What is "hipot" testing?

Many people are familiar with a continuity test. A continuity test checks for "good connections."
You do a continuity test by seeing if current will flow from one point to another point. If current
flows easily enough then the points are connected. Many people aren't familiar with a hipot test.
"Hipot" is short for high potential (high voltage). A hipot test checks for "good isolation." You
do a hipot test by making sure no current will flow from one point to another point. In some
ways a hipot test is the opposite of a continuity test.

Continuity Test: "Make sure current flows easily from one point to another point."

Hipot Test: "Make sure current won't flow from one point to another point (and turn up the
voltage really high just to make sure no current will flow)."

In the simple case a hipot test takes two conductors that should be isolated and applies a very
high voltage between the conductors. The current that flows is watched carefully. Ideally not
much current will flow. If too much current flows the points are not well isolated and they should
fail the test.

Why high voltage test?

You use a hipot test to make sure you have good isolation between the parts of a circuit. Having
good isolation helps to guarantee the safety and quality of electrical circuits. Hipot tests are
helpful in finding nicked or crushed insulation, stray wire strands or braided shielding,
conductive or corrosive contaminants around the conductors, terminal spacing problems, and
tolerance errors in IDC cables. All of these conditions might cause a device to fail.

What kinds of high voltage tests are there?

There are three common high voltage tests.

 Dielectric Breakdown Test

 Dielectric Withstanding Test
 Insulation Resistance Test

What is "dielectric breakdown testing?"

With dielectric breakdown testing you are trying to answer the question "How much voltage can
I apply between the wires before the insulation fails?" You increase the voltage until the current
suddenly increases. You are finding the highest voltage the cable can stand before it fails. Once
the cable fails it is usually damaged or destroyed.

What is "dielectric withstand testing" (DW)?

In dielectric withstand testing you are trying to answer the question "Will this cable withstand a
required voltage for a required time?" You apply the voltage for the amount of time and watch
the current that flows. Ideally no current flows and the cable is not harmed.

What is "insulation resistance testing" (IR)?

In insulation resistance testing you are trying to answer the question "Is the resistance of the
insulation high enough?" You apply a voltage and very carefully measure the current. You then
calculate the insulation resistance using Ohm's Law (R = V/I).

How do these "hipot" tests affect quality?

All of these tests are tools you can use to better understand how a cable will perform and to
monitor any changes in the cable's performance.

Dielectric breakdown testing is used in product design and qualification stages. It helps establish
the maximum voltage of the design. It can also be used on a random sample basis to verify that
the maximum voltage is not changing. Dielectric breakdown testing may be required during the
development of assemblies used in critical applications.

Many test specifications require a Dielectric Withstand Test on every cable produced. The test is
usually done at about 75% of the typical breakdown voltage. It is done as a safety net. The test is
sensitive to arcs or corona so it often finds terminal spacing problems, over-mold problems,
tolerance errors in IDC cables, or any problem that might produce arcs. This test doesn't
significantly degrade the cable.

The Insulation Resistance test is typically done on every cable tested. It is usually done at 300 to
500 Vdc with 100 to 500 Megahoms resistance. The test is a very sensitive to contamination in
the assembly process. Solder flux, oils, mold release agents, and skin oil all can cause problems.
This test excels at identifying insulation that will conduct in the presence of moisture. Doing this
test on every cable allows you to detect contamination changes in the manufacturing process.

With all the high voltage being used, what about my safety?
During a hipot test you may be at some risk. The risk can be reduced by using a tester designed
to be safe and by using that tester according the manufacturer's instructions.

Products being designed today usually must comply with product safety regulations. Some of
these regulations work to reduce the chance of you receiving a harmful electrical shock. Modern
equipment is more likely to follow these regulations. When it comes to hipot charge, energy, and
voltage you should select the "safest" machine that will still test your cables.
To minimize your risk of injury from electrical shock make sure your hipot equipment follows
these guidelines:

 The total charge you can receive in a shock should not exceed 45 uC.
 The total hipot energy should not exceed 350 mJ.
 The total current should not exceed 5 mA peak (3.5 mA rms)
 The fault current should not stay on longer than 10 mS.
 If the tester doesn't meet these requirements then make sure it has a safety interlock
system that guarantees you can not contact the cable while it is being hipot tested.

While you are testing cables there are several things you can do to reduce the risk even more:

 Verify the correct operation of the safety circuits in the equipment every time you
calibrate it.
 Follow all of the manufacturer's instructions and safety guidelines.
 Don't touch the cable during hipot testing.
 Allow the hipot testing to complete before removing the cable.
 Wear insulating gloves.
 If you have any health condition that can be aggravated by being startled then don't use
the equipment.
 Don't allow children to use the equipment.
 If you have any electronic implants then don't use the equipment.