Hipot testing has long been a routine process for ensuring that electronic equipment is electrically safe. Early hipot testers were just a variac-driven step-up transformer that increased the test voltage; after that, the operator was monitored and educated while holding it for the specified amount of time. When leakage current leads the voltage output from a high impedance transformer source to droop, this approach might easily provide inaccurate results.
Because there is no replacement for operator competency, training is the first step toward ensuring a safe testing environment. The operator must be in excellent health; working with high voltage is not recommended for certain medical disorders. All operators should be aware that high voltage is harmful, and caution should be used while handling electrified circuits. They should be aware of the impact of electrical currents on the human body and the dangers of shock. Learning how to conduct compression-only CPR is an excellent idea for all staff.
Deciding on a location for the test station
The next step is to choose a location for the test station. The industrial assembly area should be separated from the test area. To ensure the safety of passers-by and, of course, the station operator, it should be located away from foot traffic. Distractions for the operator should be limited to a bare minimum, and the location should be identified with globally recognized signs.
Ensure that the output voltage is removed quickly and safely
Furthermore, the hi-pot testing equipment shall allow for the safe and fast elimination of the output voltage utilizing internal discharge circuitry at the end of the test or if the test is stopped. The hipot tester should never be turned off. If there is a power outage, use extra caution while working with the DUT. Reconnect the DUT to the hipot tester until the power is restored and the tester can discharge.
Safety concerns for the operator
The test station should be large enough for both the tester and the DUT to be accessed without the operator reaching above the DUT. Many safety precautions, like guards or enclosures, may be installed on the test station to protect the operator from coming into contact with excessive voltage. They should be nonconducting and have safety interlocks that shut off all high voltages when they open when placed near a DUT.
Furthermore, the hi-pot testing equipment shall allow for the safe and fast elimination of the output voltage using internal discharge circuitry at the end of the test or if the test is stopped. The hipot tester should never be turned off. If there is a power outage, use extra caution while working with the DUT. It’s best to maintain the DUT connected to the hipot tester until the power is restored and the tester can discharge.