Hipot Test

What is Hipot Testing Explain the Step-by-Step

Procedure for Hipot Testing (Dielectric Strength Test)

Hipot testing gets its name from the “high potential” that
they generate in order to perform

 Dielectric withstand and

 Insulation resistance tests.
As a result, this testing remains a common procedure for
various types of equipment.

Many hipot testers also provide exact, low-resistance, high-

current outputs as well as low-resistance measurements for
measuring ground bond integrity and ground resistance.

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Most modern hipot testers are currently employing
electronic source technologies to ensure compliance
with IEC-61010, which clearly states that the voltage test
equipment must be able to perform in maintaining the
required voltage for a specific time period.

This post provides an overview of Hipot Testing.

Hipot Testing

Hipot testing is an electrical safety test that is used to

evaluate a product/component to validate the efficacy of its
insulation. This can also be referred to as a dielectric-
withstand test, a high potential test, or a pressure test. The
dielectric strength test can assist determine whether the
ground wall can withstand a higher voltage condition. This
test is also useful for assessing the insulation condition of
test objects such as

 Transformers,
 Relays,
 Switchgear,
 Bus-bar,
 Generators,
 Cables,

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 Lightning arresters, and many more.
This test can be done on devices ranging in voltage from
very low to very high.

The hipot test is extremely useful for finding terminal

spacing difficulties, faulty cable junctions and terminations,
crushed insulation, reduction in inside clearance and
creepage, corrosive/conductive impurities, and braided
shielding (or) stray wire stands.

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Importance of Hipot Test

The relevance of the Hipot test is that it basically evaluates

the electrical insulation range for the specific device.

This test simply determines whether or not the insulation

can withstand transient overvoltages.

This might be done for a wide range of devices over a set

period of time. This test is also beneficial in identifying
problems with the insulation, which is typically finished
with braided shielding, such as cuts, stray wire strands,
tolerance mistakes, terminal spacing issues, corrosive
impurities, and so on.

Many faults that occur during manufacturing, such as

creepage or incorrect clearance distances, can be detected
with this testing. A Hipot test is required to measure the
strain of an electronic component for security and quality
assurance objectives.

The Hipot test is significant because it determines the level

of the electrical insulation of a certain device or assembly.
Technicians employ testing to determine whether the
insulation can withstand transient overvoltages – the ‘push’
that triggers electromotive charges to move in a wire
(or) other electrical conductor.

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The electrical insulation is subjected to high voltage for an
extended period of time to ensure that it meets safety
& quality standards.The Hipot test identifies insulation
defects by identifying the electrical insulation to
the transient overvoltages. It is essential to look for these
problems. Insulation is frequently subjected to unexpected
surroundings (or) circumstances that can impair device
performance.

Electrical insulation to the electronic harnesses & cable

assemblies can be compromised by

 Braided shielding,
 Stray wire strands,
 Tolerance mistakes,
 Corrosive pollutants, and
 Terminal spacing problems.
It can also be used to locate cuts in the insulation, as well as
nicked or crushed insulation.Hipot testing may also be
carried out on manufacturing lines while the product is
being manufactured.

The purpose of testing is to determine whether the

assembling process of a production unit is identical as that
of type tested units. Potential manufacturing faults such as
creepage or inappropriate clearance lengths, a pinhole

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defect in insulation, & locating an expanded solder
footprint can be found.

Hipot Tests Work

To ensure the safety and quality of an electronic equipment,

a Hipot test is required. It ensures that no breakdown or
perforation occurs at high voltage & that insulation
distances on transmission line as well as the air are
observed. Tests can be carried out between mutually
insulated components of a part or between electrified parts
& electrical ground. While testing, electric current will
flows between two different locations in either case.

Typically, the test is performed by connecting one end of

the power supply to ground & the conductor other
end being tested. Conductors can be connected to either a
high voltage source (or) to ground. It ensures that your
testing contact is separated from all the other contacts.
Hipot testers may measure between 5k and 400k volts,
based on their size.

The test duration must be closely related to the device’s

safety regulations. For products specified by IEC 60950, the
international standard for the rated voltage, it should be
one minute. Otherwise, current limit might be regulated to
fulfill the assembly’s safety standards.

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Hipot Testing Procedure

The Hipot Testing step-by-step procedure is described in

detail below.

Step 1: First, open switches/CBs to disconnect the DUT

from both ends.

Step 2: A discharge rod is subsequently utilized to

discharge all of the conductors.

Step 3: Set CAUTION labels (or) Barricades near the HV

testing area.

Step 4: Connect Hipot’s Master Earthing Terminal (MET)

to the proper System Earthing.

Step 5: Connect the operational earthing terminal to

the body earth (or) safety ground.

Step 6: Confirm that the connection is correct.

Step 7: Connect the kit’s HV terminal to the conductive

portion of the test object.

Step 8: Verify all circuit phase conductors by connecting

each phase to ground according to the time, current, &
voltage settings that is pre-determined.

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When all of these procedures have been completed, the
following points must be verified.

The current flow would be measured as a result of the

voltage difference between the conductors. There must be
no breakdown of either the solid (or) air insulation. In
addition, the current flow should not exceed the 5mA peak.
In order to pass the test, the test object must be subjected to
the minimum amount of stress at the predetermined
voltage for 1 minute without showing signs of breakdown.
Hipot testing can thus ensure the security, excellence, &
consistency of essential electrical equipment.

Cable Hipot Testing

A Hipot test for the cable is used to determine whether (or)
not a power cable is in good condition. This test is carried
out with the help of a Hipot Test kit, which comprises

 Auto transformer,
 Test transformer,
 Some necessary components, &
 Power cord.

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Cable Hipot Testing Procedure

The cable hipot testing step-by-step procedure is described

in detail below.

Step 1: To get started, the power wire being checked is

entirely isolated from the both ends. The cable’s 3 phases
are discharged with the support of earth rods, allowing the
cable to work safely.

Step 2: A control box supplies 220V AC power to the

Autotransformer, and the output can be utilized to control
the input voltage to the transformer’s main windings.

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 Hipot Test
Step 3: The test transformer is employed here to increase
the voltage to the required test range.

Step 4: If the testing type is AC Hipot testing, the test

transformer’s secondary winding terminal is connected to
the cable’s phase conductor.

Step 5: If the testing is DC Hipot, the silicon rectifying

diode may be simply connected in series with the test
transformer’s secondary winding.

Step 6: The secondary terminal of the test transformer is

linked to the cable’s phase conductor via the diode, while
the other terminal is routed straight to earth via the cable
armor.

Step 7: Insulation between the phase conductor and the

ground is evaluated. Once the power cable is in operation
and charged, simply connect the cable’s armor to GND and
the armor will be at ‘0’ potential.

Step 8: As a result, insulation between phase conductor and

armor is tested. So, the input voltage of 220 volts is raised
to the required test voltage, which ranges from 6 KV to 60
KV, and the Hipot test is done. The test voltage is increased
in accordance with the voltage and insulation level of the
component to be tested.

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 Hipot Test
A similar procedure is followed for the remaining two
phases of the power cable. We might test their physical
condition of the insulation between phase and earth in this
method. To assess the condition of the insulation between
two phases, connect one high voltage lead to one phase and
the other to another phase and ground.

In a similar way the hipot test for transformers is primarily

used to determine if a resistance welding transformer is
electrically stable enough to be used in production.

This type of test is quite quick and simple to execute in

5 minutes after disconnecting from the main power and the
secondary power.

This test determines whether there is an internal short,

which is usually caused by an insulation breakdown, or
whether there is an open circuit in the secondary.

Formula for Hipot Testing

The Hipot test voltage is calculated using the formula

below.

Hipot voltages are mostly used to test the insulation and

ensure that there will be no electrical breakdown.

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A basic thumb rule for measuring the hi-pot test voltage is
twice the working voltage + 1000V.

Hipot Test Formula = 2 x (Working Voltage) + 1000 V

Ex:

If the operating voltage is 120V,

2 x 120 + 1000 = 1240V.

In general, the hipot test can be described as AC/DC. As a

result, the following formula is typically used to equalize
these hi-pot tests.

VDC = VAC (PEAK) = VAC(RMS) × √2

The hi-pot test period is generally 1 minute, however

according to safety standards, 1 to 2 seconds are allowed
for testing the manufacturing line only when the voltage
increases by 20% over the 1-minute test.

Safety Guidelines in Hipot Test

When working on an electrical instrument, the output is

potentially dangerous voltages and currents, so it is
important to check that device on a regular basis and
recommend secure testing methods such as setting up a

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 Hipot Test
secure work area, properly training test operators, and
setting up safe test procedures.

Knowing and detecting safety problems so assist a

manufacturer in securing their workplace.

The primary safety considerations when doing the Hipot

test are outlined below.

 Keep unauthorized workers out of the testing area.

 Arrange the test station in a safe and orderly manner.
 Make no unauthorized adjustments to the test
equipment.
 Verify any custom test setups and record the
appropriate ratings.
 During a Hipot test, never touch the connectors or
the product.
 When there is a problem, first turn OFF the high
voltage.
 Before switching connections, discharge any tested
equipment correctly through DC supply.

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Advantages of Hipot Test

 This test protects operators from electrical shock

injuries.
 It lowers the cost of replacement or repair.
 It reduces the risk of motor vehicle injury.
 It extends the equipment’s life.
 This test assists manufacturers in determining
corrosion and damaged insulation.
 This test often includes either high potential or high
voltage testing.
 The key advantage of this test is its adaptability.

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 Hipot Test
 This test detects material and workmanship
faults, insulation weak points, conductor gap
spacing, dirt, pollutants, and moisture within the
insulation.

Disadvantages of Hipot Test

 It just measures total leakage current.

 Because it measures the total leakage current, a large
Hipot transformer is required.
 It is not usually accepted by safety departments.
 The DC hipot test is more expensive than the AC
hipot test.

Application of Hipot Test

 Ensure the insulating integrity of power

transmission cables.
 The insulation between the windings and the earth is
being tested.
 Checking the insulation of appliances, PCBs, & other
electrical components.
 Electrical systems can benefit from preventative
maintenance.

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 Motors, transformers, and high-voltage systems are
examples of industrial equipment.
 Manufacturing of electrical appliances
 Aerospace and defense technology

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