What should a factory hi-pot test record contain?
Request a competently approved, product-specific test plan and records showing connections, voltage and waveform, duration, trip criteria and results linked to each tested unit. Do not specify a universal voltage or accept a batch pass stamp alone. Use this checklist when briefing Cambridge China Bridge.
Agree who approves the test plan
Ask a competent electrical safety specialist or testing laboratory to approve the plan before production testing. Record the approver, approval date, plan revision, exact model and construction revision. Ask for the applicable product standard, edition and clause, and an explanation of whether the method is for design assessment or routine production testing.
HSE's UK guidance says people working on electrical equipment must be competent. Treat specialist approval of your factory plan as a purchasing control, with evidence of relevant experience. The wider importer duties are covered in our electrical goods guide.
Request settings for the actual product
Ask the approver to specify the test voltage, alternating or direct current waveform, frequency where relevant, ramp-up, hold duration, ramp-down and discharge procedure. Request the reasoning for these settings against the product's insulation construction and approved test method. Avoid copying settings from another model or choosing a higher voltage as a purchasing shortcut.
Include the tester identity, calibration status, programme name and revision in the record. Ask for the actual settings used, including units of measurement, rather than a photograph of a default screen. Any component exclusions or alternative procedures should have a documented reason and approval.
Make the connections reproducible
Request a labelled connection diagram and photographs of the fixture. Ask the approver to identify the points between which voltage is applied, any conductors joined together, accessible parts included and the position of switches. Record whether the unit is fully assembled and which cables, adaptors or accessories are fitted.
Ask how the fixture detects missing or poor contact, and how operators confirm the correct programme is selected. Have the specialist approve safe connection, guarding and discharge arrangements. A photograph of a unit beside a tester does not show which insulation path was tested.
Define what causes a failure
Request the approved current trip limit, how the instrument measures it, and any breakdown or arc-detection criteria used. Record how charging current during the ramp is handled and what happens if the target voltage or hold duration is not achieved. Ask the specialist to justify any disabled detection function.
Agree how an interrupted test, instrument error, contact failure and electrical failure appear in the export. Keep these distinguishable from a completed pass. Require failed units to be held for investigation, with repair and retest authorised under the approved procedure rather than repeated testing until a pass appears.
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Link results to units and release decisions
Request an export linking each tested unit's serial number or other unique identifier to its model revision, batch, test time, operator, tester, programme revision, actual voltage, achieved duration, measured current and outcome. Ask the approver which measured values the instrument can reliably report. Record the agreed testing coverage and reconcile the export against the production list.
Retain original failures alongside repair details and subsequent results. Investigate missing identifiers, duplicate entries and unexplained gaps before accepting the record. Use our test report verification guide for report authenticity and our automated final test guide for the wider station checks. A hi-pot pass alone does not establish complete product compliance.
Frequently asked questions
What hi-pot voltage should I ask the factory to use?
Ask a competent specialist to approve the setting for the exact product and test method. Request its basis, waveform, connections, duration and trip criteria together.
Is a batch hi-pot pass certificate enough?
Request results linked to identifiable tested units, the approved plan and the settings actually used. Reconcile the recorded coverage against the production list.
Should every product receive a hi-pot test?
Have the specialist determine whether the test is appropriate and approve its production coverage. Keep that decision separate from the sampling agreed for general inspection.
Can the factory retest a failed unit?
Agree an approved investigation, repair and retest procedure. Keep the original failure and link subsequent results to the same unit; do not accept an unexplained replacement pass.