Vitrek Products for the Cable Testing Applications

Cable failures can shut down production, compromise safety, and create costly compliance risks. That’s why manufacturers across aerospace, EV, medical, industrial, telecommunications, and defense industries rely on Vitrek cable testing solutions to verify performance, insulation integrity, and long-term reliability before products ever reach the field.

Vitrek’s advanced cable testing platforms help manufacturers meet demanding industry and regulatory standards while improving throughput, traceability, and quality assurance. From high-voltage harnesses to mission-critical interconnects, Vitrek automated cable testing solutions deliver safer products, stronger compliance documentation, and greater confidence in every connection.

Hipot Testing for Electrical Safety Compliance

Hipot testing plays a critical role in verifying electrical safety, ensuring regulatory compliance, and identifying insulation or assembly defects before products reach the field. Modern electrical safety testers measure leakage current, insulation resistance, continuity, and ground bond integrity by applying controlled high voltages and currents between conductors, connectors, grounds, and chassis points while accurately recording test results. Advanced systems such as the Vitrek V7X and 95X Series Hipot Testers are designed to deliver the precision, repeatability, and automation required for today’s manufacturing environments.

As cable assemblies and electronic products become more complex, the number of required test points increases dramatically. Even relatively simple cable assemblies may require dozens of individual measurements, while high-conductor-count harnesses can require hundreds of unique test combinations.

Typical cable testing may include:

Continuity testing for each conductor
Insulation resistance testing between conductors
Ground bond verification
Dielectric withstand (hipot) testing
Connector-to-shell isolation testing
Multi-point harness validation

Performing these tests manually is slow, labor intensive, and highly susceptible to operator error. Manufacturers must ensure:

Every conductor combination is tested correctly
No tests are skipped or duplicated
All test parameters are applied consistently
Results are accurately recorded for traceability and compliance

To streamline this process, many manufacturers rely on programmable high-voltage switching systems that automate multi-point electrical safety testing. Working alongside a hipot tester, a switching system rapidly routes high-voltage and return paths across all required test combinations through a single fixture connection.

Benefits of automated cable testing include:

Faster throughput
Improved repeatability
Reduced operator dependency
Enhanced safety
Automated reporting and traceability
Simplified high pin-count testing

This automated approach helps manufacturers improve testing accuracy, reduce bottlenecks, and support modern compliance and production requirements.

Applicable Products

V10X Series Hipot Testers

Vitrek V10X Series is an advanced, automation-ready electrical safety testing platform built for high-voltage dielectric withstand, insulation resistance, ground bond, and 4-wire low-resistance testing of cable assemblies, wire harnesses, power cords, and high-reliability interconnects. With AC hipot up to 10 kV and DC hipot up to 15 kV standard, expandable to 30 kV AC with an external module, the V10X handles everything from light-gauge signal cables to heavy industrial harnesses and high-voltage power distribution conductors on a single platform. Optional 40 A ground bond and 400 Hz AC withstand testing extend the system into appliance, industrial, avionics, and MIL-STD / DO-160 cable compliance work.

For multi-conductor cable and connector testing, the V10X directly controls up to 1,600 high-voltage scanner channels without external relay controllers, making it an ideal pairing with the Vitrek 964i HV Switching System for automated multi-point hipot, continuity, and isolation verification. Advanced DSP technology delivers pico-ampere leakage resolution (100 pA) and phase-angle analysis to separate resistive leakage from capacitive coupling in shielded and bundled cables, while configurable broadband arc detection (4 to 30 µs pulse width, 2 to 20 mA peak) catches insulation breakdown without false failures from fixture noise. A full-color touchscreen with graphical sequence editing, native SCPI control over Ethernet, USB, RS232, and optional GPIB, plus onboard PDF and CSV report generation, deliver audit-ready documentation for ISO, IEC, and UL compliance workflows.

See V10X

95x Series Hipot Testers

Oftentimes, military equipment is large and ruggedized. Therefore, it can also have a higher capacitance. The 95x Series of Hipot testers is ideal for this application because it provides the power and versatility you need for your most demanding electrical safety test applications and can be equipped to handle up to 500VA of power. Other testers may not have the current drive to charge and test these larger systems.

The 95x features DSP Technology to bring you the safest, fastest, feature rich Hipot tester available. The 95x series combines high output power with a range of AC & DC voltage outputs and extremely low leakage current measurement. The unit is equipped with a 4-wire milli-ohmmeter with dynamic range up to 150K ohms and an overlapping Tera-ohm class Insulation Resistance function. Top that off with an available 40 Amp ground bond capability and you can see that the 95x series is the ideal choice for most electrical safety testing requirements.

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964i High Voltage Switching (Multi-Conductor, Multi-Point Hipot Testing) System

One of the highest failure rates in military and aerospace applications is cabling. Vitrek’s 964i High Voltage Switching System is the ideal choice for automated multi-conductor, multi-point hipot testing.

You have a job to do — you have to hipot test a cable at 2500V to ensure that each conductor is properly isolated from every other conductor. You have two choices, you can try to do it manually or you can use the Vitrek 964i to automatically route the HV and return signals to the proper test points. The manual method is extremely problematic. Slow, error prone, labor intensive, operator hazardous — and don’t even think about recording the test results.

The 964i on the other hand, is purpose built to fully automate all of your high voltage switching needs. The 964i makes the perfect tool for depot repair because it can quickly screen through cables and determine which are bad. When used with QT Insite, testing profiles for many different types of cables can be saved and recalled as needed.

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MTI Instruments 1510A Signal/Function Generator

A portable signal source for calibration, testing, troubleshooting, and system monitoring.

The 1510A Precision Portable Signal Generator and Calibrator is a must-have for engineers and technicians working in a variety of fields – from routine troubleshooting and maintenance, to calibrating and tuning advanced equipment such as eddy current probes, strain gauge amplifiers, or charge amplifiers for jet turbine vibration analysis.

SEE 1510A

QT Insite Software

QT Insite is the most powerful and flexible electrical safety test automation software available on the market today. QT Insite software is available for use with Vitrek V7X and 95X Series Hipot testers, 964i HV Switching system and the 98X Series of IR Testers to streamline your test sequences and record keeping and provide the features you want….and need…for your electrical safety tests.

Procedures stored via QT Insite can be recalled via a bar coded scan to enable fast and accurate setup. For complex setups, QT Insite can display detailed instructions and images to the operator to ensure proper connections prior to testing.

Data from every test is recorded and can be recalled for auditing purposes or detailed analysis on testing or product performance.

See QT Insite Software