Atec TOS9201 User Manual

TOS9200 SERIES

Hipot Tester with Insulation Resistance Test

Perfect design for System Operation, introducing our top of the
line of Hipot / Insulation Resistance Testers

TOS9201(AC/DC)

TOS9200(AC)

Capable of performing hipot and insulation testing in com-

ply with safety standards, including IEC, EN, VDE, BS,

UL,CSA, JIS and the Electrical Application and Material

Safety Law (Japan)

The TOS9200 Series has been developed to meet a wide diversity of
customer needs. Including the refi nement and enforcement of Kikusui’
s former series, its specifi cations refl ect the results of detailed study of
our large database of user’s requirements including special orders and
modifying specifi cations.
The TOS9200 Series consists of four products : the testers TOS9200
and TOS9201, and the high-voltage scanners TOS9221 and TOS9220.
The TOS9200 is equipped with AC hipot and insulation resistance
testing functions, while the TOS9201 has a DC hipot testing function in
addition to these two functions. The power block, a core component,
employs a high-efficiency switching power supply and a switching
amplifi er based on PWM systems. These features realize high power
and enhanced stability, as well as reducing the size and weight of
the unit. When combined with the ground bond tester TOS6200,
the TOS9200 Series integrates three or four types of tests in a single
process.
Furthermore, when used together with the high-voltage scanner
TOS9220/9221 (equipped with a contact check function), the tester is
capable of automatically checking test points for up to 16 channels,
thereby facilitating a safe, reliable automatic testing system.

Rise-time control function

●

Fall-time control function

●

Offset cancel function

●

Measured-value hold function

●

Output voltage monitoring function

●

Memory function

●

Program function

●

Interlock function

●

DC discharge function

●

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TOS9200 SERIES

Hipot Tester with Insulation Resistance Test

Basic performance

Three functions - AC hipot testing, DC hipot testing and insulation
resistance testing

The TOS9200 can perform AC hipot tests and insulation
resistance tests, while the TOS9201 can also conduct DC
withstanding tests. Once connected to a device being tested, the
TOS9201 executes an AC hipot test, DC hipot test, and insulation
resistance testing in succession in one process.

Insulation resistance testing at 25 V to 1000 V and 0.01 M

The test voltage can be set to 25 V through 1000 V at a resolution
of 1 V. Insulation
resistance covers a
wide measurement
range from 0.01 MΩ to

9.99 GΩ *.
A single unit of the

AC hipot testing at 5 kV and 100 mA

Equipped with a high-effi ciency switching power supply in its high­voltage power block, a PWM-based switching amplifi er and a 500
VA high-voltage transformer, the TOS9200/TOS9201 realizes
a maximum output of 5 kV/100 mA (continuous output for 30

TOS9200/9201 is
capable of handling
all test voltages required by JIS C 1302 1994 (Insulation Resistor
Meter) and fully meets the JIS requirements.

*At a maximum rated current of 1 mA to 50 nA.
minutes), or 2.5 times the output of Kikusui’s former models. At a
test voltage of 500 V or more and an upper current of 100 mA, or
greater the tester instantaneously satisfi es the requirements of a
short-circuit current of 200 mA or more which is required by the
IEC standard *. In addition, the tester ensures a load effects of
30% or less and the generation of a consistent 50 Hz/60 Hz test
voltage free from the affect of the supply voltage. These features
eliminate the need to readjust the output voltage once the test
voltage is preset.
*Continuous outputs are impossible because the output is cut off
if an overcurrent is detected.

Enhanced measurement accuracy

The TOS9200/9201 is provided with a digital voltmeter for hipot

testing at an accuracy of ±(1% of reading + 30 V) and another one

for insulation resistance testing at an accuracy of ±(1% of reading

+ 1 V). Measured values are displayed not only during a test, but

while a program is being executed. A digital ammeter with an

accuracy of ±(3% of reading + 20 µA) is also provided for hipot

testing. Kikusui’s predecessors had the highest measurement

resolution of about 1 mA , with an accuracy of ±5% of the upper

cutoff current when it is set to 100 mA. In contrast, the digital

ammeter allows the TOS9200/9201 to make measurements at an

DC hipot testing at 6 kV and a maximum output of 50 W

The TOS9201 permits DC hipot testing at up to 6 kV *. The tester
is equipped with a stable, low-ripple DC/DC converter with a load

accuracy of ±(3% of reading + 20 µA), even if the upper current is

set to 100 mA. The ammeter displays measured values while the

program executes, as well as during an AC or DC hipot test.
factor of 1% or less.
*Maximum output of 50 W for up to 1 minute.

*At 1 µA< measured current ≤ 1 mA

to 9.99 G

Ω

Test voltage Resistance measurement range

25V 0.03 MΩ to 500 M

50V 0.05 MΩ to 1.00 G

100V 0.10 MΩ to 2.00 G

125V 0.13 MΩ to 2.50 G

250V 0.25 MΩ to 5.00 G

500V 0.50 MΩ to 9.99 G

1000V 1.00 MΩ to 9.99 G

Type

Voltmeter for hipot testing ± (1% of reading + 30V)

Ammeter for hipot testing ± (3% of reading + 20µA)

Voltmeter for insulation resistance testing ± (1% of reading + 1V)

Insulation resistance meter ± (2% of reading)*

Display accuracy

Ω

Ω

Ω

Ω

Ω

Ω

Ω

Ω

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TOS9200 SERIES

Hipot Tester with Insulation Resistance Test

Diverse functions

Rise-time control function

In AC hipot testing, DC hipot testing
and insulation resistance testing, you
can apply a voltage gradually to reach
the test voltage, instead of applying
the test voltage directly at the start of
a test. The voltage increase time can
be set to 0.1 s through 99.9 s at a
resolution of 0.1 s, and to 100 s to 200
s at a resolution of 1 s. The start voltage is also adjustable between
0% and 99% at a resolution of 1%.

Fall-time control function

In AC hipot testing, you can gradually
decrease the test voltage after a PASS
judgment. The voltage fall time is
adjustable between 0.0 s and 99.9 s at
a resolution of 0.1 s, and between 100
s and 200 s at a resolution of 1 s.

Offset cancel function

In AC hipot tests that require high sensitivity and high voltages,
currents flowing into the stray capacity of the test lead wire, jigs,
and other components can cause measurement errors. The
TOS9200/9201 features a function to cancel these offset currents.

Voltage hold function

During measurement, this function allows you to hold the value of the
voltage measured at the end of an AC or DC hipot test, as long as
the test results are being displayed. When combined with the rise­time control function, this function enables to observe the insulation
breakdown voltage.

Maximum Leakage current and minimum resistance hold function

By selecting “MIN/MAX Mode” in the measurement mode settings,
you can hold the maximum current in hipot testing and the minimum
resistance after the judgment wait time in insulation resistance testing.
These values are shown on the tester’s display. They can also be
read back via interface (GPIB or RS-232C).

Output voltage monitoring function

When the output voltage deviates from ±(10% of setting + 50 V), the
monitoring function activates to suspend the test, thus ensuring highly
reliable testing.

Memory function

Up to 100 test conditions used in AC and DC hipot testing and

insulation resistance testing, such as the test voltage, judgment value

and test time, can be stored with a specifi c name. For instance, you

can store the name of an applied safety standard and the destination

of the product to be tested. If test conditions are preset, operator can

recall relevant test conditions simply by entering the memory number.

If you previously assigned a special name to each of these test

conditions, operator can check recalled test conditions by name. The

memory function allows you to recall test conditions not only through

the recall operation on the front panel, but also by remote control.

[Storable test conditions]

Test voltage

Test frequency

Lower cutoff value

ON/OFF of the lower
judgment function

Upper cutoff value

ON/OFF of the upper
judgment function

ON/OFF of the offset
function

Test time and ON/OFF
of the timer function

Start voltage

Voltage rise time

Voltage fall time

Judgment wait time

Test voltage range

SLOW/MID/FAST settings
for the response fi lter

FLOAT/GND of the
LOW terminal

HIGH/LOW/OPEN settings
for the scanner channel

ON/OFF of the contact
check function

AC withstanding
voltage testing

✔✔✔

✔

✔✔✔

✔✔✔

✔✔✔

✔

✔✔✔

✔✔

✔✔✔

✔

✔

✔

✔✔✔

✔✔✔

✔✔✔

DC withstanding
voltage testing

✔✔

Insulation resistance
testing

✔

Program function

By coordinating test conditions stored in an AC hipot test, DC hipot

test, and insulation resistance test, operator can sequentially run tests

that comprise up to 100 steps. When used together with the ground

bond tester TOS6200/6210, the TOS9200 Series permits continuous

tests combining test conditions stored in the TOS6200, as well as on

the TOS9200 itself. Sequential tests are possible, for example, on AC

hipot, insulation resistance, DC hipot, and ground bond, in order. The

TOS9200 Series stores up to 500 steps and 100 programs, which

can be recalled through the recall operation on the front panel or by

remote control.

Current detection response speed adjustment function

This function switches current detection response speeds for UPPER
judgment by adjusting the integrated time constant of the current
detection circuit. Three modes are available for the integrated
time constant: SLOW (about 40 ms),MID (about 4 ms) and FAST
(about 0.4 ms). SLOW mode is used in normal operations. MID
and FAST modes are more effective in detecting a discharge
occurring instantaneously or containing a large number of frequency
components. They are also useful for hipot tests of test devices that
insulation likely be breakdown, such as small electronic components.

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[Sample program]

Step 00 Step 01 Step 02

Memory Interval Memory Interval Memory Interval

ACW01

0.2s DCW01 0.2s IR01 0.2s

END

At Step 00, Step 01 and Step 02, memory ACW01 (AC hipot
test), DCW (DC hipot test: TOS9201 only) and IR01 (insulation
resistance test) are performed, receptively, in succession at

0.2-second intervals.

TOS9200 SERIES

Hipot Tester with Insulation Resistance Test

Interfaces

REMOTE connector & SIGNAL I/O connector

The REMOTE connector on the
front panel is intended exclusively
for Kikusui’s options (remote control/
test probe). It allows start and stop
operations by remote control. The SIGNAL I/O connector on the
rear panel permits operator to recall panel memory and program
memory contents by remote control, as well as controlling start
and stop operations. Seven different signals are output from the
SIGNAL I/O connector through the open collector.

[SIGNAL I/O]

No. Signal name I/O Details of signal
1 PM0 I LSB, LSD *1
2 PM1 I LSD *1
3 PM2 I LSD *1
4 PM3 I LSD *1
5 PM4 I MSD *1
6 PM5 I MSD *1
7 PM6 I MSD *1
8 PM7 I MSB, MSD *1
9 STB I Input terminal for the strobe signal of the panel memory and
program memory
10 MODE0 I Selects a test mode *2
11 MODE1 I Selects a test mode *2
12 NC
13 COM Circuit common (chassis potential)
14 H.V ON O ON during a test and an automatic test (AUTO) or while a voltage
remains between the output terminals
15 TEST O ON during a test (except for voltage rise and voltage fall)
16 PASS O ON during the time preset in the PASS HOLD settings when a
PASS judgement is made
17 U FAUL O Continuously ON in an UPPER FAIL judgement. Continuously
ON in a CONTACT FAIL judgement with the scanner connected.
18 L FAUL O Continuously ON in an LOWER FAIL judgement. Continuously
ON in a CONTACT FAIL judgement with the scanner connected.
19 READY O ON during the READY status

PROTECTION

20
21 START I Input terminal for the START signal
22 STOP I Input terminal for the STOP signal
23 ENABLE I Input terminal for the ENABLE signal for the START signal
24 +24V Output terminal for +24 V internal power, with a maximum output
current of 100 mA
25 COM Circuit common (chassis potential)

Input signal [Low active control input High-level input voltage: 11 V to 15 V /

●

Low- level input voltage: 0 V to 4 V / Low-level input current: Maximum –5 mA /
Input interval: Minimum 5 ms]

Output signal [Open collector output (DC4.5V to 30V) / hipot: DC 30 V / Output

●

saturation voltage : Approximately 1.1 V (25 °C) /Maximum output current : 400 mA
(TOTAL)]

* The input signal circuit is pulled up to +12V. Therefore, opening the input terminal is

equivalent to inputting a high-level signal.

*1 2-digit BCD low active input Signal input terminal for selection between the panel memory

for ACW, DCW, and IR, and the program memory for AUTO Memory recall by latching this

selection signal at the rise of the strobe signal
*2 2-bit low active input Test mode ACW DCW IR AUTO
MODE0 H L H L
MODE1 H H L L

O ON when the PROTECTION function is activated

GPIB/RS-232C interface

A GPIB/RS-232C interface is
provided as a standard feature to
facilitate the remote control of all
functions of the TOS9200/9201
except the POWER switch, the KEYLOCK function, and the
program execution (AUTO) function.

RS-232C [Baud rate: 9600/19200/38400 bps/TOS6200/6210 interface
(AUTO mode only): START/STOP control, test condition settings, reading of
TOS6200/6210 measured values, and measurement results]
GPIB [Remote control of all functions except the POWER switch, the KEYLOCK
function, and the program execution (AUTO) function/SH1, AH1, T6, TE0, L4,
LE0, SR1, RL1, PP0, DC1, DT0, C0, E1]

[Pin Confi guration for the
SIGNAL I/O Connector]

Peripheral devices

High-voltage scanner TOS9220/TOS9221

TOS9221 Front View (same for TOS9220)

TOS9221

TOS9220

The high-voltage scanner TOS9220/TOS9221 has a function that
distributes the test voltage provided by the TOS9200/9201 to
multiple test points. Up to four channels can be used for outputs
on this scanner. Each channel can be set to one of the three
electric potential modes – HIGH, LOW, or OPEN. Operator can
conduct AC/DC hipot and insulation resistance tests on any of
the four test points. Furthermore, up to four scanners can be
connected to the tester, allowing a maximum of 16 channels. The
TOS9200 is equipped with a “contact check function” to check
the contact between the output of each channel and a test point.
These features ensure highly reliable and labor-saving hipot and
insulation resistance tests for electrical and electronic equipment
with multiple test points.

Pictures below are showing rear views of the units with cable clamp of output terminal removed.

     

TOS9221 Rear View

TOS9220 Rear View

Operation of the high-voltage scanner

On the TOS9200/TOS9201, you can select an electric potential
mode for each channel–HIGH(high voltage side), LOW (low
voltage side), and OPEN (open mode). The high-voltage scanner
permits AC/DC hipot or
insulation resistance tests
on any of the four test points
A to D. For instance, you
can set CH1 (test point A) to
HIGH,CH2 (test point B) to
OPEN,and CH3 (test point
C)CH4 (test point D)to LOW.
To specify these settings, you
can use the TOS9200/9201
panel or the GPIB/RS-232C.

*

High-voltage
scanner(TOS9220)

Device being tested

CH1[HIGH]

CH2[OPEN]

CH3[LOW]

CH4[LOW]

OUT HIGH VOLTAGE terminal

OUT LOW terminal

IN HIGH VOLTAGE terminal

IN LOW terminal

Test point A

Test point B

Test point C

Test point D

To TOS9200

}

/9201

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