White Paper: Design
Fundamentals of Electrical Safety Testing
SPONSORED BY: ![]()
Electrical safety testers, or “hipot” testers, are essential in electronics manufacturing. They apply high voltage to check dielectric withstand, insulation resistance, ground resistance, and bond integrity. Originally, hipot testers were simple step-up transformers, but modern versions use electronic sources to ensure accurate results. They comply with IEC-61010, which mandates maintaining test voltage for a specified duration. These advancements improve reliability, preventing voltage drops that could lead to incorrect safety assessments.
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Overview
The white paper titled "Fundamentals of Electrical Safety Testing" by Kevin Clark, CEO of Vitrek Inc., provides a comprehensive overview of the critical aspects of electrical safety testing, particularly focusing on hipot (high potential) testing. It emphasizes the importance of ensuring that electronic devices meet stringent safety standards before they are marketed and used.
The document outlines the various international safety standards that manufacturers must comply with, including those from organizations such as UL (United States), CSA (Canada), EN/IEC (Europe), and others. It highlights the certification process, which involves rigorous evaluation of a product's construction and safety to ensure it operates safely under high-stress conditions.
A significant portion of the paper is dedicated to the safety guidelines for conducting hipot testing. It stresses the necessity of having properly trained operators who understand the dangers associated with high voltage and the importance of safety interlocks. Operators are advised to be in good health, avoid wearing metallic jewelry, and be familiar with emergency procedures, including how to perform CPR.
The paper also discusses the setup of a safe testing area, recommending that the test station be spacious and organized to minimize hazards. It covers essential testing procedures, including ground continuity and ground bond tests, which are crucial for verifying the integrity of electrical connections.
Additionally, the white paper addresses the need for accurate testing equipment, such as low resistance meters and high current sources, to ensure reliable results. It concludes by underscoring the importance of harmonizing international standards to facilitate global compliance and enhance product safety.
Overall, the white paper serves as a vital resource for manufacturers and safety professionals, providing insights into best practices for electrical safety testing and the critical role it plays in protecting consumers and ensuring product reliability.