Standard 5 kV AC Hipot Testing for Electrical Safety
The KIKUSUI TOS5200 is a dedicated AC hipot tester for performing controlled withstand-voltage tests on electrical and electronic equipment and components.
The tester provides an AC output range of 0.05 kV to 5.00 kV with a maximum rated output of 5 kV, 100 mA, and 500 VA. Its PWM switching amplifier maintains a controlled 50 Hz or 60 Hz test waveform while reducing the effect of AC input-voltage variation on the applied test voltage.
5 kV AC
Maximum rated withstand-test voltage
100 mA
Maximum rated AC test current
500 VA
Maximum rated AC output
0.1 s
Minimum programmable test time
Digital voltage and current measurement, upper and lower current-limit judgment, rise and fall time control, interlock protection, panel memory, and external-control interfaces support repeatable bench, inspection, and production-line electrical safety testing.
5 kV / 100 mA AC Hipot Output
The TOS5200 provides AC withstand-voltage testing from 0.05 kV to 5.00 kV with a maximum rated output of 5 kV, 100 mA, and 500 VA.
PWM-Controlled High-Voltage Output
A PWM switching amplifier provides controlled high-voltage output with selectable 50 Hz or 60 Hz frequency and reduced sensitivity to variations in the AC input supply.
Precise Voltage and Current Measurement
The digital voltmeter and ammeter support True RMS measurement. Accuracy is ±1.5% of reading at 500 V or above for voltage and at 1 mA or above for current.
0.1-Second Minimum Test Time
Test duration can be programmed from 0.1 seconds to 999 seconds or operated with the timer disabled, supporting both fast inspection and longer-duration test procedures.
Rise and Fall Time Control
Voltage rise can be programmed from 0.1 to 10.0 seconds. A 0.1-second voltage fall function can be applied after a PASS judgment or disabled as required.
PASS / FAIL Current Judgment
Upper and lower current limits can be set from 0.01 mA to 110 mA, with automatic PASS, upper-fail, and lower-fail evaluation.
Production-Line Safety Controls
Interlock, double-action start, momentary operation, key lock, fail mode, and a protective actuator cover support controlled operation in inspection environments.
Multiple Control Interfaces
USB 2.0, RS232C, front-panel REMOTE, and rear-panel SIGNAL I/O provide flexible integration with PCs, remote-control accessories, PLCs, and automated test systems.
AC withstand-voltage testing of electrical and electronic products
Production-line dielectric-strength inspection
Electronic component withstand-voltage testing
Incoming, outgoing, and quality-control safety inspection
Automated PASS / FAIL hipot test stations
Withstand-voltage test procedures required by IEC, EN, UL, VDE, JIS, and other applicable product-safety requirements
TOS5200 Specifications
| Product Type | AC Hipot / AC Withstand Voltage Tester |
|---|---|
| AC Output Range | 0.05 kV to 5.00 kV |
| Voltage Setting Range | 0.00 kV to 5.50 kV |
| Voltage Setting Resolution | 10 V |
| Maximum Rated Output | 500 VA (5 kV / 100 mA) |
| Maximum Rated Voltage | 5 kV AC |
| Maximum Rated Current | 100 mA at output voltage of 0.5 kV or greater |
| Output Method | PWM switching |
| Output Waveform | Sine wave |
| Test Frequency | 50 Hz / 60 Hz |
| Voltage Frequency Accuracy | ±0.5%, excluding voltage rise time |
| Voltage Measurement Range | 0.000 kV to 6.500 kV AC |
| Voltage Measurement Accuracy | ±1.5% of reading at 500 V or greater |
| Current Measurement Range | 0.00 mA to 110 mA AC |
| Current Measurement Accuracy | ±1.5% of reading at 1.00 mA or greater |
| Measurement Response | True RMS / average-value response with RMS display, selectable |
| Upper Current Limit | 0.01 mA to 110 mA |
| Lower Current Limit | 0.01 mA to 110 mA / OFF |
| Voltage Rise Time | 0.1 s to 10.0 s, 0.1 s resolution |
| Voltage Fall Time | 0.1 s / OFF after PASS judgment |
| Test Time | 0.1 s to 999 s / TIMER OFF |
| Panel Memory | Up to 3 test-condition sets |
| USB | USB 2.0 |
| RS232C | Rear-panel D-sub 9-pin, EIA-232-D compliant |
| REMOTE | Front-panel 9-pin MINI DIN |
| SIGNAL I/O | Rear-panel D-sub 25-pin |
| Input Voltage | 100 VAC to 240 VAC nominal; 90 VAC to 250 VAC allowable |
| Input Frequency | 47 Hz to 63 Hz |
| Operating Temperature | 0 °C to 40 °C |
| Dimensions | 320 W × 132 H × 350 D mm |
| Weight | Approx. 14 kg (30.9 lb) |
Production-Line Integration and Safety Controls
TOS5200 supports both computer-controlled and external I/O-based operation for integration into electrical safety inspection stations.
USB and RS232C provide digital communication with a PC or controller, while the rear-panel SIGNAL I/O connector provides test-control and status signals for external equipment. A front REMOTE connector supports compatible KIKUSUI remote-control accessories.
RS232C
Remote programming and test-result communication
USB 2.0
PC-based control interface
SIGNAL I/O
25-pin interface for production-line control and status signals
Interlock
Supports external door or safety-fence interlock systems
When the interlock circuit is open, testing is inhibited and the TOS5200 enters its protection state. Additional protection functions monitor output voltage, output loading, temperature, output-rating conditions, remote connections, SIGNAL I/O status, and USB-control state.
