Electrical Safety Tester - Hi-Pot, IR, Ground

Name: Electrical Safety Test Equipment
Brand: VoltTest
Availability: InStock

Electrical Safety

Verify Insulation. Prevent the Shocking Failure.

The VT-ESA series performs the full suite of electrical safety tests required by IEC 61010, UL and GB 4706: AC/DC hi-pot, insulation resistance and ground continuity — with pass/fail decisions in seconds.

✓ AC hi-pot to 5 kV, DC hi-pot to 6 kV, 10 mA leakage
✓ Insulation resistance to 1 TΩ at up to 5 kV test voltage
✓ Ground continuity: 30 A, 0.001–0.5 Ω range
✓ Ramp, dwell and discharge control per test standards
✓ Remote PLC I/O, RS-232 and Ethernet integration

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Models & Specifications

VT-ESA Series Model Overview

Model	Test Function	Key Specification	Accuracy	Best For
VT-HP-5K	AC/DC Hi-pot	AC 5 kV / DC 6 kV, 10 mA	±2%	Battery packs, chargers, inverters
VT-IR-5G	Insulation Resistance	0.1 MΩ–1 TΩ @ 5 kV	±3%	High-voltage equipment insulation
VT-GC-30A	Ground Continuity	30 A, 0.001–0.5 Ω	±2%	Grounding verification per IEC 61010
VT-ESA-COMBO	Hi-pot + IR + Ground	All-in-one test station	±2–3%	Pack EOL and production lines

Combo stations integrate with battery module/pack test benches for a complete EOL sequence.

Key Features

Safety Testing You Can Automate

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High Voltage Range

AC 5 kV and DC 6 kV output covers EV pack and industrial equipment requirements.

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Precise Leakage

Leakage current measured to 10 µA resolution with arc detection for insulation faults.

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Fast Test Cycle

Sub-second ramp and measurement cycles keep production takt times low.

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Safe Discharge

Automatic DUT discharge after hi-pot protects operators and downstream equipment.

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Programmable Steps

Sequence hi-pot, IR and ground tests into one key-press program per product.

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Data Logging

Store results by serial number and export to MES for full production traceability.

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Interlock Safety

Two-hand start, door interlocks and e-stop as standard for operator protection.

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Rack Integration

19-inch rack-mount options integrate directly into existing test benches.

Applications

Electrical Safety Testing Applications

Every product that carries current deserves a final electrical safety check.

✓ EV battery pack end-of-line insulation and hi-pot testing
✓ Battery chargers, adapters and power supplies production testing
✓ Inverters and energy storage system components
✓ Consumer electronics and power tools per IEC/UL standards
✓ Laboratory electrical safety verification services

Add Electrical Safety Testing to Your Line

Tell us your test standard and DUT voltage class — we'll configure the right tester.

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Product Gallery

Electrical Safety Test Equipment

Salt Water Immersion Test Chamber

Model: VT-ESA-HIPOT
Simulates salt water exposure for EV battery pack sealing and electrical safety verification. Per IEC 60068-2-11 and GB/T 31467.3.

Salt Spray Corrosion Test Chamber

Model: VT-ESA-IR
NSS/AASS/CASS salt spray testing for battery enclosure corrosion resistance. Validates long-term electrical safety under corrosive conditions.

Mechanical Impact Test Platform

Model: VT-ESA-GND
Impact resistance testing platform for battery pack structural integrity. Validates grounding continuity after mechanical stress per UN 38.3 T.4.

Vibration Test System

Model: VT-ESA-CABLE
Electrodynamic vibration testing for battery packs under transport and operational conditions. Per IEC 60068-2-6 and GB/T 31467.3.

Salt Spray Environmental Chamber

Model: VT-ESA-PD
Accelerated corrosion testing for battery terminals and connectors. Simulates harsh marine and road salt environments per ISO 9227.

Environmental Test Chamber 1000L

Model: VT-ESA-LEAK
Large capacity environmental chamber for full EV pack testing. Temperature -70°C to +150°C, humidity control for comprehensive electrical safety validation.

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FAQ

Frequently Asked Questions

What is a hi-pot test for batteries?

A hi-pot (dielectric withstand) test applies a high voltage (typically 500–5000 V DC or AC) between the battery's live conductors and its enclosure or external terminals to verify insulation integrity. It ensures that the battery can withstand voltage transients without dangerous breakdown or arc-over.

What insulation resistance values are acceptable?

For EV and ESS battery packs, insulation resistance should be ≥500 Ω/V of the pack's nominal voltage (e.g., ≥192 kΩ for a 384 V pack) per IEC 62133 and GB/T 31485. For consumer cells, ≥100 MΩ at 500 V DC is typical. The VoltTest electrical safety tester measures from 0.01 Ω to 10 GΩ with ±2% accuracy.

Can the tester be integrated into an EOL production line?

Yes. The VoltTest electrical safety tester is designed for automated EOL integration with PLC trigger inputs, pass/fail outputs, and RS-485/Ethernet communication. It can be combined with pack test systems to perform insulation and hi-pot tests as part of the automated EOL sequence.

What safety standards require electrical safety testing?

Electrical safety testing is mandated by IEC 62133-2, GB/T 31485, GB 38031, UL 1973 and UN 38.3 for lithium battery packs. These standards require insulation resistance, dielectric withstand and continuity verification as part of the type test and production safety verification.

What is the difference between dielectric withstand and insulation resistance testing?

Insulation resistance testing applies a moderate DC voltage (e.g., 500 V) and measures the resistance value (in MΩ or GΩ) — it quantifies insulation quality. Dielectric withstand (hi-pot) testing applies a higher voltage (e.g., 1500 V AC) for a set duration and checks for breakdown — it verifies safety margin. Both are complementary and both are performed in battery EOL testing.