Withstanding Voltage and Insulation Resistance Tester, TOS9200 Series

The TOS9200 Series has been developed to meet a wide diversity of customer needs. Including the refinement and enforcement of Kikusui's former series, its specifications reflect the results of detailed study of our large database of user's requirements including special orders and modifying specifications.

The TOS9200 Series consists of four products the testers TOS9200 and TOS9201, and the high-voltage scanners TOS9221 and TOS9220.

The TOS9200 is euipped with AC withstanding voltage and insulation resistance testing functions, while the TOS9201 has a DC withstanding voltage testing function in addition to these two functions. The power block, a core component, employs a high-efficiency switching power supply and a switching amplifier 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 earth continuity 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/TOS9221 (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.


Basic Performance

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

AC withstanding voltage testing at 5kV and 100mA

Equipped with a high-efficiency switching power supply in its high-voltage power block, a PWM-based switching amplifier and a 500 VA high-voltage transformer, the TOS9200/TOS9201 realizes a maximum output of 5kV/100mA (continuous output for 30 minutes), or 2.5 times the output of Kikusui's former models. At a test voltage of 500V or more and an upper current of 100mA, or greater the tester instantaneously satisfies the requirements of a short-circuit current of 200mA 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 50Hz/60Hz 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.

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

The TOS9201 permits DC withstanding voltage testing at up to 6kV*. The tester is equipped with a stable, low-ripple DC/DC converter with a load factor of 1% or less.

*Maximum output of 50W for up to 1 minute.

Insulation resistance testing at 25V to 1000V and 0.01MΩ to 9.99GΩ

The test voltage can be set to 25V through 1000V at a resolution of 1V. Insulation resistance covers a wide measurement range from 0.01MΩ to 9.99GΩ*.

A single unit of the TOS9200/TOS9201 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 1mA to 50nA.

Test Voltage Resistance measurement range
25V 0.03MΩ to 500MΩ
50V 0.05MΩ to 1.00GΩ
100V 0.10MΩ to 2.00GΩ
125V 0.13MΩ to 2.50GΩ
250V 0.25MΩ to 5.00GΩ
500V 0.5MΩ to 9.99GΩ
1000V 1.00MΩ to 9.99GΩ

Enhanced Measurement Accuracy

The TOS9200/TOS9201 is provided with a digital voltmeter for withstanding voltage testing at an accuracy of ±(1% of reading + 30V) and another one for insulation resistance testing at an accuracy of ±(1% of reading + 1V). 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 + 20µA) is also provided for withstanding voltage testing. Kikusui's predecessors had a highest measurement resolution of about 1mA, with an accuracy of ±5% of the upper cutoff current when it is set to 100mA. In contrast, the digital ammeter allows the TOS9200/TOS9201 to make measurements at an accuracy of ±(3% of reading + 20µA), even if the upper current is set to 100mA. The ammeter displays measured values while the program executes, as well as during an AC or DC withstanding voltage test.

Type Display Accuracy
Voltmeter for withstanding voltage testing ±(1% of reading + 30V)
Ammeter for withstanding voltage testing ±(3% of reading + 20µA)
Voltmeter for insulation resistance testing ±(1% of reading + 1V)
Insulation resistance meter ±(2% of reading)*

*At 1µA < measured current ≤ 1mA

Diverse Functions

Rise-time Control Function

In AC withstanding voltage testing, DC withstanding voltage 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 ca be set to 0.2s through 99.9s at a resolution of 0.1s, and 100s to 200s at a resolution of 1s. The start voltage is also adjustable between 0% and 99% at a resolution of 1%.

Fall-time Control Function

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

Offset Cancel Function

In AC withstanding voltage 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/TOS9201 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 withstanding voltage test, as long as the test results are being displayed. When combined with the rise-time 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 withstanding voltage 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 + 50V), the monitoring function activates to suspend the test, thus ensuring highly reliable testing.

Current Detection Response Speed Adjustment Function

This function switches current dtection response speeds for UPPER judgment by adjusting the integrated time constant of the current detection circuit. Three modes are available for the integrated tim constant: SLOW (about 40ms), MID (about 4ms) and FAST (about 0.4ms). 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 withstanding voltage tests of test devices that insulation likely be breakdown, such as small electronic components.

Memory Function

Up to 100 test conditions used in AC and DC withstanding voltage testing and insulation resistance testing, such as the test voltage, judgment value and test time, can be stored with a specific 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
  AC withstanding voltage testing DC withstanding voltage testing Insulation resistance testing
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 filter
FLOAT/GND of the LOW terminal
HIGH/LOW/OPEN settings for the scanner channel
ON/OFF of the contact check function

Program Function

By coordinating test conditions stored in an AC withstanding voltage test, DC withstanding voltage test, and insulation resistance test, operator can sequentially run tests that comprise up to 100 steps. When used together with the earth continuity tester TOS6200, 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 withstanding voltage, insulation reesistance, DC withstanding voltage, and earth continuity, 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.

Dimensions/Weight (approx)

TOS9201/TOS9200: 430(455)W x 132(150)H x 370(440)D mm per 19kg


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