mode.
In order to handle kilo's of high voltage when the Hipot (Withstandvoltage) and insulation tests are conducted, there are number of safetymeasures are required to take place. Having with these functions
improve, the operational safety and the protection for the EUT.

▲LIMIT VOLTAGE setting (example)

4

Functions and Safety that focus in the production site

Rise time / Fall time control function
Rise time control function
The Rise time control function enables you
to increases the test voltage gradually toreach the setting voltage while the AC Hipot(Withstanding voltage) test is conducted.
The voltage rise time can be set from 0.1 s to
10.0 s at a resolution of 0.1 s.

Fall time control function
The Fall time control function enables you
to decrease the test voltage gradually when
the PASS judgment is made at the AC Hipot(Withstanding voltage) test. The voltage falltime is fixed at 0.1 s. (OFF is also selectable).

▲Rise time control waveform (example)

The rise time control function is to prevent the EUT (test object) from being exposed
to stress that exceeds the required amount. The Hipot (Withstanding voltage) test
is conducted to verify the safety performance of the EUT and which test voltage for
Hipot (Withstanding voltage) test is applied approximately five to ten times greaterthan the voltage that handles by the EUT. If a high voltage is applied rapidly with norise time, the transitional large voltage (current) will be occurred, and it may cause
a damage to the EUT. If, as a result of the test, the EUT is suffered of the insulation(dielectric) breakdown, the failure of defect can easily be identified without any
problem. However, when breakage is occurred partially, it becomes hard to identify the
problem. In other words there are cases in which "at a glance, a Hipot (Withstanding
voltage) test appears to have been successfully passed, however, the fact is found thatthe insulation performance has degraded." In such cases there is a potential risk ofdanger that the insulation failure will occur after the EUT has been released into themarket as a commercial product. The result of testing performed to confirm safety
may cause the loss of product's safety. For this reason, safety standards stipulate theprocedure of Hipot (Withstanding voltage) test, and the test voltage must be gradually
increased to the specified voltage when the test is performed. The rise time control
function adopted in the in the TOS5300 Series can set the voltage rise time from 0.1
s to 10.0 s (at a resolution of 0.1 s) andalso it is capable to set the 50 % (fixed)of the applied test voltage. In addition,
the fall time control function enables todecrease the test voltage gradually after
the completion of a PASS judgement.
The voltage fall time is fixed at 0.1 s (OFF▲Start voltage can be set at 50 % of the test voltage.
is also selectable).

▲Fall time control waveform (example)

Examples of Safety Standards (Routine Tests)●IEC60950/J60950- Information processing equipment
The test voltage applied to the insulation part should
be increased gradually from zero to the specified voltage, then hold at the specified voltage for 60 seconds.

●IEC60335/J0335 - Home appliances

The initial test voltage should be applied less thanhalf of the specified voltage, then gradually increase
to the specified voltage.

●IEC60065/J0065 - Audio/video

The initial test voltage should be applied less thanhalf of the specified voltage, then rapidly increase
to the specified voltage and hold for 1 minute.

●IEC61010/JIS C 1010
-Measurement equipments

Avoids any detectable transient phenomenon, thetest voltage should be increased gradually to thespecified voltage within 5 seconds, then hold at the
specified voltage for 5 seconds.

Q.What is a Hipot (Withstanding voltage) test?

Q.What is PASS / FAIL criteria ?

Q.How is the test conducted?

A. Withstanding test also called a dielectricstrength test or Hipot test, a withstanding
voltage test is intended to verify whether
an electrical product or part has sufficientdielectric strength with respect to thevoltage being handled.

A. It is considered as "Electrical breakdown" when the current exceeds
the limit value flowing through theinsulated section during a test. If"the Electrical breakdown" does notoccur, the insulator is determined tohave sufficient insulating strength.

A. Apply the voltage with much higher stress than it would normally beapplied to the insulated section forthe specified time period.
While testing, it evaluates to verify
whether any insulation breakdown
has occurred on the insulator.
5

Functions and Safety that focus in the production site

Interlock feature

Upper limits / Lower limits setting function

The product is equipped with an interlock function that operates
together with external devices to interrupt output. To ensure thesafe operation of tester, the interlock function activates when the
SIGNAL I/O connector pins number 1 and 13 are opened, and when
they are short-circuited, the interlock function is released.

It automatically detects connector lead breaks and disconnections ofwiring by measuring extremely small amounts of current that flows
when voltage is applied to the EUT.

▲Example setting display of Upper limit, Lower limit, and Test time

Normally, even with a good-quality EUT, a certain degree of leakage
current flows. If the current value is set at slightly smaller than thespecific range of the EUT, it is useful in detecting breaks of the test
lead and faulty connections, which enables tests to be performed
with even higher reliability. You can perform testing effectively if you
set the lower limit value with LOWER ON during Hipot (Withstanding
voltage) test, and the upper limit value with UPPER ON during
insulation resistance test.

Calibration due notice and Warning function
To assure the traceability of periodic calibration of the product, thisfunction gives a notice of calibration due managed by the builtin real-time clock. Even if the due data has elapsed, it is possible to
avoid the oversight of operator with limiting the operation with adisplay of warning message.

▲The picture shown above indicates the caution sign of " HI VOLTAGE DANGER " witha chain surrounding the test site.

Discharge feature (Model TOS5301 / TOS5302)▲Example setting display of Calibration due

Equipped with a forced discharge function that forcibly discharge theelectricity which has been charged in the EUT after the completion of
DC Hipot (Withstanding voltage) test or insulation resistance test.

6

Q.What is an insulation resistance test?

Q.What is the procedure of testing?

A. An insulation resistance test is to measure theresistance value of insulator and verify thatwhether the insulator has a sufficient performance. It is similar to the Hipot (Withstanding
voltage) test that confirms the function or
performance of an insulator, and it shouldbe the required conditions to prevent theaccidents from an electrical shock and fire.

A. In many cases, after moisture is absorbed(or is not absorbed in some cases), 500
volts or other specified value of DC voltage is applied, and the resistance value
is measured from the current flowing.

Q.What is the difference between
an insulation resistance test anda Hipot test?
A. The Hipot (Withstanding voltage) test
detects a faulty insulation whether
insulation breakdown occurs.
In contrast, the insulation resistance test
detects faulty insulation by measuring
the resistance value.

Functions and Safety that focus in the production site▲

To set the test conditions such as test voltage,
judgment value and test duration, simply
press a key and turn the knob on the front
panel. The test conditions can be saved in thepanel memory (3 sets).
Panel memory setting key(Model TOS5302)

AUTO TEST feature for consecutive testing
The TOS5302 can perform an AC Hipot (Withstanding voltage) test
and an insulation resistance test consecutively.
Either of the following can be conducted :Insulation resistance test →AC Hipot (Withstanding voltage) test, or
AC Hipot (Withstanding voltage) test →Insulation resistance test.

▲Insulation resistance test → AC withstand-voltage test

▲AC withstand-voltage test → Insulation resistance test

REMOTE connector & USB interface
Equipped with the REMOTE connectorand USB interface on the front panel are
exclusive use for the options.
Easy connection with the PC.

SIGNAL I/O Connector
The rear panel is equipped with SIGNAL I/O that provides functions
such as start and stop operation and signal output.
PIN No Signal name I/O TOS5300
1

INTERLOCK+

I

2

PM0

I

3

PM1

I

TOS5301

TOS5302

If you open the positive and negative terminals, the output is turnedoff, and the TOS5300 Series is switched to Protection mode.Open:The resistance between the two terminals is 1.2 kΩ or greater. Short:
The resistance between the two terminals is 1 kΩ or less.
Panel memory selection signal.
PM0 PM1 Called Panel Memory Number
The selection signal is latched on the
H
H Memory 1
rising edge of the input strobe signal toL
H Memory 2
recall panel memory.
L Memory 3* The selection of memory is prioritized H
L
L Enables TEST SEL and AUTO SEL selection
over TEST SEL and AUTO SEL.

4

NC

—

—

5

NC

—

—

6

NC

—

—

7

NC

—

—

8

NC

—

—

9

STB

I

Panel memory's strobe signal input terminal

10

TEST SELI

NA

ACW/DCW
selection signal
L: ACW
H: DCW

Single/Independent test's
selection signal/AUTO
Test's sequence selection
signal Selection of single
test with AUTO SEL
L: ACW ; H: DCW
Selection of AUTO testwith AUTO SEL
L: ACW→ IR
H: IR → ACW

11

AUTO SEL

I

NA

NA

Selection of AUTO
test/single test
L: Single test
H: AUTO test

12

COM

— Circuit's common terminal

13

INTERLOCK-I

When + terminal and - terminal are opened, output is interrupted
and the system shifts to the Protection status.
Open: Terminal-to-terminal resistance is 1.2 kΩ or more
Short: Terminal-to-terminal resistance is 1.2 kΩ or less

14

HV.ON

O

ON during test and while voltage remains
between output terminals

15

TEST

O ON during test (except when voltage is rising or falling)

16

PASS

O

ON for at least 0.2 sec. when PASS has been determined (PASS
HOLD time) Continuously ON when PASS HOLD time is set for HOLD

17

U-FAILO

Continuously ON when value over acceptable maximum is
detected, and UPPER FAIL is determined

18

L-FAILO

Continuously ON when value under acceptable minimum is
detected, and LOWER FAIL is determined

O ON during standby (READY status)

ON during test, while
voltage remains between
output terminals, andduring automatic test
(AUTO TEST)

19

READY

20

PROTECTION O ON while protection function is activated (PROTECTION ON)

21

START

I

Start signal input terminal

22

STOP

I

Stop signal input terminal

23

ENABLE

I

Start signal's ENABLE signal input terminal:
Shifts to the Protection status when the ENABLE signal changes

24

+24V

— +24V internal power supply output terminal: Maximum output current 100 mA

25

COM

— Circuit's common terminal▲

Easy setting of test conditions withpanel memory feature!

Rear panel

7Unless specified otherwise, the specifications are for the following settings and conditions.
• The warm-up time is 30 minutes.
• TYP:These are typical values. These values do not guarantee the performance of the product.
• rdng: Indicates the readout value.
• set: Indicates a setting.
• f.s: Indicates full scale.

■ Specifications ‒Withstanding voltage tester
TOS5300

TOS5301

Output range
Accuracy±(2 % of set + 20 V) when no load is connected

Setting range

0.00 kV to 5.50 kVResolution

10 V steps

Max. rated output *1

AC output
section

500 VA (5 kV/100 mA)

Max. rated voltage

5 kV

Max. rated current

100 mA (when the output voltage is 0.5 kV or greater)

Transformer rating

500 VA

Output voltage waveform *2

Sine

Distortion

If the output voltage is 0.5 kV or more: 3 % or less (when no load or a pure resistive load is connected).

Accuracy±0.5 % (excluding during voltage rise time)

Frequency

50 Hz or 60 Hz

Voltage regulation

10 % or less (when changing from maximum rated load to no load)

Input voltage variation±0.3 % (5 kV when no load is connected; power supply voltage: 90 V to 250 V)

Short-circuit current

200 mA or more (when the output voltage is 1.0 kV or greater)

Output method

PWM switching

Output range

0.05 kV to 6.00 kV±(2 % of set + 20 V)
when no load is connected

Accuracy
Setting range

0.00 kV to 6.20 kV

Resolution

10 V steps

Max. rated output *1
DC output
section

TOS53020.05 kV to 5.00 kV

50 W (5 kV/10 mA)

Max. rated voltage

6 kV

Max. rated current

10 mA

—

5 kV when no
Ripple (TYP) load is connected—

50 Vp-pMax. rated load

100 Vp-p
3 % or less (when changing from maximum
rated load to no load)

Voltage regulation
Short-circuit current (TYP)

40 mA (when generation 6 kV output)

Discharge feature

Forced discharge after test completion(discharge resistance: 125 kΩ)Start Voltage

The voltage at the start of withstanding voltage tests can be set to 50% of the test voltage.

Limit Voltage

The test voltage upper limit can be set . AC: 0.00 kV to 5.50 kV, DC: 0.00 kV to 6.20 kV

Output voltage monitor feature

If output voltage exceeds the specified value + 350 V or is lower than the specified value - 350 V,
output is turned off, and protective features are activated.

Scale
Analog

6 kV AC/DC f.s

Accuracy±5 % f.s

Indication

Mean-value response/rms scale

Measurement
range

Voltmeter
Digital0.000 kV to 6.500 kV AC/DC

Display□.□□□ kV

Accuracy

V < 500 V: ±(1.5 % of rdng + 20 V); V ≥ 500 V: ±1.5 % of rdng

Response *3

True rms/ Mean-value response rms display Can be switched

Hold feature

After a test is finished, the measured voltage is retained until the PASS or FAIL judgment is cleared.

Measurement
range

AC: 0.00 mA to 110 mA

AC: 0.00 mA to 110 mA
DC: 0.00 mA to 11 mA

AC: 0.00 mA to 110 mA

i = measured current
Display
Ammeter

DigitalAccuracy *4

8i < 1 mA□□□ μA

1 mA ≤ i < 10 mA□.□□□ mA

10 mA ≤ i < 100 mA□□.□□ mA

100 mA ≤ i□□□.□ mA

1.00 mA ≤ i: ±(1.5 % of rdng); i < 1.00 mA: ±(1.5 % of rdng + 30 μA)

Response *3

True rms/ Mean-value response rms display Can be switched

Hold feature

After a test is finished, the measured voltage is retained until the PASS judgment is cleared.

■ Specifications ‒Withstanding voltage tester
TOS5300

TOS5301

Judgment

UPPER
FAIL

Judgment method

Display

PASS

Judgment
featureBuzzer

SIGNAL I/O

ONGenerates a
U-FAIL signal

FAIL LED lights
UNDER is displayed on thescreenON

Generates a
L-FAIL signal

PASS LED lights

ON

Generates a
PASS signal

FAIL LED lights
If a current that is greater than or equal to the upper limit is detected,
OVER is displayed
the output is turned off, and an UPPER FAIL judgment occurs.
on the screen

If a current that is less than or equal to the lower limit is detected,
the output is turned off, and a LOWER FAIL judgment occurs. This
LOWER
judgment is not performed during voltage rise time (Rise Time) of all
FAILtests and during the voltage fall time (Fall Time) of AC withstanding
voltage tests.

Judgment method andjudgment operation

TOS5302

If the specified time elapses without any problems, the output isturned off, and a PASS judgment occurs.

• If PASS HOLD is enabled, the PASS signal is generated continuously until the TOS5300 Series receives a STOP signal.
• The UPPER FAIL and LOWER FAIL signals are generated continuously until the TOS5300 Series receives a STOP signal.
• The FAIL and PASS buzzer volume levels can be changed.
• For PASS judgments, the length of time that the buzzer sounds for is fixed to 0.2 seconds.
Even if PASS HOLD is enabled, the buzzer turns off after 0.2 seconds.
Upper limit setting

AC: 0.01 mA to 110 mA

AC: 0.01 mA to 110 mA
DC: 0.01 mA to 11 mA

AC: 0.01 mA to 110 mA

Lower limit setting

AC: 0.01 mA to 110 mA / OFF

AC: 0.01 mA to 110 mA / OFF
DC: 0.01 mA to 11 mA / OFF

AC: 0.01 mA to 110 mA / OFF

Judgment accuracy *4

1.00 mA ≤ i: ±(1.5 % of set), i < 1.00 mA: ±(1.5 % of set + 30 μA)

Current detection method

Calculates the current’s true rms value or mean-value and compares this value with the reference value

Calibration

Calibrated with the rms of a sine wave using a pure resistive load

Voltage rise time

0.1 s to 10.0 s

Resolution

0.1 s

Voltage fall timeTime

0.1 s / OFF (only enabled when a PASS judgment occurs)

Test time

0.1 s to 999 s, can be turned off (TIMER OFF)
Resolution

0.1 s to 99.9 s: 0.1 s. 100 s to 999 s: 1 s.
±(100 ppm + 20 ms)
AC: Excluding Fall Time
DC: Rise Time Add ±50 ms at 1 kV or more, Add ±100 ms at less than 1kV.

Accuracy*1. Regarding the output time limits:
Taking size, weight, and cost into consideration, the heat dissipation capability of the voltage generator that is used for withstanding
voltage tests has been designed to be one half that of the rated output. Use the TOS5300 Series within the following limits. If you use theproduct in a manner that exceeds these limits, the output section may overheat, and the internal protection circuits may be activated. If
this happens, stop testing, and wait until the TOS5300 Series returns to its normal temperature.
Ambient temperature Upper limitACt ≤ 40 °C
DC

Pause time

Output time

50 mA < i ≤ 110 mA

Greater than or equal to the output time

30 min. max.

i ≤ 50 mA

Not necessary

Continuous output possible

5 mA < i ≤ 11 mA

Greater than or equal to the output time

1 min. max.

i ≤ 5 mA

Greater than or equal to the wait time (WAIT TIME)

Continuous output possible(Output time = voltage rise time + test time + voltage fall time)*2. Regarding the test voltage waveform:
Waveform distortions may occur if an DUT whose capacitance is dependent on voltage (for example, an DUT that consists of ceramic
capacitors) is connected as the load. However, if the test voltage is 1.5 kV, the effect of a capacitance of 1000 pF or less can be ignored.
Because the product’s high-voltage power supply uses the PWM switching method, if the test voltage is 500 V or less, the switching andspike noise proportions are large. The lower the test voltage, the greater the waveform is distorted.
*3. For both True rms and Mean-value response, 50 ms or above response time is required to satisfy the measurement accuracy.
*4. Regarding ammeter and judgment accuracy:
During AC withstanding voltage tests, current also flows in the stray capacitance of items such as the measurement leads and jigs.
This current that flows in the stray capacitances is added to the current that flows in the DUT, and the sum of these currents is measured.
Especially if you want to perform judgments with high sensitivity and accuracy, it is necessary to consider methods to limit the current thatflows in these stray capacitances, such as by adding upper and lower limits.
Output voltage

1 kV

2 kV

3 kV

4 kV

5 kV

When using 350 mm long test leads
that are suspended in air (TYP)

2 μA

4 μA

6 μA

8 μA

10 μA

When using the accessory,high test lead TL31-TOS (TYP)

16 μA

32 μA

48 μA

64 μA

80 μA

9

■ Specifications ‒Insulation resistance test section
TOS5302
Output voltage

25 V, 50 V, 100 V, 125 V, 250 V, 500 V, 1000 VDC (negative)

Accuracy

Outputsection-0 %, +5 %Max. rated load

1 W (-1000 V DC / 1 mA)

Max. rated current

1 mA

Ripple1000 V when noload is connected

2 Vp-p or lessMax. rated load

10 Vp-p or less

Voltage regulation

1 % or less (when changing from maximum rated load to no load)

Short-circuit current

12 mA or less

Discharge feature

Forced discharge after test completion (discharge resistance: approx. 25 kΩ)Limit voltage

The test voltage upper limit can be set : 25 V, 50 V, 100 V, 125 V, 250 V, 500 V, 1000 V

Output voltage monitor feature

If output voltage exceeds “10 % of set + 10 V” or is lower than “-(10 % of set + 10 V),” output is turned off, and protective features are activated.

Scale
AnalogVoltmeter

6 kV AC/DC f.s

Accuracy±5 % f.s

Indication

Mean-value response/rms scale

Measurement range
Digital0 V to -1200 V
Measured voltage

Display

V < 100 V

Accuracy

Resistancemeter

Measurement
range /
measurement
accuracy*5 *6

100 V ≤ V < 1000 V□□ V

Display

25 V

50 V

0.05 MΩ ≤ R ≤ 50 MΩ / ±(2 % of rdng + 2 digits)
50 MΩ < R ≤ 250 MΩ / ±5 % of rdng
250 MΩ < R ≤ 500 MΩ / ±10 % of rdng

100 V

0.100 MΩ ≤ R ≤ 100 MΩ / ±2 % of rdng
100 MΩ < R ≤ 500 MΩ / ±5 % of rdng
500 MΩ < R ≤ 1 GΩ / ±10 % of rdng

125 V

0.125 MΩ ≤ R ≤ 125 MΩ / ±2 % of rdng
125 MΩ < R ≤ 625 MΩ / ±5 % of rdng
625 MΩ < R ≤ 1.25 GΩ / ±10 % of rdng

250 V

0.250 MΩ ≤ R ≤ 250 MΩ / ±2 % of rdng
250 MΩ < R ≤ 1.25 GΩ / ±5 % of rdng
1.25 GΩ < R ≤ 2.5 GΩ / ±10 % of rdng

500 V

0.50 MΩ ≤ R ≤ 500 MΩ / ±2 % of rdng
500 MΩ < R ≤ 2.5 GΩ / ±5 % of rdng
2.5 GΩ < R ≤ 5 GΩ / ±10 % of rdng

1000 V

1 MΩ ≤ R < 1 GΩ / ±2 % of rdng
1 GΩ ≤ R ≤ 5 GΩ / ±5 % of rdng
25 kΩ ≤ R < 1.00 MΩ

□□□ kΩ

Hold feature

1.00 MΩ ≤ R < 10.0 MΩ□ . □□ MΩ

10.0 MΩ ≤ R < 100 MΩ

□□ . □ MΩ

100.0 MΩ ≤ R < 1.00 GΩ

1.00 GΩ ≤ R ≤ 9.99 GΩ□ . □□ GΩ

Can be switched between three levels: Fast, Mid, Slow
Judgment

Judgment method

Display

Buzzer

SIGNAL I/O

FAIL LED lights;
OVER is displayedon the screen

ON

Generates
a U-FAIL
signalFAIL LED lights;
If a resistance that is less than or equal to the lower limit is detected or if
LOWER FAIL a problem occurs during the voltage rise time (Rise Time), the output is UNDER is displayedon the screen
turned off, and a LOWER FAIL judgment occurs.

ON

Generates
a L-FAIL
signalON

Generates
a PASS signal

If a resistance that is greater than or equal to the upper limit is detected,
UPPER FAIL the output is turned off, and an UPPER FAIL judgment occurs. This
judgment is not performed during voltage rise time (Rise Time).

Judgment method and judgment
operation

PASS
Judgment
featureIf the specified time elapses without any problems, the output is turned
off,and a PASS judgment occurs.

PASS LED lights• If PASS HOLD is enabled, the PASS signal is generated continuously until the TOS5300 Series receives a STOP signal.
• The UPPER FAIL and LOWER FAIL signals are generated continuously until the TOS5300 Series receives a STOP signal.
• The FAIL and PASS buzzer volume levels can be changed.
• For PASS judgments, the length of time that the buzzer sounds for is fixed to 0.2 seconds.
Even if PASS HOLD is enabled, the buzzer turns off after 0.2 seconds.
Upper limit setting range

0.03 MΩ to 5.00 GΩ

Lower limit setting range

0.03 MΩ to 5.00 GΩ

Judgment accuracy(the same for UPPER and
LOWER)

Measurement accuracy + 2 digits
Humidity: 20 %rh to 70 %rh (no condensation). No interference caused by wobbly test leads or other problems.
For judgments of 5 μA or less, a test time of at least 1.0 seconds is necessary.
If the current detection response speed is set to Mid, a test time of at least 0.3 seconds is necessary.
If the current detection response speed is set to Slow, a test time of at least 0.5 seconds is necessary.

Voltage rise time

10 ms (TYP)

Test Time

0.1 s to 999 s, can be turned off (TIMER OFF)
Resolution

Accuracy

0.1 s to 99.9 s: 0.1 s. 100 s to 999 s:1 s.
± (100 ppm + 20 ms)*5. Humidity: 20 %rh to 70 %rh (no condensation). No bends in the test leads. *6. R = measured insulation resistance10□□□ MΩ

After a test is finished, the measured resistance is retained until the PASS judgment is cleared.

Current detection response speedTime□□□□ V± (1 % of rdng + 1 V)
0.03 MΩ ≤ R ≤ 25 MΩ / ±(2 % of rdng + 2 digits)
25 MΩ < R ≤ 125 MΩ / ±5 % of rdng
125 MΩ < R ≤ 250 MΩ / ±10 % of rdng

Display *61000 V ≤ V□□□ V

■ Specifications ‒Other features / Interfaces
TOS5300
TOS5301
TOS5302
Double action feature
Tests can only be started by pressing and releasing STOP and then pressing START within 0.5 seconds of releasing the STOP switch.
Length of time to maintain a PASS judgment result
You can set the length of time to maintain a PASS judgment: 50 ms, 100 ms, 200 ms, 1 s, 2 s,5 s, or HOLD.
Momentary feature
Tests are only executed while the START switch is held down.
Fail mode featureThis feature enables you to prevent remotely transmitted stop signals from clearing FAIL judgments and PROTECTION modes.
Timer featureThis feature finishes tests when the specified time elapses.
If output voltage exceeds “setting + 350 V” or is lower than “setting - 350 V,”
Output voltage monitor feature
the TOS5300 Series switches to PROTECTION mode, output is turned off, and testing finishes.
MemoryUp to three sets of test conditions can be saved to memory.
Key lock
Locks panel key operations (settings and changes).
Under any of the following conditions, the TOS5300 Series switches to the PROTECTION state, immediately turns output off,
Protective featuresand stops testing. A message is displayed on the screen.
Interlock Protection
An interlock signal has been detected.
Power Supply Protection
An error was detected in the power supply.
While monitoring the output voltage, a voltage outside of the rated limits was detected.
Volt Error Protection
AC or DC withstanding voltage tests: ±350 V Insulation resistance test: ±(10 % of set + 10 V)
During a withstanding voltage test, a value that is greater than or equal to the output limit power was specified.
Over Load Protection
AC withstanding voltage test: 550 VA. DC withstanding voltage test: 55 VA.
Over Heat Protection
The internal temperature of the TOS5300 Series became too high.
Over Rating Protection
During a withstanding voltage test, the output current was generated for a length of time that exceeds the regulated time.
Calibration Protection
The specified calibration period has elapsed.
Remote Protection
A connection to or disconnection from the front-panel REMOTE connector was detected.
SIGNAL I/O Protection
The rear-panel SIGNAL I/O connector’s ENABLE signal has changed.
USB Protection
The USB connector has been disconnected while the TOS5300 Series was being controlled through the USB interface.
System clock
Set in the following format: year/month/day hour/minutes/seconds.
Calibration date
Set when the TOS5300 Series is calibrated.
Calibration period setting
Sets the period before the next calibration is necessary.
Notification of when the calibration
Sets the operation that is performed when the specified calibration period elapses.
period elapses
When the TOS5300 Series turns on, it can display a notification or switch to the protection mode and disable testing.
USB
USB Specification 2.0
Front-panel 9-pin MINI DIN connector.
Interfaces
REMOTE
By connecting an optional device to this connector, you can control the starting and stopping of tests remotely.
SIGNAL I/O
Rear-panel D-sub 25-pin connector■ Specifications ‒General
TOS5300

Display
Backup battery life
Installation location
Spec guarante- Temperature
ed range
Humidity
EnvironTemperature
Operating
ment
range
Humidity
Temperature
Storage range
Humidity
Nominal voltage range(allowable voltage range)
PowerPower con- When no load is connected (READY)
supplysumption When rated load isconnected
Allowable frequency range
Insulation resistance (between AC LINE and the chassis)
Withstanding voltage (between AC LINE and the chassis)
Earth continuity
Safety *7

Electromagnetic compatibility (EMC) *7 *8

Dimensions
WeightAccessories■ Outline drawing
Unit: mm (inch)

TOS5301
TOS5302
VFD: 256 × 64 dots + 4 status indicators
3 years (at 25 °C or 77 °F)
Indoors, at a height of up to 2000 m
5 °C to 35 °C (41 °F to 95 °F)
20 %rh to 80 %rh (no condensation)
0 °C to 40 °C (32 °F to 104 °F)
20 %rh to 80 %rh (no condensation)-20 °C to 70 °C (-4 °F to 158 °F)
90 %rh or less (no condensation)
100 VAC to 240 VAC (90 VAC to 250 VAC)
100 VA or less
800 VA max.
47 Hz to 63 Hz
30 MΩ or more (500 VDC)
1400 VAC, 2 seconds (Routine test) / 1500 VAC, 1 minutes (Type test)
25 AAC, 0.1 Ω or lessComplies with the requirements of the following directive and standard.
Low Voltage Directive 2014/35/EU *8, EN 61010-1 (Class I*11, Pollution degree 2 *12)
Complies with the requirements of the following directive and standards.
EMC Directive 2014/30/EU, EN 61326-1 (Class A*9), EN 55011 (Class A*9, Group 1*10), EN 61000-3-2, EN 61000-3-3
Applicable under the following conditions: The maximum length of all cabling and wiring connected to the TOS5300 is less than 2.5 m.
Shielded cables are being used when using the SIGNAL I/O. The high-voltage test lead TL31-TOS is being used.
Electrical discharges are not occurring outside the DUT.
See “Outline drawing.”
Approx. 14 kg (30.9 lb.)
Approx. 15 kg (33.1 lb.)
Approx. 14 kg (30.9 lb.)
Power cord : 1pc. / High test lead (TL31-TOS) : 1set (1 red wire and 1 black wire, each with alligator clips); 1.5 m /D-sub 25-pin plug : 1set ; assembly type / High-voltage warning sticker : 1pc. / User’s manual : 1pc. / CD-R : 1pc. *9*7		 Does not apply to specially ordered or modified TOS5300s.
*8		 Limited to products that have the CE mark on their panels.
		 Not be in compliance with EMC limits unless the ferrite core is attached on
the cable for connection of J1 connector.
*9		 This is a Class A equipment. The TOS5300 is intended for use in an industrial environment. This product may cause interference if used inresidential
areas. Such use must be avoided unless the user takes special measures toreduce electromagnetic emissions to prevent interference to the receptionof radio and television broadcasts.
*10 This is a Group 1 equipment. The TOS5300 does not generate and/or use
intentionally radio-frequency energy, in the from of electromagnetic radiation, inductive and/or capacitive coupling, for the treatment of material or
inspection/analysis purpose.
*11		 This is a Class I equipment. Be sure to ground the TOS5300's protective
conductor terminal. The safety of this product is only guaranteed when the
product is properly grounded.
*12		 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 foran occasional temporary conductivity caused by condensation.

11Ordering information
Product Name

Model

Remarks

TOS5302

Hipot (Withstanding voltage) test: AC 5 kV/100 mA
Insulation Resistance test: 25V - 1000V

AC/DC Hipot (Withstanding voltage) tester (ACW/DCW)TOS5301

Hipot (Withstanding voltage) test: AC 5 kV/100 mA, DC 6 kV/50 W

AC Hipot (Withstanding voltage) tester (ACW)TOS5300

Hipot (Withstanding voltage) test: AC 5 kV/100 mA

AC Hipot (Withstanding voltage) &Insulation Resistance tester (ACW/IR)

Options
Test Lead

Remote Control Box■TL31-TOS (Max.AC5 kV/1.5 m)*Standardly attached to main unit in TOS5300 Series.

■RC01-TOS* (For single-handed operation/1.5 m)■RC02-TOS* (For two-handed operation/1.5 m)

Warning Light Unit
■PL02-TOS (for DC24 V)■TL32-TOS (Max.AC5 kV/3 m)

RC01-T0S
TL31-T0S

TL32-T0S

Test Probe■HP01A-TOS* (Max.AC4 kV•DC5 kV/1.8 m)■HP02A-TOS* (Max.AC4 kV•DC5 kV/3.5 m)

RC02-T0S

Rack Mount Adapter*The remote control conversion cable [DD-5P/9P] is required
when used with TOS5300 Series.

DIN Cable■KRA4-TOS (inch rack for EIA standards)■KRA200-TOS (millimeter rack for JIS standards)■DD-5P/9P conversion adapter (DIN - MIni DIN)

KRA4-T0S*The remote control conversion cable [DD-5P/9P] is required
when used with TOS5300 Series.

TOS Series

Electrical safety testers developed under the quality brand of KIKUSUI !!

Electrical Safety Multi-analyzer

Insulation Tester

TOS9300 Series

TOS7200

Ground Bond Tester

Leakage Current Tester

TOS6210 / 6200A

Hipot Tester

TOS5200

TOS3200

For details of the each products,
please refer to the catalog‘‘Electrical Safety Testers’’.

●Distributor/Representative

1-1-3, Higashiyamata, Tsuzuki-ku, Yokohama, Kanagawa, 224-0023, Japan
Phone:(+81)45-593-0200, Facsimile:(+81)45-593-7591, https://global.kikusui.co.jp/■ All products contained in this catalogue are equipment and devices that are premised on use under the supervision of qualifi ed
personnel, and are not designed or produced for home-use or use by general consumers. ■ Specifi cations, design and so forth
are subject to change without prior notice to improve the quality. ■ Product names and prices are subject to change and production
may be discontinued when necessary. ■ Product names, company names and brand names contained in this catalogue represent
the respective registered trade name or trade mark. ■ Colors, textures and so forth of photographs shown in this catalogue may
differ from actual products due to a limited fi delity in printing. ■ Although every effort has been made to provide the informationas accurate as possible for this catalogue, certain details have unavoidably been omitted due to limitations in space. ■ If you fi nd
any misprints or errors in this catalogue, it would be appreciated if you would inform us. ■ Please contact our distributors to confirm
specifications, price, accessories or anything that may be unclear when placing an order or concluding a purchasing agreement.

Issue:Nov.2022 202211PDFEC51