Electrical safety inspectionHipot test “(High Potential Test) is an important testing method for verification dielectric strength This involves testing the insulating materials in electrical equipment to ensure they adequately protect users from the risk of electric shock or dangerous electrical discharge. This is a mandatory test according to many international and Vietnamese product safety standards such as IEC 60950, TCVN 6447:1998, and QCVN 4:2009. Depending on the nature of the voltage used and the measurement objective, specific methods include AC Hipot, DC Hipot, and IR (Insulation Resistance) testing.

Purpose of the Hipot Test

• Verify insulation integrity: Ensure that the insulation between live parts and contact points is designed to be safe.
• Manufacturing defect detected: It helps detect defects such as air gaps, small cracks, or impurities in insulation materials that could lead to electrical failures during operation. 

Electrical Safety Testing Chroma ATE

Safety Procedures and Standards

The testing process typically involves applying a high voltage (AC or DC) far exceeding the device's normal operating voltage for a specified period. If the measured leakage current is within acceptable limits or no electrical discharge occurs, the device is considered to meet safety standards. 

AC 5kV 100mA high voltage simulation device KIKUSUI TOS5200

Basic steps to perform a Hipot Test (for reference):

1. Prepare the equipment: Ensure the device to be tested is disconnected from the main power supply and all other connections.
2. Connect the testing machine: Connect the probes of the Hipot tester to the electrical circuit and the metal casing/frame of the device (or the grounding point).
3. Parameter settings: Set the test voltage (typically double the operating voltage plus 1000V according to some standards), test time, and leakage current threshold on the Hipot tester.
4. Conduct the experiment: Turn on the machine and apply high voltage according to the preset parameters.
5. Evaluating the results:
   • Passed: No arc discharge (flashover) or breakdown occurred, and the leakage current was below the permissible threshold.
   • Fail: An electrical discharge or leakage current exceeding the limit occurs, indicating a problem with the insulation.

The Chroma Hipot Tester Model 19020 (AC5kV/10mA, DC6kV/5mA, IR/ 10channel)

IR Test (Insulation Resistance Test)

The IR test is a fundamental and often the first step in an electrical inspection. It measures the electrical resistance of an insulating material to determine the overall degree of insulation degradation over time or due to environmental factors.

• Type of voltage used: Typically, a low direct current (DC) voltage (e.g., 500V, 1000V) is applied between the conductor and the equipment casing.
• Purpose: Measure very small leakage currents (typically in the microampere or nanoampere range) and calculate the insulation resistance (in megaohms – MΩ or gigaherms – GΩ).
• Criteria for achievement: The insulation resistance value must be higher than a specific minimum threshold (e.g., > 2 MΩ or > 5 MΩ).

KIKUSUI TOS9303LC (hipot 5kV AC/DC – IR-EC-LC)

International standards such as IEC 62368-1 (for IT/AV/Communications equipment) and IEC 60335 series (For household appliances) it is usually specified which method is mandatory for each type of product.

Characteristic	IR Test (Insulation Resistance)	DC Hipot Test (High Potential)	AC Hipot Test (High Potential)	LC Test (Leakage Current)
Main purpose	Measure the quality of insulating materials (degradation due to time/environment).	Dielectric strength testing, detection of structural defects.	Dielectric strength testing under real-world conditions (AC).	Measure the actual leakage current while the device is operating.
Operating voltage	Low DC (500V, 1000V).	High DC voltage (1kV – 10kV+).	High AC voltage (1kV – 4kV+).	The rated voltage (mains voltage) of the device.
Measurement parameters	Resistance (MΩ, GΩ).	Leakage current (mA or µA), breakdown/discharge.	Leakage current (mA), breakdown/discharge.	Leakage current (mA or µA).
Destructive	Very low (non-destructive).	Low (less likely to damage good insulation).	Higher (easier to damage weak points).	Do not destroy.
Application	Maintenance, preliminary inspection, electrical cables.	Long electrical cables, capacitors, motors, quality control.	Most electronic, household, and medical devices.	All devices sold on the market.
Main standard	IEC 62368-1, IEC 60335, UL 60950, etc.	IEC 62368-1, IEC 60335, UL 60950, etc.	IEC 62368-1, IEC 60335, UL 60950, etc.	IEC 62368-1, IEC 60335, UL 60950, etc.

1. IR Test (Insulation Resistance Test

• Focus: Measure the ability of the insulation layer to impede the flow of electric current.
• Standard: Most safety standards require that the insulation resistance must meet a minimum standard. 1 MΩ (Megaohm), but in actual new production, this number is often much higher (several hundred MΩ or GΩ).
• Role: Perform a quick check to ensure the insulation is intact at a basic level before conducting high-voltage testing. 

2. DC Hipot Test (High Potential Test – DC) 

• Focus: Testing the dielectric strength under high DC voltage.
• Standard: The test voltage is usually calculated using the formula: $(2\times \text{Hot voltage})+1000V$(2 × Hot voltage) + 1000V.
• Role: Often used to test cables or components with high capacitance because capacitive leakage current does not distort the actual leakage current (resistance current) measurement. 

3. AC Hipot Test (High Potential Test – AC) 

• Focus: The insulation strength test was conducted under high AC voltage, simulating real-world operating conditions and generating higher dielectric stress than a DC Hipot.
• Standard: This is usually the primary testing method required by QCVN 4:2009/BKHCN and relevant IEC/UL/TCVN standards to achieve conformity certification (CR mark).
• Role: This is the most comprehensive test to ensure there is no breakdown or arc flash when the equipment is operating at maximum voltage. 

4. LC Test (Leakage Current Test) 

• Focus: Measure the actual current flowing from the live part to the device casing (usually through the user's body if they touch it).
• Standard: Standards specify very strict leakage current limits, usually only a few mA (milliamperes) depending on the type of device (medical devices have the lowest limits).
• Role: This is the final and most important electrical safety test, ensuring that even if the insulation is partially faulty, the current flowing through the human body remains safe. The device is tested at its rated voltage (220V/50Hz in Vietnam). 

Kikusui TOS9311 ACW/DCW/IR high voltage test equipment (10 kV/50 mA)

You can absolutely trust Semiki to advise you on Hipot test equipment. Semiki As a reputable and professional distributor in the Vietnamese market, we specialize in providing electrical safety measurement and testing solutions and equipment from leading global brands such as Hioki (Japan), Kikusui, Chroma ATE, GW INSTEK, etc.

Semiki has experience in advising on electrical safety testers that comply with Vietnamese (QCVN, TCVN) and international (IEC, UL) standards for various industries.

To receive the best advice tailored to your specific needs, please prepare the following information before contacting us:

1. Types of products to be tested:
   • Household appliances? (TV, refrigerator, washing machine, etc.)
   • IT/Office equipment? (Computers, adapters, chargers, etc.)
   • Industrial equipment? (Motors, electrical cabinets, cables, electric vehicle (EV) charging stations, etc.)
   • Medical devices? (Require stricter standards).
2. Standards you need to adhere to:
   • You need to get certified. CR Mark (Complying with QCVN 4:2009/BKHCN) for sale in Vietnam?
   • You need to get certified. CE Mark For export to Europe (according to IEC 62368-1, IEC 60335)?
   • Do you need UL certification for the US market?
3. Requirements for the types of tests:
   • Do you just need a basic AC/DC hipot?
   • Do you need a device that integrates all four functions: AC Hipot, DC Hipot, IR (Insulation Resistance), and LC (Leakage Current)?
   • Do you need automation capabilities (computer connectivity, automated report generation for mass production)?

Contact Semiki:

Website: You can find out more details and send a consultation request via Semiki.com.

Business email: [email protected]

Phone number (Hotline): +84 979 761 016.