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The Hipot Test: Learning Objectives

Understanding the What is hipot test? What is tested?

Hipot test

Hipot Test Test Parameters

Requirements

Hipot Test
Leakage Current and
Considerations Dielectric Breakdown
Arc Detection
and Failures
 The Hipot Test
The Dielectric Voltage-Withstand Test is commonly known as the Hipot test.

Hipot test is the most common type of electrical safety test.

Designed to verify that the insulation of a product is adequate enough to withstand high
voltage.

The test is performed by stressing the insulation of the product far beyond what it
would encounter during normal use.

Hence, the term “voltage withstand test”.

The hipot test is performed at high voltage to test the insulation of a product.
 The Hipot Test
The diagram shows a basic circuit used for hipot test.

It is a deliberate application of high voltage potential between the current carrying conductors and
any exposed dead-metal.

The resulting leakage current is measured to determine whether a product’s insulation is able to
withstand the high voltage without breaking down.

This test verifies that the insulation of a product is capable of protecting the user from any leakage
currents as a result of an electrical fault within the product.

Leakage current is gives a measure of the product’s insulation quality.

 The Hipot Test
Hipot test PASS condition.

The insulation is able to withstand the high voltage and does not break down or does not allow excess
leakage current to flow on the surface of the product under test.

Quality insulation will not allow excess leakage current to flow on a product’s surface.
 The Hipot Test
Hipot test FAIL condition.

Insulation breakdown results in excessive leakage to the chassis of the DUT.

Poor insulation will breakdown and dangerous leakage current can flow on the surface of a product.
 The Hipot – A Versatile Test
When performed as Type tests Hipot tests are helpful in finding various important
defects.

Nicked or crushed insulation, stray wire strands or braided shielding.

Conductive or corrosive contaminants around the conductors.

Terminal spacing problems and tolerance errors in cables.

Inadequate creepage and clearance distances introduced during the manufacturing

process.
The Hipot – A Versatile Test

The production-line hipot test is used to determine whether the construction of a

production unit is about the same as the construction of the unit that was
subjected to type testing.

Some of the process failures that can be detected by a production-line hipot test
include, for example, a transformer wound in such a way that creepage and
clearance have been reduced.

Such a failure could result from a new operator in the winding department.

The hipot is more than just a go/no-go test. It can be used to find various insulation problems.
 The Hipot – A Versatile Test

Scrapes • Pinholes • Spacing • Crimps • Heat

Material Build-up • Moisture

Insulation of any electrical device can become weak over time.

 The Hipot Test
The best indication of a dielectric breakdown is a leakage current measurement
significantly higher than the nominal current measurement.

Test voltage, the product being tested and the capacitance of the product can all impact
the total leakage current measurement.

When we perform a hipot test on a product, we can think of the product as a giant
capacitor.

The voltage is applied between the mains input and the chassis of the product which
are separated by the insulation, which is just like a capacitor.
 Test Voltages
Unless and otherwise stated by the safety standard, a good rule of thumb to calculate the
hipot test voltage is: (2 X Nominal Input Voltage) + 1000V

In some cases, safety agency requirements call out for hipot test voltage for certain
devices.

For example, medical equipment with applied parts that have direct contact with a
patient is tested at 4000V or 4KV.

Most double insulated (Class II) products are subjected to design tests at voltage levels
much higher than the rule of thumb described above.

Hipot test parameters are called out by the standards but when in doubt, use the rule of thumb.
Production Hipot test parameters may differ from Type test parameters.
Class I vs. Class II Application
Poll Question 1
Maybe quiz question on class II
 Failure Detectors
• 400μsec interrupt
Breakdown • Shorts and Breakdowns

• Leakage high and low limits

Leakage Limits • 100msec samples

• Leakage high and low limits

Arc Detection • 100msec samples

Each failure detector has a priority on the instrument. Shorts and breakdowns will always be
detected with a high speed interrupt. Leakage limits will trigger a failure if leakage current strays
from user set values. Arc detection is a extra feature which is enabled.
 AC vs. DC Hipot Testing
• Depending on the product being tested and the test standard, the hipot test can
either be performed using AC or DC potential.
AC or DC

• Both AC and DC hipot tests have inherent advantages and disadvantages which
are evident depending on the product being tested.
Differences

• It is important to understand the difference between the nature of AC and DC

Which to voltage/current.
use?
 Total Leakage Current
The leakage current that is measured by most AC hipot testers is the vector sum of the
resistive leakage current and the reactive leakage current.

Some Associated Research hipot testers are capable of displaying real and total leakage
current for manufacturers who require extra information.

Vector Sum Relationship

The hipot is more than just a go/no-go test. It can be used to find various insulation problems.
 Leakage Current

Leakage current is the stray current that actually flows through the insulation. It is undesired
current that we want to quantify to better understand the quality of an insulation barrier.
 AC vs. DC

AC HIPOT ADVANTAGES DC HIPOT ADVANTAGES

No ramping of voltage required due to the Can be performed at a much lower current
changing polarity of the AC voltage level with less risk to the operator
Discharging the DUT is not necessary Often easier to perform on capacitive DUT’s
Insulation is stressed in both polarities Leakage current measurement is purely real

Measures both real and reactive current Cost effective

Commonly accepted by safety agencies Not always accepted by safety agencies

500 VA Hipot Testing – By the Standards
Standard Description Hipot Requirements
The generator shall be able to supply a power of
at least 500 VA. The test voltage is raised
Equipment for Measurement, uniformly from 0 V to the specified value within
IEC 61010-1
Control and Laboratory Use 5 s and held at that value for at least the
specified time.

A voltage of substantially sine-wave form, with

a frequency of 50 Hz or 60 Hz and the value
specified in Table 10.2, shall be applied for 1
min across the insulation shown in that table.
Short circuit current
IEC 60598-1 Luminaires shall be at least 200 mA.
The overcurrent relay shall not trip when the
output current is less than 100 mA.

The insulation is subjected to a voltage of

substantially sinusoidal waveform having a
frequency of 50 Hz or 60 Hz for 1 min…No
breakdown shall occur.
IEC 60335-1 Household Appliances
Tests run at 4000V or less require 100mA trip
limit and 200mA short circuit current.
 500 VA Hipot Testing
VA Rating - Certain standards require the use of a 500VA hipot transformer

Energy and Breakdown - Originally this was required to ensure hipot voltage output remained
constant under varying line and load conditions

High Leakage Applications - Higher mA output may also be required for high leakage currents.
For example, a 2000m length of cable may have 60mA of leakage.

Most Associated Research instruments have a 5000V output. Thus, the instruments have a 100mA
trip current rating and 200mA short circuit current rating.
 Line Vs. Load Regulation

If the hipot circuit is too heavily loaded or the input voltage drops, the hipot test voltage can dip causing an improper
hipot test.
How to Set Leakage Current Limits?
Perform & Calculate Add Subtract
Record

• Take 25% • Use that

• Perform • Calculate same
hipot on the of this
number 25% and
known average subtract
good leakage and add
to the from the
products. current average
Record value for average
value. value.
all results these This is
products This is
your Hi- your Lo-
Limit Limit

Say I test 10 DUTs and calculate an average leakage current of 5.5mA. My limits would be:
Hi-Limit  (5.5mA)*0.25 = 1.375mA  5.5mA + 1.375mA = 6.88mA
Lo-Limit  5.5mA – 1.375mA = 4.13mA
 Ramp HI and Charge-Lo
DC Hipot Test – At test start, there will be inrush current. Once the insulation is charged (full test
potential), the leakage current drops off to near zero mA.

Ramp-Hi will ignore inrush current values so that the DC hipot does not falsely fail

Charge-Lo monitors hipot circuit with DUT attached. The Charge-Lo circuit takes
half the inrush current value and substitutes as a low limit check.

These features are used with a DC hipot or IR test. Due to the nature of a DC withstand test, setting
high and low leakage limits can prove difficult. These features compensate for this difficulty and allow
the user to properly monitor the limits.
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