Hipot (Withstanding Voltage) & Insulation Resistance Tester OS5300 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
Newly developed, high-efficiency PWM switching amplifier ! Providing a stable output of high voltage without being affected by AC line variation. Ensure the user to perform highly reliable testing with confidence, even in regions with large voltage variations. (Input voltage fluctuation rate: ±0.3%) Increasing the productivity. Capable of setting the test time from 0.1s Usable globally ! 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. Increasing your work efficiency! Weighs Approx. 15 kg 40% lighter than conventional models *Compared to TOS5300 and TOS8870A Fall time control function Prevents from an excessive stress applied to the EUT or for standard tests. 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 as providing the protection cover for the front panel. Short-circuit current: Max rated output: 5 Hipot (Withstand-Voltage) & Insulation Resistance Tester The "TOSS300 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, and other 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, consistent testing can be performed, even when the power supply environment is in an unstable region. The TOS5300 is also equipped with a number of features that are capable of meeting a variety of test needs. It is low-cost standard model that provides thorough operability, reliability and safety.
Features and Functions ●ACW: 5 kV/100 mA; DCW: 6 kV/50 W ●lR: 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 2 The achievement of AC Hipot (Withstanding voltage) testing with a cons The output waveform is essential 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 high- efficient PWM amplifier that can output a stable high-voltage without being affected by the variation of AC power line, users can perform "safe", "stable", and highly "reliable" tests with confidence, even in regions with large voltage variations.
Realizing high-precision measurement with
high-resolution and high-speed judgement
Equipped with a high-accuracy, high-resolution of True RMS measure- ment 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 the Upper 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 can be performed, thanks to high-precision, high-resolution, high-speed measurement and the judgment functions.
Supporting the World-wide
input voltage
Usable globally ! 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 converter with a low-ripple and the load variation of 3 % or less.
Insulation resistance test for 25 V to 1000 V*
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 the insulation resistance test up to 5.00 GΩ. *At 500 V and above, measurements up to 5.00 GΩ are possible. C 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 equip- ment production lines and inspection lines are not technical experts. Therefore, it is possible 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 lock function and a protection cover to disable a physical key operation from the front panel.
New design of output terminal improves safety and functionality
Eliminates the projected components from the front panel. The new design of LOW terminal. In consideration of safety for the operator and the environment, the output terminal of HIGH-side has been placed in the most distant location from the control area. The free rotation machanisim protects from twisting (or breaking) of the cable. Also, with having the lock function for the LOW terminal on the main unit, the metal plate is no longer attached to the test lead of LOW-side, and it makes to resist damage to the test lead. Because of elimination of these projected components, the TOS5300 can avoid from unexpected accidents such as when the unit travels to other location. And also when the test lead is snagged on something, or unexpected stress is applied on 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 of terminal are also different design. and the LOW terminal with lock function
[ I ] N ] T
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 order to 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 Prevents the user from setting a test voltage that exceeds the preset voltage.

Monitoring output voltage function
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 (Withstand voltage) and insulation tests are conducted, there are number of safety measures are required to take place. Having with these functions improve, the operational safety and the protection for the EUT.
Rise time / Fall time control function
Rise time control function
The Rise time control function enables you to increases the test voltage gradually to reach 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 fall time is fixed at 0.1 s. (OFF is also selectable). ▲Rise time control waveform (example) ▲Fall time control waveform (example)
T ( N ) T
o
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 greater than the voltage that handles by the EUT.  If a high voltage is applied rapidly with no rise 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 that the insulation performance has degraded." In such cases there is a potential risk of danger that the insulation failure will occur after the EUT has been released into the market 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 the procedure 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) and also it is capable to set the 50 % (fixed) Output ON of the applied test voltage. In addition, the fall time control function enables to 50 9 decrease the test voltage gradually after the completion of a PASS judgement. 0.1.8 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).
Examples of Safety Standards (Routine Tests)
DIEC60950/J60950
- Information processing equipment The test voltage applied to the insulation part should be increased gradually from zero to the specified vol- tage, then hold at the specified voltage for 60 seconds. DIEC60335/J0335 - Home appliances The initial test voltage should be applied less than half of the specified voltage, then gradually increase to the specified voltage.
DIEC60065/J0065 - Audio/video
The initial test voltage should be applied less than half of the specified voltage, then rapidly increase to the specified voltage and hold for 1 minute.
DIEC61010/JIS C 1010
-Measurement equipments
Avoids any detectable transient phenomenon,  the test voltage should be increased gradually to the specified voltage within 5 seconds, then hold at the specified voltage for 5 seconds. Q.What is a Hipot (Withstanding voltage) test? A. Withstanding test also called a dielectric strength test or Hipot test, a withstanding voltage test is intended to verify whether an electrical product or part has sufficient dielectric strength with respect to the voltage being handled.
Q.What is PASS / FAIL criteria ?
A. It is considered as "Electrical break- down" when the current exceeds the limit value flowing through the insulated section during a test. If "the Electrical breakdown" does not occur, the insulator is determined to have sufficient insulating strength.
Q.How is the test conducted?
A. Apply the voltage with much high- er stress than it would normally be applied to the insulated section for the specified time period. While testing, it evaluates to verify whether any insulation breakdown has occurred on the insulator. 5

Interlock feature
The product is equipped with an interlock function that operates together with external devices to interrupt output. To ensure the safe 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. a chain surrounding the test site.
Discharge feature (Model TOS5301 / TOS5302)
Equipped with a forced discharge function that forcibly discharge the electricity which has been charged in the EUT after the completion of DC Hipot (Withstanding voltage) test or insulation resistance test.
Upper limits / Lower limits setting function
It automatically detects connector lead breaks and disconnections of wiring 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 tim
[ I ] N ] T
o
Normally, even with a good-quality EUT, a certain degree of leakage current flows. If the current value is set at slightly smaller than the specific 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, this function gives a notice of calibration due managed by the built- in real-time clock. Even if the due data has elapsed, it is possible to avoid the oversight of operator with limiting the operation with a display of warning message.
Q.What is an insulation resistance test? A. An insulation resistance test is to measure the resistance value of insulator and verify that whether the insulator has a sufficient perfor- mance. It is similar to the Hipot (Withstanding voltage) test that confirms the function or performance of an insulator, and it should be the required conditions to prevent the accidents from an electrical shock and fire. Q.What is the procedure of testing? A. In many cases, after moisture is absorbed (or is not absorbed in some cases), 500 volts or other specified value of DC vol- tage is applied, and the resistance value is measured from the current flowing. Q.What is the difference between an insulation resistance test and a 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.
Easy setting of test conditions with
panel memory feature!
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 the panel 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.
▲AC withstand-voltage test → Insulation resistance test
REMOTE connector & USB interface
Equipped with the REMOTE connector and 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
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.
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 the product 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.
*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 and spike 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 that

■ Outline drawing
Unit: mm (inch) "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 indust- rial environment. This product may cause interference if used inresidential 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. *10 This is a Group 1 equipment. The TOS5300 does not generate and/or use intentionally radio-frequency energy, in the from of electromagnetic radia- tion, 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 Poliution 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. Ordering information

Options
Test Lead ■TL31-TOS (Max AC5 kV/1.5 m) *Standardly attached to main unit in TOS5300 Series. Test Probe ■HP01A-TOS* (Max.AC4 kV•DC5 kV/1.8 m) ■HP02A-TOS* (Max.AC4 kV•DC5 kV/3.5 m) The remote control conversion cable [DD-5P/9P] is required when used with TOS5300 Series. Remote Control Box DIN Cable ■DD-5P/9P  conversion adapter (DIN - Mini  DIN)
Warning Light Unit
■PL02-TOS (for DC24 V) Rack Mount Adapter ■KRA4-TOS (inch rack for EIA standards) ■KRA200-TOS (millimeter rack for JIS standards) Electrical safety testers developed under the quality brand of KIKUSUI !! Ground Bond Te ●Distributor/Representative KIKUSUI ELECTRONICS CORPORATION 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/ KIKUSUI AMERICA, INC. 1-310-214-0000 www.kikusuiamerica.com 3625 Del Amo Blvd, Suite 160, Torrance, CA 90503 Phone : 310-214-0000 Facsimile : 310-214-0014 KIKUSUI TRADING (SHANGHAI) Co., Ltd. | www.kikusui.cn Room 305,Shenggao Building No.137,Xianxia Road,Shanghai City,China Phone : 021-5887-9067 Facsimile : 021-5887-9069 For our local sales disvibutors and representatives, plaase refer to "sales natwork" of cur wateds. r the supervision of qualifi ed ■■ All products contained in this catalogue are equipment and devices that are premised on in unde ers subers and also whole provides and the same and provides and prov arly miscritss of errors in this catalogue, it would be appreciated if you would inform us. ■ Please contact our detributors to conferm
specifications, price, accessories of