DC Hipot and Insulation Resistance Testing in One Instrument
The KIKUSUI TOS5403 combines high-voltage DC withstand testing and insulation resistance measurement in a DC-only electrical safety tester.
The DC withstand section provides programmable output from 0.05 kV to 6.00 kV with a maximum rated current of 10 mA and maximum rated output of 50 W. The insulation resistance section provides negative-polarity test voltage from 25 Vdc to 1000 Vdc and resistance judgment up to 10.000 GΩ.
6 kV / 10 mA
Maximum DC withstand capability
50 W
Maximum rated DC output
10 GΩ
Insulation resistance judgment range
7-inch Touch Panel
Intuitive test setup and monitoring
High-efficiency PWM switching provides stable high-voltage output, while discharge detection, forced discharge after testing, programmable judgment limits, automatic test programs, and standard network interfaces support repeatable safety testing in both engineering and production environments.
6 kV DC Withstand Testing
The TOS5403 provides programmable DC hipot output from 0.05 kV to 6.00 kV with 1 V setting resolution, up to 10 mA rated current, and a maximum rated output of 50 W.
Insulation Resistance Testing
Negative-polarity insulation resistance test voltage is programmable from 25 Vdc to 1000 Vdc, with resistance judgment settings extending to 10.000 GΩ.
High-Stability PWM Output
A high-efficiency PWM switching amplifier maintains stable high-voltage output against AC line-voltage fluctuations, supporting consistent safety testing across different power environments.
Adjustable Discharge Detection
Independent discharge detection can identify momentary and high-frequency discharge events. Selectable filtering and sensitivity settings support detection of events including arc and corona discharge.
Forced Discharge After DC Testing
The TOS5403 automatically discharges the connected EUT after DC withstand and insulation resistance tests, helping reduce residual high voltage after testing.
7-Inch Touch Panel
The touchscreen displays test settings, measurement results, diagrams, and test information in a graphical interface designed for efficient setup and operation.
61 Automatic Test Programs
Up to 61 auto-test programs are available, with two programmable steps per program for combining supported DC withstand and insulation resistance test operations.
LAN, USB and RS232C
LXI-compliant LAN, USB 2.0 with USBTMC support, and RS232C are standard for remote control and automated test-system integration.
Programmable Pass / Fail Judgment
Upper and lower judgment limits, programmable timers, PASS/FAIL indicators, audible notification, and SIGNAL I/O outputs support automated test decisions.
Start Long Safety Function
The Start Long function requires the START control to be held before testing begins, helping reduce unintended high-voltage test initiation.
Battery DC withstand voltage testing
Battery insulation resistance evaluation
Photovoltaic system DC withstand testing
Photovoltaic insulation resistance testing
Electronic component DC dielectric withstand testing
Electrical equipment insulation evaluation
Research and development safety testing
Quality assurance and validation testing
Production-line electrical safety inspection
Certification laboratory safety testing
TOS5403 Specifications
| Test Functions | DC Withstand Voltage / Insulation Resistance |
|---|---|
| AC Withstand Voltage | Not supported |
| DC Withstand Output Range | 0.05 kV to 6.00 kV |
| DC Output Setting Range | 0.000 kV to 6.200 kV |
| DC Output Resolution | 1 V |
| DC Output Setting Accuracy | ±(2% of setting + 20 V), no load |
| Maximum Rated DC Output | 50 W — 5 kV / 10 mA |
| Maximum Rated DC Voltage | 6 kV |
| Maximum Rated DC Current | 10 mA |
| DC Voltage Regulation | 3% or less, maximum rated load to no load |
| DC Short-Circuit Current | 40 mA typical at 6 kV output |
| DC Output Method | PWM switching |
| DC Voltmeter Measurement Range | 0.000 kV to 6.500 kV |
| DC Voltmeter Accuracy | Below 500 V: ±(1.5% of reading + 10 V); 500 V or higher: ±1.5% of reading |
| DC Current Measurement Range | 0.00 mA to 11 mA |
| DC Current Measurement Accuracy | ≥1.00 mA: ±1.5% of reading; below 1.00 mA: ±(1.5% of reading + 20 μA) |
| DC Current Judgment Upper Limit | 0.01 mA to 11.00 mA |
| DC Current Judgment Lower Limit | 0.00 mA to 10.99 mA or OFF |
| DC Forced Discharge | After test completion; approx. 125 kΩ discharge resistance |
| DC Discharge Maximum Capacitance | 1 μF for discharge within 2 seconds |
| DC Discharge Time Setting | 0.0 s to 100.0 s |
| Insulation Resistance Test Voltage | 25 Vdc to 1000 Vdc, negative polarity |
| IR Voltage Setting Range | 0.00 kV to 1.02 kV |
| IR Voltage Setting Resolution | 1 V |
| IR Voltage Setting Accuracy | ±(1.0% of setting + 2 V) |
| IR Maximum Rated Load | 1 W — -1000 Vdc / 1 mA |
| IR Maximum Rated Current | 1 mA |
| IR Judgment Upper Limit | 0.001 MΩ to 10.000 GΩ |
| IR Judgment Lower Limit | 0.000 MΩ to 9.999 GΩ |
| IR Forced Discharge | After test completion; approx. 25 kΩ discharge resistance |
| IR Discharge Maximum Capacitance | 2 μF for discharge within 2 seconds |
| Auto Test Programs | 61 |
| Auto Test Steps | 2 per program |
| Interfaces | LAN (LXI) / USB 2.0 / RS232C |
| Display | 7-inch touch panel |
| Operating Temperature | 0°C to 40°C |
| AC Input | 100 Vac to 240 Vac nominal |
| Dimensions | 320 W × 132 H × 350 D mm nominal |
| Weight | Approx. 9 kg (19.84 lb) |
Discharge Detection and Automated Safety Testing
The TOS5403 combines programmable DC safety testing with independent discharge detection and remote-control functions for repeatable automated test workflows.
During DC withstand testing, discharge detection operates separately from the normal upper-current judgment. Low-pass and high-pass detection modes allow the tester to respond to different discharge characteristics, including momentary arc and corona events.
LPF / HPF
Selectable discharge detection modes
61 Programs
Stored automatic test programs
2 Steps
Per automatic test program
LXI LAN
Network-based test automation
Automatic tests can execute two supported test steps with selectable Continue or Abort behavior after a failure. Immediate, BUS, External, and Once step-start conditions support both software-controlled and externally triggered test systems.
