Guide to Electrical Safety Testing

Our safety testing guide is the definitive resource for test operators, engineers and managers looking to learn more about electrical safety testing. Use this guide to help create a safe testing station, learn about the benefits of electrical safety testing your products, and understand the different tests and their applications. This is the ideal place to start if you’re unfamiliar with any aspect of electrical safety testing.

Inside the Guide:

  • Learn why electrical safety testing products is beneficial to you, your company and your customers.
  • Reduce the risk of injury by setting up a safe work station.
  • Become an expert with detailed descriptions of the most commonly required safety tests.
  • Refer to application examples to guide you through creating your own electrical safety testing routine.

Download the Guide to Electrical Safety Testing

Applications Notes

Setting Up A Safe Workstation
Setting up a safe and secure workstation is one of the best ways to protect your test operators from the dangers of electric shock. Follow this quick and easy best practice App Note to ensure operator safety on your production line.

Protect Your Tester from Line Voltage
Line voltage can damage hipot testers which can result in high repair costs and production downtime. This App Note provides important information for all users of SCI hipot testers.

White Papers


500 VA Testing with the Slaughter 2525
Whether or not a 500 VA tester is required for safety compliance is often a source of confusion for manufacturers that must perform a Hipot test. This paper discusses the reasons for using a 500 VA tester as well as common 500 VA test applications.

Applicable Instruments: 4000, 2500

Topic in Brief

  • Why is a 500 VA tester required for Hipot testing?
  • Details regarding capacitive loads and line vs. load regulation.
  • Standards and application examples of 500 VA testing.

Slaughter Testers and Remote Communication: Using HyperTerminal
The HyperTerminal program is a simple means to communicate directly with a Slaughter tester using a PC. This paper outlines setting up a HyperTerminal session and remotely communicating with your Slaughter Hipot tester.

Applicable Instruments: 6000, 4000, 2900

Topic in Brief

  • Remote communication with an tester using RS-232.
  • Details regarding capacitive loads and line vs. load regulation.
  • Remotely setting up test sequences and querying the unit for results.

Understanding the Failure Indications of Slaughter Hipot Testers
Slaughter Hipot testers give you various failures indications depending upon the failure detectors built into each unit. These failure messages give you a clue as to why your test failed and how to more efficiently test.

Applicable Instruments: All Testers

Topic in Brief

  • The difference between HI and LO leakage limit failure messages.
  • The importance of insulation BREAKDOWN failure mode indications.
  • Additional features such as built in continuity failure detectors.

Exploring the Benefits of the Line Leakage and Functional Run Tests
The Line Leakage test and Functional Run test provide useful information in regards to the electrical characteristics of a device. This paper explores the benefits of Line Leakage and Functional Run for full spectrum electrical safety testing.


Applicable Instrument: 6000

Topic in Brief

  • The 4 main types of Line Leakage tests.
  • The importance of simulating fault conditions on a product.
  • Benefits of including the Functional Run test.
  • Incorporating Line Leakage and Functional Run tests on the production line.

Improving Production Line Efficiency
New electrical safety testing equipment has helped make automating safety testing in a manufacturing environment even more productive. All-in-one testers and microprocessor controlled devices allow for a simple setup and easy testing.

Applicable Instruments: 6000, 4000, 2900

Topic in Brief

  • What is electrical safety testing?
  • Improving production line efficiency by utilizing new tester features.
  • Multi-functional programmable testers with built-in failure detectors.

Line Leakage Testing - Is it right for your Application?
The Line Leakage test is generally performed only as a laboratory or type test. However, this test has advantages over the more common electrical safety tests and can provide critical information about an electrical product.

Applicable Instrument: 6000

Topic in Brief

  • Differences between a Hipot, Ground Bond, Insulation Resistance and Line Leakage test.
  • Line Leakage test description and parameters.
  • Proper Line Leakage testing procedures.

Exploring the Benefits of New Hipot Testing Technology
In the last 50 years, Hipot testers have advanced from analog to digital units. These digital units incorporate a series of features that would not have been available on analog testers.


Applicable Instruments: All Testers

Topic in Brief

  • Metering and leakage current reading accuracy.
  • Remote operation and programmable memory.
  • High voltage transformers that include variable output frequencies.

Ground Bond or Ground Continuity Testing?
While the Ground Continuity test is required by most safety agencies as a means to verify the ground circuit of an electrical product, it is the Ground Bond test that gives a complete and detailed analysis of the ground circuit of an electrical product.

Applicable Instrument: 2600

Topic in Brief

  • Shortcomings of the Ground Continuity test.
  • How the Ground Bond test provides a complete verification of the ground circuit.
  • Efficient ways of performing the Ground Bond Test.

Benefits of PLC Control
Electrical safety testing on a heavy production line can be very time consuming, costly and could give rise to safety hazards. Basic automation can help reduce test time, cost and safety concerns.


Applicable Instruments: All Testers

Topic in Brief

  • How simple relay control can be configured for basic test commands.
  • Advanced options for automation can make life very easy for operators.
  • Various options for automation.

Best Methods for Safe Hipot Testing
Safe test stations, safety measures and proper training can greatly reduce the risk of shock hazards to operators. This paper highlights some of the key points to help maintain safe Hipot test areas.


Applicable Instruments: All Testers

Topic in Brief

  • What is a safe work station and how to keep it safe.
  • Test operator training and responsibilities.
  • Safe testing procedures.

Dielectric Withstand Testing of Modular and Manufactured Homes
Hipot testing of Modular and Manufactured Homes has been a topic of discussion for years due to the fact that it involves testing the entire manufactured home with all the appliances connected and without damaging the appliances.


Applicable Instruments: 2500

Topic in Brief

  • Should the test be performed with AC or DC potential?
  • Advantages and disadvantages of AC and DC testing.
  • What is the proper test voltage and what part of the circuit needs to be tested.
  • How to interpret the test results.

Basic Facts about Electrical Safety Testing
Although manufacturers of electrical products are becoming more familiar with electrical safety testing and compliance, there are still areas which are misunderstood and unclear. This paper gives a clear understanding of why electrical safety tests are performed, what types of tests are required and how do these tests conform compliance with safety standards.


Applicable Instruments: All Testers

Topic in Brief

  • Why perform electrical safety tests?
  • The types of tests required.
  • How are the tests performed and what is the concept behind every test.
  • Operator safety and safe test stations.

Modular Home Testing Comparison Advantages and Disadvantages of AC and DC Hipot
This Modular Manufactured home testing comparison discusses the advantages and disadvantages of AC and DC Hipot testing.


Applicable Instruments: 2500

Topic in Brief

  • Tables of information comparing AC and DC Hipot tests.
  • AC Hipot testing advantages and disadvantages.
  • DC Hipot testing advantages and disadvantages.

Setup Guide and Splitter Kit Instructions
This document discusses how to setup your modular manufactured home for both an AC Hipot test and a DC Hipot test. It also provides instructions on how to use our splitter kit for modular manufactured home testing.


Applicable Instruments: 2500

Topic in Brief

  • Explains methods for Hipot testing Modular Manufactured homes.
  • Testing the breaker box with a DC Hipot.
  • Testing the breaker box with an AC Hipot.
  • Testing diagrams.

Common AC and DC Test Parameters for Modular Manufactured Homes
This document is a sample of common test parameters for both AC and DC Dielectric Withstand testing of Modular Manufactured homes.


Applicable Instruments: 2500

Topic in Brief

  • Hipot testing Values according to H.U.D. specification # 24 CRF 3280.810(a).
  • DC Hipot test parameters.
  • AC Hipot test parameters.