Kikusui TOS5400 | Hipot and Insulation Resistance Tester
Depending on the model, the series covers AC and DC dielectric withstand tests and insulation resistance measurements, with clear pass/fail results
- ✓ AC Hipot: up to 5 kV/100 mA
- ✓ DC Hipot: up to 6 kV
- ✓ IR Test Voltage: 25–1000 V DC
- ✓ Insulation Resistance: up to 10 GΩ
Hipot Testers: Withstand Voltage Testing and Insulation Resistance Measurement
Kikusui TOS5400: Three Models for Different Electrical Safety Tests
The Kikusui TOS5400 Series includes three electrical safety testers for withstand voltage testing of devices and components. The required test voltage type determines the appropriate model:
- TOS5401: AC and DC withstand voltage testing without insulation resistance measurement
- TOS5402: AC withstand voltage testing with insulation resistance measurement
- TOS5403: DC withstand voltage testing with insulation resistance measurement, particularly for batteries and PV systems
Detect Insulation Faults Under High Voltage
During withstand voltage testing, the hipot tester applies a defined test voltage to the device under test (DUT) and monitors the test current. The adjustable discharge detection function additionally detects short-duration electrical discharges.
Depending on the model, AC test voltages up to 5 kV or DC test voltages up to 6 kV are available. The PWM switching amplifier compensates for mains voltage fluctuations and maintains a stable high-voltage output. This ensures reproducible test conditions.
Measure Insulation Resistance
The TOS5402 and TOS5403 measure insulation resistance using an adjustable DC test voltage. This allows the measurement parameters to be adapted to the DUT and the applicable test requirements.
Automate Electrical Safety Testing
For recurring tests, test voltage, limit values, and test times do not need to be entered again. This saves time and reduces input errors.
With LAN/LXI, USB-TMC, RS-232C, and SIGNAL I/O, the TOS5400 Series can be integrated into automated test systems and production lines.
The instruments are used in development, quality assurance, and production and support testing in accordance with relevant IEC, EN, VDE, and UL requirements. They do not cover ground bond, leakage current, or partial discharge testing.
Alternative Products
For users who need to cover additional electrical safety tests beyond withstand voltage testing, three suitable alternatives to the Kikusui TOS5400 Series are available. Depending on the model, the GW Instek GPT-12000/GPT-15000 Series combines AC and DC withstand voltage testing, insulation resistance measurement, and ground bond testing. The Associated Research HypotULTRA 78xx Series is particularly suitable for automated electrical safety testing with extensive data storage capabilities. Another 500 VA alternative is the GW Instek GPT-9900 Series for AC and DC withstand voltage testing as well as insulation resistance measurement.
Related Product Categories
Hipot and High-Voltage Testers
Which TOS5400 Model Fits Your Test?
AC, DC, or an additional insulation resistance test? The test requirement determines the right TOS5400 model. Together, we define the test voltage, limits, and integration into your test system.
Specifications
| TOS5401 | AC Hipot 0.05 to 5.00 kV, max. 500 VA at 5 kV / 100 mA; DC Hipot 0.05 to 6.00 kV, max. 50 W at 5 kV / 10 mA |
|---|---|
| TOS5402 | AC Hipot 0.05 to 5.00 kV, max. 500 VA at 5 kV / 100 mA; insulation resistance testing with 25 to 1,000 V DC and measurements up to 10 GΩ |
| TOS5403 | DC Hipot 0.05 to 6.00 kV, max. 50 W at 5 kV / 10 mA; insulation resistance testing with 25 to 1,000 V DC and measurements up to 10 GΩ |
| AC Hipot output current | max. 100 mA at output voltages of 0.5 kV or higher (TOS5401, TOS5402) |
| DC Hipot output current | max. 10 mA; max. rated voltage 6 kV (TOS5401, TOS5403) |
| Insulation resistance test | max. 1 mA / 1 W, negative polarity (TOS5402, TOS5403) |
| Hipot voltage measurement | ±(1.5 % of reading + 10 V) |
| Hipot current measurement | ±(1.5 % of reading + 20 µA) |
| IR voltage measurement | 0 to -1,200 V; accuracy ±(1 % of reading + 1 V) (TOS5402, TOS5403) |
| AC test frequency | 50 Hz or 60 Hz (TOS5401, TOS5402) |
| High-voltage generation | PWM switching amplifier |
| Discharge detection | LPF with Fast, Medium and Slow settings and HPF with High, Medium and Low settings for detecting discharges including arc and corona discharges |
| DC discharge function | forced discharge after test completion; max. capacitance 1 µF, discharge time 0.0 to 100.0 s (TOS5401, TOS5403) |
| IR discharge function | forced discharge after test completion; max. capacitance 2 µF, discharge time 0.0 to 100.0 s (TOS5402, TOS5403) |
| Rise and fall time | 0.1 to 100 s; availability depends on test method and operating mode |
| Hipot test time | 0.1 to 1,000 s or OFF; cycle-based setting also available for AC Hipot |
| Automatic test | 61 programs with 2 test steps each |
| Operation | integrated 7-inch touchscreen |
| Interfaces | LXI-compliant LAN, USB and RS232C as standard |
| Power supply | 100 to 240 V AC nominal; allowable range 90 to 250 V AC, 47 to 63 Hz |
| Dimensions | 320 × 132 × 350 mm (W × H × D); maximum external dimensions 330 × 150 × 380 mm |
| Weight |
|
Options & Accessories
| TL31-TOS | high-voltage test leads, additional 1.5 m test lead set; one set is already included as standard |
|---|---|
| RC01-TOS | remote control box for one-hand starting and stopping of DCW and IR tests; DD-5P/9P adapter cable required |
| RC02-TOS | remote control box for two-hand starting and stopping of DCW and IR tests; DD-5P/9P adapter cable required |
| DD-5P/9P | 5-pin to 9-pin DIN adapter cable for remote control boxes and high-voltage test probes |
| HP01A-TOS / HP02A-TOS | high-voltage test probe for two-hand operation, 1.8 m / 3.5 m cable length, and maximum 5 kV DC; DD-5P/9P adapter cable required |
| PL02A-TOS | warning light unit for indicating active tests and other instrument states |
| KRA4-TOS | rack mount bracket for EIA inch racks |
| KRA200-TOS | rack mount bracket for JIS millimeter racks |
Scope of Delivery
| Kikusui TOS5400 Series instrument(s) |
| Power cord, 2.5 m, version depending on country of delivery |
| TL31-TOS high-voltage test leads, one set |
| 1x set of user-assembled D-Sub connectors for SIGNAL I/O |
| 1x cable tie for securing USB cables |
| 1x high-voltage warning label |
| Quick start guide |
| Safety information |
| China RoHS information sheet |
Applications
| DC withstand voltage testing of electrical devices and components |
| Insulation resistance measurements on electrical devices and components |
| Testing in accordance with IEC, EN, BS, VDE, UL, CSA, GB, and JIS requirements |
| DC withstand voltage and insulation testing of batteries |
| DC withstand voltage and insulation testing of photovoltaic systems |
| Testing in research and development |
| Quality assurance and certification testing |
| Automated testing in manufacturing and production lines |
Links & Downloads
Supplier
Kikusui Electronics is a leading manufacturer of power supplies, electronic loads and test equipment for electrical safety and has a worldwide sales and service network in 40 countries. The company was founded in 1951 and is based in Yokohama, Japan.
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