What is a Hipot Tester?
A Hipot Tester (short for "High Potential Tester") is a critical piece of electrical safety testing equipment used to verify the insulation strength of electrical products. Also known as a Withstand Voltage Tester, it applies a high voltage between a product's live parts and its accessible surfaces to ensure no breakdown occurs under stress.
Why is Hipot Testing Important?
- Safety Assurance — Prevents electric shock hazards to end users
- Product Reliability — Identifies insulation weaknesses before market
- Regulatory Compliance — Meets IEC, UL, VDE, and other global standards
- Liability Prevention — Reduces risk of product recalls and lawsuits
Types of Hipot Testers
| Type |
Description |
Typical Use |
| AC Hipot Tester |
Applies alternating high voltage |
Most common, general testing |
| DC Hipot Tester |
Applies direct high voltage |
Capacitors, semiconductors, cables |
| AC/DC Combined |
Both AC and DC in one unit |
Full-spectrum safety testing |
| Automatic Hipot |
Computer-controlled with data logging |
Production line automation |
| Portable Hipot |
Handheld, field testing |
On-site inspections |
Key Specifications to Consider
- Output Voltage Range: Low voltage (0-5kV AC), Standard (0-10kV AC), High voltage (0-15kV+)
- Current Measurement: Breakdown current typically 0-5mA, 0-10mA, or 0-20mA
- Test Duration: Adjustable: 1s, 2s, 5s, 10s, 30s, 60s
- Arc Detection: Advanced hipot testers detect arcing events for partial failure identification
Common Standards Compliance
| Standard |
Application |
Required Test Voltage |
| IEC 60335-1 |
Household appliances |
1250V AC (basic) |
| IEC 60950-1 |
IT equipment |
1500V AC |
| IEC 60601-1 |
Medical electrical |
1500V AC |
| UL 60335-1 |
US market appliances |
1250V-1500V AC |
| IEC 61010-1 |
Laboratory equipment |
1200V AC |
Applications by Industry
Home Appliances: Refrigerators, washing machines, air conditioners, vacuum cleaners
Electronics: Power supplies, adapters, computer peripherals, chargers
Wiring & Cables: Power cables, extension cords, wire harnesses
Medical Devices: Patient monitors, diagnostic equipment, therapeutic devices
Automotive: Wire harnesses, EV charging equipment, in-vehicle electronics
FAQ
Q: What is the difference between hipot tester and megohmmeter?
A hipot tester applies high voltage to test insulation strength under stress conditions. A megohmmeter (megger) measures insulation resistance at low voltages. Hipot testing is more comprehensive for safety validation.
Q: How often should hipot testing be performed?
Production line: 100% of products. Quality control: random sampling per batch. Design validation: during R&D and certification phases.
Q: Can hipot testing damage products?
If properly set up within specifications, hipot testing is non-destructive. However, products with manufacturing defects may fail and should be rejected.
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