7630 Hipot Tester

The Microtest 7630 Hipot Tester is a 3-in-1 electrical safety test instrument combining AC withstand voltage testing up to 5 kV, DC withstand voltage testing up to 6 kV, and insulation resistance measurement up to 12 GΩ in a single bench-top unit. Programmable multi-step test sequences automate the complete safety test workflow required by IEC, UL, and EN standards for transformers, cables, motors, power supplies, and assembled electrical products.

Test Capabilities

Test Mode	Range	Application
AC Withstand (Hipot)	100 V to 5 kV AC	Dielectric strength per IEC 60950, IEC 61010
DC Withstand	100 V to 6 kV DC	Insulation integrity for DC-rated components
Insulation Resistance	Up to 12 GΩ at 50-1000 V DC	Inter-winding isolation, cable insulation quality
Ground Bond	Programmable current	Protective earth continuity verification
Leakage Current	Programmable limits	Touch current and earth leakage measurement

Specifications

Feature	Specification
AC Withstand Voltage	100 V to 5 kV AC, 50/60 Hz
DC Withstand Voltage	100 V to 6 kV DC
Insulation Resistance	Up to 12 GΩ, test voltage 50-1000 V DC
Ground Bond Current	Programmable
Leakage Current Detection	0.001 mA resolution
Ramp Rate	Programmable voltage ramp (linear)
Dwell Time	Programmable per step
Arc Detection	Configurable sensitivity levels
Test Memory	Multiple test programs
Interface	USB, RS232, handler
Safety	Interlock, GFI protection, emergency stop

Programmable Test Sequences

The 7630 executes multi-step test sequences that chain different safety tests in the order required by the applicable product standard. A typical sequence for a power transformer might include: ground bond check, followed by AC withstand at rated voltage with dwell time, then insulation resistance measurement between all winding pairs. Each step has independently programmable voltage, current limits, dwell time, and pass/fail thresholds. The instrument advances through steps automatically, generating a single pass/fail verdict for the complete sequence.

Arc detection with configurable sensitivity distinguishes between genuine insulation breakdown and benign corona discharge at high test voltages, reducing false failures on components where partial discharge is expected below the breakdown threshold. Programmable voltage ramp rates ensure controlled stress application per standard requirements, preventing premature failures caused by excessive dV/dt.

Safety Compliance Applications

Transformer manufacturers use the 7630 to verify dielectric strength between primary and secondary windings, winding-to-core insulation, and inter-layer insulation per IEC 61558 and UL 1561. The combination of AC withstand, DC withstand, and insulation resistance in a single instrument covers the full safety test suite without switching between separate testers.

Cable and wire harness producers verify insulation integrity for power cables, control cables, and signal harnesses per IEC 60227, IEC 60245, and UL 758. High-voltage withstand testing catches insulation defects — pinholes, thin spots, contamination — that would cause field failures.

Motor manufacturers test winding-to-frame insulation, phase-to-phase insulation, and ground bond integrity for electric motors per IEC 60034 and UL 1004. Production-line integration with handler interfaces enables 100% safety testing at production speed.

Power supply and electronics assemblers perform routine production safety testing per IEC 60950/62368 and UL 60950/62368 for switched-mode power supplies, LED drivers, battery chargers, and assembled electronic products.

The interlock system, GFI protection, and emergency stop ensure operator safety during high-voltage testing. Remote interlock connections integrate with test fixture safety enclosures to prevent high-voltage application when the fixture is open.

Watch the 7630 Hipot Tester on YouTube

GSAS Micro Systems provides Microtest 7630 hipot testers with test sequence programming, fixture design consultation, and calibration services for Indian manufacturers requiring IEC/UL safety compliance testing.