AC Hipot Tester

https://global.kikusui.co.jp/

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An ideal AC Hipot Testerwith low cost of ownershiprealized, built on more than
50 years of experience in market

Hipot (Withstanding Voltage) Tester

AC Hipot Tester

TOS5200

Highly-stable output with PWM Amp System
5 kV/100 mA (500 VA) AC Hipot test
Short-circuit current 200 mA or more
Rise time/Fall time control
Equipped with RS232C and USB Interface00An ideal AC Hipot Tester withownership realized, built on
50 years of experience !
Rise/Fall Time
control function of
the applied voltage
Equipped with a Rise time/
Fall time control function
Prevents from an excessive stress applied
to the EUT or for standard tests.

Highly stable output
Newly developed, high-efficiency
PWM switching amplifier !
Providing a stable output of high voltage without being
affected by AC line variation. Ensure the user to perform highly
reliable testing with confidence, even in regions with large
voltage variations. (Input voltage fluctuation rate: ±0.3 %)Variation of
input voltage

Distortion of
input voltage

Input waveform( phrases in these circles)

Rise Time

Stable High-voltage output !

Fall TimePursuing usability
and safety
All new smart design of control panel andoutput terminals!
Eliminates the projected components of
output terminals, and equips with a new
type of the LOW terminal. Pursuing theimprovement of safety and a conveniencein production line, such as providing theprotection cover for the front panel.

▲ Output terminal
Left: HIGH (red)Right: LOW(black, with lock function)▲ View with the protection cover
removed from front panel

Reducing
the tact time
Increasing the productivity!
Capable of setting the test time from 0.1 s

2low cost of
more thanHigh PrecisionHigh Resolution± 1.5 % of reading*High-precision measurement ±1.5 % ofreading *(with voltmeter 500 V or higher,
Ammeter 1 mA or higher)

More than 50 years ofexperience to support"JAPAN-quality"
Our electronic safety tester
has more than 50 years of history
since the first product was released in 60's.

Supporting theWorld-wide
input voltage
Universal usability !
Usable in any country without changing
the input power supply.

Selectable output frequency !
Not rely on the input power environment.
It supplies the stable test voltage with
50/60 Hz frequencies.

▲ Rear panel

AC Hipot Tester

TOS5200

TOS5200 is designed for AC Hipot Test with 500 VA capacity and 200 mA short circuit current output capability.
Equipped with the PWM amplifier, the TOS5200 can provide a stable & reliable output without being affected by AC
power line. Therefore, it is a perfect solution for electronic equipment or devices complied to IEC, EN, UL, VDE andJIS etc. requirement. As TOS5200 covers most of features of our upper class model for AC Hipot Test, it achieves thesuperb cost / performance ratio for those who need 200 VA or 500 VA capacity, or both. Also, as it equips the Interlock
function together with other safety features, operator can carry out the test with higher current value in safe.

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The TOS5200 has many improvements from the predecessor !

VALUE!

● Comparison with the Kikusui previous model
TOS5200

TOS5050A

PWM switching amp system

Slide transformer method

Specification comparison item
Output method

Test voltage

Test time

Distortion

3 % or lessAs per commercial power supply waveform

Frequency

50 Hz or 60 Hz

Synchronized with commercial power supply waveform

Output voltage waveform

Sine

Commercial power supply waveform

Voltage regulation

10 % or less

15 % or less

Input voltage variation±0.3 %-

Minimum setting value

0.1 s

0.5 s

Accuracy±(100 ppm + 20 ms) excluding Fall Time±(100 ppm + 20 ms)

Upper limit setting

AC: 0.01 mA to 110 mA

AC: 0.1 mA to 110 mA

Lower limit setting

AC: 0.01 mA to 110 mA

AC: 0.1 mA to 110 mA

Accuracy

1.00 mA ≤ i: ±(1.5 % of set),i <1.00 mA: ±(1.5 % of set +30 μA)

Upper limit: ±(5 % + 20 μA)

Rise Time and Fall Time
control features

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Digital, analog

Judgment
featureDisplay

DigitalMeasurement accuracy±1.5 % of reading (V>500V)±1.5 % f.s

Measurement method

True rms/mean-value

Mean-value/rms value

RS232C Interface

POWER Switch and all function except Key lock

Output for data, test result

WeightApprox. 14 kg (30.9 lbs)

Approx. 15 kg (33.07 lbs)

100 Vac to 240 Vac

100 V ± 10 %Voltmeter
Voltmeter/Ammeter

Other

Input power supply

Appearance

VALUE!

Highly stable output is realized with PWM Switching Amplifier!

Equipped with the PWM switching amplifier system,
the TOS5200 realizes highly stable output without
influenced by input form AC line.
A conventional Hipot Tester boosts and outputs the AC
line's input voltage through the use of a slide transformer
system With this slide transformer system, input voltage
fluctuations will affect the output, preventing test frombeing performed properly. Since the TOS5200 equips witha high-efficient PWM amplifier that can output a stablehigh-voltage without being affected by the variation of AC
power line, users can perform "safe", "stable", and highly"reliable" tests with confidence, even in regions with large
voltage variations.

VALUE!

The output waveform is essential factor
in Hipot (Withstanding oltage) testing!

▲ AC output waveform of TOS5200▲ AC output waveform of the slide
transformer system

High-Accuracy = Less measurement error! "+/-1.5 % of reading" versus "+/-1.5 % f.s."

TOS5200 ► reading: Accuracy is specified against reading value.
TOS5050A ► f.s: Accuracy is specified against full scale.
When using TOS5200 at 1500 V output measurement, the max error would be 1500 V(reading value) x 1.5 % = 22.5 V
On the other hand, when using equipment which specifies its accuracy with "+/- 1.5 % f.s.",the max error could be 2500 V(max voltage) x 1.5 % =37.5 V (it needs to set the range 0 to 2.5 kV)
So, there is 15 V difference of max measurement error at 1500 V output.
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Hipot (Withstanding Voltage)Tester TOS5200
VALUE!

Capable of Test Time setting from 0.1 s, which enables to reduce the tact time !

TOS5200 can set the test time from 0.1 sec without sacrificing measurement accuracy.
This makes test time 5 times faster compared to the TOS5050A(max test time:0.5sec) and it leads to reduce the tact time.
Reduction of the tact time leads to improve the productivity, so it has
been an issue that reducing the tact time may cause to worsen themeasurement accuracy when the test time is faster than measurement
respond speed.

VALUE!

Cycle timeminimize to

0.32 sRise time / Fall time control function

The rise time control function is to prevent the excessive stress thatis being applied to the EUT (test object). The Hipot (Withstanding
voltage) test is conducted to verify the safety performance of the EUT
and which test voltage for Hipot (Withstanding voltage) test is applied
approximately five to ten times greater than the voltage that handles
by the EUT. If a high voltage is applied rapidly with no rise time, thetransitional large voltage (current) will be occurred, and it may cause
a damage to the EUT. For this reason, safety standards stipulate theprocedure of Hipot (Withstanding voltage) test, and the test voltage
must be gradually increased to the specified voltage when the test
is performed. The rise time control function adopted in the in the
TOS5300 Series can set the voltage rise time from 0.1s to 10.0 s(at a resolution of 0.1 s) and also it is capable to set the 50 % (fixed)of the applied test voltage. In addition, the fall time control function
enables to decrease the test voltage gradually after the completion of
a PASS judgement. The voltage fall time is fixed at 0.1 s (OFF is also
selectable).

Start
voltagevalue

Rise Time control function
The Rise time control
function enables you
to increases the test
voltage gradually toreach the setting voltage while the AC Hipot(Withstanding voltage)
test is conducted. The
voltage rise time canbe set from 0.1 s to
10.0 s at a resolution of
0.1s.
▲Rise time control waveform (example)

Fall Time control function
The Fall time c ontrol
fun- ction enables you
to decrease the test
voltage gradually when
the PASS judgment ismade at the AC Hipot(Withstanding voltage)
test. The voltage fall time
is fixed at 0.1 s. (OFF isalso selectable).

Output ON

Output OFF
Voltage Rise Time▲Start voltage can be set at 50 % of the test voltage

VALUE!

▲Fall time control waveform (example)

Improved the setting resolution of the leak current by 0.01 mA !

TOS5200 is can set the current limit from0.01 mA to 110 mA.
(TOS5050A: 0.1 mA to 110 mA)● Enable to clarify the actual value of device under test (DUT)● The setting resolution of the lower limit setting has been improved from theprevious model ,it enables to defect the failure more accurately.

▲AC Hipot (Withstanding voltage) test settings display (example)

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■ Specifications

Unless specified otherwise, the specifications are for the following settings and conditions.
• The warm-up time is 30 minutes.
• TYP: These are typical values. These values do not guarantee the performance of the product.
• rdng: Indicates the readout value. • set: Indicates a setting. • f.s: Indicates full scale.

■ Withstanding voltage tester
Output range

AC
Outputsection0.05 kV to 5.00 kV
Setting accuracy± (2 % of set + 20 V) [at no load]

Setting range

0.00 kV to 5.50 kVResolution

10 V STEP

Max. rated output *1

500 VA (5 kV/100 mA)

Max. rated voltage

5 kV

Max. rated current

100 mA [output voltage 0.5 kV or higher]

Transformer rating

500 VA

Output voltage waveform *2

Sine

Distortion
Crest factor

If the output voltage is 0.5 kV or more: 3 % or less (when no load or a pure resistive load is connected)
Within √2 ± 3 % (output voltage 800 V or higher, at no load)

Frequency

50 Hz or 60 Hz
Accuracy± 0.5 % (excluding during voltage rise time)

Voltage regulation

10 % or less (when changing from maximum rated load to no load)

Input voltage variation±0.3 % (5 kV when no load is connected; power supply voltage: 90 V to 250 V)

Short-circuit current

200 mA or more (when the output voltage is 1.0 kV or greater)

Output method

PWM switching

Start voltage

The voltage at the start of withstanding voltage tests can be set to 50 % of the test voltage.

Limit voltage

The test voltage upper limit can be set . AC: 0.00 kV to 5.50 kV

Output voltage monitor feature

If output voltage exceeds the specified value + 350 V or is lower than the specified value - 350 V,
output is turned off, and protective features are activated.

Voltmeter

DigitalMeasurement range

0.000 kV to 6.500 kV AC

Display□.□□□ kV

Accuracy

V < 500 V: ± (1.5 % of reading + 20 V), V ≥ 500 V: ±1.5 % of reading

Response *3

True rms, Average value response/rms display switchable

Hold feature

After a test is finished, the measured voltage is retained until the PASS or FAIL judgment is cleared.

Measurement range

0.00 mA to 110 mA
i = measured current

Display
Ammeter

Digitali < 1 mA

1 mA ≤ i < 10 mA

10 mA ≤ i < 100 mA

100 mA ≤ i□.□□□ mA□.□□□ mA□□.□□ mA□□□.□ mA

Accuracy *4

1.00 mA ≤ i: ± (1.5 % of reading), i < 1.00 mA: ± (1.5 % of reading + 30 μA)

Response *3

True rms/ Mean-value response rms display Can be switched

Hold feature

After a test is finished, the measured current value is retained until the PASS judgment is cleared.

Judgment method andjudgment operation
Judgment feature

Judgment

Judgment method

UPPER
FAIL

If a current that is greater than or equal to the upper limit
is detected, the output is turned off, and an UPPER FAIL
judgment occurs.

LOWER
FAIL

If a current that is less than or equal to the lower limit isdetected, the output is turned off, and a LOWER FAIL
judgment occurs. This judgment is not performed during
voltage rise time (Rise Time) of all tests and during thevoltage fall time (Fall Time) of AC withstanding voltage
tests.

PASS

If the specified time elapses without any problems, theoutput is turned off, and a PASS judgment occurs.

Display
FAIL LED lights;
UPPER isdisplayedon the screen

Buzzer

SIGNAL I/O

ONGenerates
a U-FAIL signal

FAIL LED lights;
LOWER isdisplayed on thescreenON

Generates
a U-FAIL signal

PASS LED lights;
displayed on thescreenON

Generates
a PASS signal• If PASS HOLD is enabled, the PASS signal is generated continuously until the TOS5300 Series receives a STOP signal.
• The UPPER FAIL and LOWER FAIL signals are generated continuously until the TOS5300 Series receives a STOP
signal.
• The FAIL and PASS buzzer volume levels can be changed.
• For PASS judgments, the length of time that the buzzer sounds for is fixed to 0.2 seconds.
Even if PASS HOLD is enabled, the buzzer turns off after 0.2 seconds.
Upper limit setting

0.01 mA to 110 mA

Lower limit setting

0.01 mA to 110 mA / OFF

Judgment accuracy *4

1.00 mA ≤ i: ± (1.5 % of set), i < 1.00 mA: ± (1.5 % of set + 30 μA)

Current detection method

Calculates the current’s true rms value and compares this value with the reference value

Calibration

Calibrated with the rms of a sine wave using a pure resistive load

Voltage rise time

0.1 s to 10.0 s
Resolution

Time

Voltage fall time

0.1 s / OFF (only enabled when a PASS judgment occurs)

Test Time

0.1 s to 999 s, can be turned off (TIMER OFF)
Resolution

Accuracy

6

0.1 s

0.1 s to 99.9 s: 0.1 s/100 s to 999 s: 1 s±(100 ppm + 20 ms) excluding Fall Time

Hipot (Withstanding Voltage)Tester TOS5200■ Specifications*1. Regarding the output time limits:
Taking size, weight, and cost into consideration, the heat dissipation capability of the voltage generator that is used for withstanding
voltage tests has been designed to be one half that of the rated output. Use the TOS5300 Series within the following limits.
If you use the product in a manner that exceeds these limits, the output section may overheat, and the internal protection circuits may be
activated. If this happens, stop testing, and wait until the TOS5300 Series returns to its normal temperature.
Ambient temperaturet ≤ 40 °C

Pause time

Output time

50 mA < i ≤ 110 mA

Greater than or equal to the output time

30 min. max.

i ≤ 50 mA

Not necessary

Continuous output possible(Output time = voltage rise time + test time + voltage fall time)*2. Regarding the test voltage waveform:
Waveform distortions may occur if an DUT whose capacitance is dependent on voltage (for example, an DUT that consists of ceramic
capacitors) is connected as the load. However, if the test voltage is 1.5 kV, the effect of a capacitance of 1000 pF or less can be ignored.
Because the product’s high-voltage power supply uses the PWM switching method, if the test voltage is 500 V or less, the switching andspike noise proportions are large. The lower the test voltage, the greater the waveform is distorted.
*3. For both True rms and Mean-value response, 50 ms or above response time is required to satisfy the measurement accuracy.
*4. Regarding ammeter and judgment accuracy:
During AC withstanding voltage tests, current also flows in the stray capacitance of items such as the measurement leads and jigs.
This current that flows in the stray capacitances is added to the current that flows in the DUT, and the sum of these currents is measured.
Especially if you want to perform judgments with high sensitivity and accuracy, it is necessary to consider methods to limit the current
that flows in these stray capacitances, such as by adding upper and lower limits.
Output voltage

1 kV

2 kV

5 kV

When using 350 mm long test leads
that are suspended in air (TYP)

2 μA

4 μA

10 μA

When using the accessory,high test lead TL31-TOS (TYP)

16 μA

32 μA

80 μA

In case of 70 % humidity or higher, it is considerable to add 50 μA on the Limit value.

■ Other features / Interfaces
Test mode
Double action feature

Tests can only be started by pressing and releasing STOP and then pressing START within 0.5 seconds of releasing the
STOP switch.

Length of time to maintain a PASS judgment result

You can set the length of time to maintain a PASS judgment: 50 ms, 100 ms, 200 ms, 1 s, 2 s,5 s, or HOLD.

Momentary feature

Tests are only executed while the START switch is held down.

Fail mode featureThis feature enables you to prevent remotely transmitted stop signals from clearing FAIL judgments and PROTECTION modes.

Timer featureThis feature finishes tests when the specified time elapses.

Output voltage monitor feature

If output voltage exceeds “setting + 350 V” or is lower than “setting - 350 V,”
the TOS5200 switches to PROTECTION mode, output is turned off, and testing finishes.

MemoryUp to three sets of test conditions can be saved to memory.

Key lock

Locks panel key operations (settings and changes).
Under any of the following conditions, the TOS5200 switches to the PROTECTION state,
immediately turns output off, and stops testing. A message is displayed on the screen.

Protective features
Interlock Protection

An interlock signal has been detected.

Power Supply Protection

An error was detected in the power supply.

Volt Error Protection

While monitoring the output voltage, a voltage outside of the rated limits was detected.
AC or DC withstanding voltage tests: ±350 V

Over Load Protection

During a withstanding voltage test, a value that is greater than or equal to the output limit power was specified.
AC withstanding voltage test: 550 VA.

Over Heat Protection

The internal temperature of the TOS5200 became too high.

Over Rating Protection

During a withstanding voltage test, the output current was generated for a length of time that exceeds the regulated time.

Remote Protection

A connection to or disconnection from the front-panel REMOTE connector was detected.

SIGNAL I/O Protection

The rear-panel SIGNAL I/O connector’s ENABLE signal has changed.

USB Protection

The USB connector has been disconnected while the TOS5200 was being controlled through the USB interface.

USB

USB Specification 2.0

RS232C *1

D-SUB 9-pin connector on the rear panel (compliant with EIA-232-D)
All functions other than the POWER switch and KEY-LOCKREMOTE

Front-panel 9-pin MINI DIN connector. By connecting an optional device to this connector,
you can control the starting and stopping of tests remotely.

SIGNAL I/O

Rear-panel D-sub 25-pin connector

Interfaces*1. "Talk mode" can be set, when RS232C is used as comunication interface.
Talk mode

Description0

It responds only for commands from PC. (Default setting)It responds automatically for start and end test, and returns the status, setting value, measured value.

1

Response at start
Response atend of test

<START>
Status<PASS>, <U_FAIL>, <L_FAIL>, <PROT>, <ABOUT>

Setting value, Measured value

Test No., Programme No., Test mode, Measured voltage, Measured current, Test time7

■ Specifications■ General
Display
EnvironmentPowersupplyLCD: LED back custom indicators
Installation location

Indoors, at a height of up to 2000 m

Spec guaranteed range temperature/humidity

5 °C to 35 °C (41 °F to 95 °F)/20 %rh to 80 %rh (no condensation)

Operating range temperature/humidity

0 °C to 40 °C (32 °F to 104 °F)/20 %rh to 80 %rh (no condensation)

Storage range temperature/humidity-20 °C to 70 °C (-4 °F to 158 °F)/90 %rh or less (no condensation)

Nominal voltage range (allowable voltage range)

100 VAC to 240 VAC (90 VAC to 250 VAC)

Power
consumptio

When no load is connected (READY)

100 VA or less

When rated load isconnected

800 VA max.

Allowable frequency range

47 Hz to 63 Hz

Insulation resistance (between AC LINE and the chassis)

30 MΩ or more (500 VDC)

Withstanding voltage (between AC LINE and the chassis)

1500 Vac, 1 minute

Earth continuity

25 Aac, 0.1 Ω or lessElectromagnetic compatibility (EMC) *1 *2

Complies with the requirements of the following directive and stan-dards. EMC Directive 2014/30/EU
EN 61326-1(ClassA *3), EN 55011(ClassA *3, Group1 *4), EN 61000-3-2, EN 61000-3-3
Applicable under the following conditions. The maximum length of all cabling and wiring connected to the TOS5200
is less than 2.5 m. Shielded cables are being used when using the SIGNAL I/O.
The high-voltage test lead TL31-TOS is being used. Electrical discharges are not occurring outside the DUT.

Safety *1

Complies with the requirements of the following directive and standard.
Low Voltage Directive 2014/35/EU *2, EN 61010-1 (Class I *5 Pollution degree 2 *6)

Dimensions (mm(inches))(maximum)

320 (12.6") (330(12.99")) W × 132(5.2") (150(5.91")) H × 350(13.78") (420(16.54")) D

WeightApprox. 14 kg (30.9 lbs)

Accessories

Power cord : 1pc. / High test lead (TL31-TOS) : 1set (1 red wire and 1 black wire, each with alligator clips); 1.5 m /SIGNAL I/O plug : 1 set (assembly type) / High-voltage warning sticker : 1pc. / Setup Guide /Quick Reference(1 each for English and Japanese) / Safety informaion / CD-R

*1 Does not apply to specially ordered or modified TOS5200s.
*2 Limited to products that have the CE mark on their panels. Not be in compliance with EMC limits unless the ferrite core is attachedon the cable for connection of J1 connector.
*3 This is a Class A equipment. The TOS5200 is intended for use in an industrial environment. This product may cause interferenceif used in residential areas. Such use must be avoided
unless the user takes special measures to reduce electromagnetic emis-sions to prevent interference to the reception of radio and television broadcasts.
*4 This is a Group 1 equipment. The TOS5200 does not generate and/or use intentionally radio-frequency energy, in the from of elec-tromagnetic radiation, inductive and/or capacitive
coupling, for the treatment of material or inspection/analysis purpose.
*5 This is a Class I equipment. Be sure to ground the TOS5200's protective conductor terminal. The safety of this product is onlyguaranteed when the product is properly grounded.
*6 Pollution is addition of foreign matter (solid, liquid or gaseous) that may produce a reduction of dielectric strength or surface resis-tivity. Pollution Degree 2 assumes that only nonconductive pollution will occur except for an occasional temporary conductivitycaused by condensation.

■ Outline drawing

TU01-TOS

Option(s) for Electrical Safety Testers
The TU01-TOS is a terminal unit that converts the 25 pin
SIGNAL I/O connector of the Kikusui TOS5200 Withstanding Voltage Tester to the 14 pin SIGNAL I/O connector of
the TOS5050A/ 5051A. You can insert this unit between acontroller and a TOS5200 to perform the same external
control that you can perform on the TOS5050A/ 5051A.

294 (11.57”)

350 (13.78”)

265 (10.43”)

MAX20(0.79”)

38(1.50”)132 (5.20”)

MAX150 (5.91”)

MAX330 (12.99”)
320 (12,60”)

MAX420 (16.54”)

250 (9.84”)

Unit: mm (inch)●Distributor/Representative

1-1-3, Higashiyamata, Tsuzuki-ku, Yokohama, Kanagawa, 224-0023, Japan
Phone:(+81)45-593-0200, Facsimile:(+81)45-593-7591, https://global.kikusui.co.jp/

Printed in Japan■ All products contained in this catalogue are equipment and devices that are premised on use under thesupervision of qualified personnel, and are not designed or produced for home-use or use by general consumers.
■ Specifications, design and so forth are subject to change without prior notice to improve the quality. ■ Productnames and prices are subject to change and production may be discontinued when necessary. ■ Product names,
company names and brand names contained in this catalogue represent the respective registered trade name ortrade mark. ■ Colors, textures and so forth of photographs shown in this catalogue may differ from actual products
due to a limited fidelity in printing. ■ Although every effort has been made to provide the information as accurate
as possible for this catalogue, certain details have unavoidably been omitted due to limitations in space. ■ If you
find any misprints or errors in this catalogue, it would be appreciated if you would inform us. ■ Please contact our
distributors to confirm specifications, price, accessories or anything that may be unclear when placing an order orconcluding a purchasing agreement.

Issue:Nov.2022 202211PDFEC31