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What is HIPOT Testing (Dielectric Strength Test)? | EEP
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Home / Technical Articles / Energy and Power / What is HIPOT Testing (Dielectric StrengthTest)?
What is HIPOT Testing (Dielectric Strength Test)?
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category-energy-and-power category-protection tag-ac-test tag-dc-testtag-dielectric-strength tag-hipot tag-test tag-test-voltage tag-testing"id="post_id_16285">
title="Posts by jiguparmar" rel="author">jiguparmarPower, ProtectionComments
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for high potential HV testing."src="http://electrical-engineering-portal.com/wp-content/uploads/hipot-dielectric-strength-test-device.jpg" alt="Hi-Pot test is a contraction for highpotential HV testing." width="302" height="283"srcset="http://electrical-engineering-portal.com/wp-content/uploads/hipot-dielectric-strength-test-device.jpg 302w,http://electrical-engineering-portal.com/wp-content/uploads/hipot-dielectric-strength-test-device-120x112.jpg 120w" sizes="(max-width: 302px) 100vw, 302px"/>Hi-Pot test is a contraction for highpotential HV testing.
Hipot Test is short name of high potential (high voltage) Test and it is alsoknown as DielectricWithstand Test. A hipot test checks for “goodisolation.”
Hipot test makes surety of no current will flow fromone point to another point.
Hipot test is the opposite of a continuity test.
Continuity Test checks surety of current flows easily from one point to anotherpoint while Hipot Test checks surety of current would not flow from one point toanother point (and turn up the voltage really high just to make sure no currentwill flow).
Importance of HIPOT TestingThe hipot test is a nondestructive test that determines the adequacy of electrical insulation for the normallyoccurring over voltage transient. This is a high-voltage test that is applied toall devices for a specific time in order to ensure that the insulation is notmarginal.
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Hipot tests are helpful in finding nicked or crushed insulation, stray wirestrands or braided shielding, conductive or corrosive contaminants around theconductors, terminal spacing problems, and tolerance errors in cables. Inadequatecreepage and clearance distances introduced during the manufacturing process.
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The production-line hipot test, however, is a test of the manufacturing processto 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 processfailures 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.
HIPOT test is applied after tests such as fault condition,humidity, and vibration to determine whether any degradation has takenplace.Other examples include identifying a pinhole defect in insulation or findingan enlarged solder footprint.
As per IEC 60950, The Basic test Voltage for Hipot test is the 2X(Operating Voltage) + 1000 V
The reason for using 1000 V as part of the basic formula is that the insulationin any product can be subjected to normal day-to-day transient over voltages.Experiments and research have shown that these over voltages can be as highas 1000 V.
Video: HIPOT Test After Repair Generator
Test method for HIPOT TestHipot testers usually connect one side of the supply to safetyground (Earth ground). The other side of the supply isconnected to the conductor being tested. With the supply connected like this thereare two places a given conductor can be connected: high voltage or ground.
When you have more than two contacts to be hipot tested you connect one contactto high voltage and connect all other contacts to ground. Testing a contact inthis fashion makes sure it is isolated from all other contacts.
If the insulation between the two is adequate, then the application of a largevoltage difference between the two conductors separated by the insulator wouldresult in the flow of a very small current. Although this small current isacceptable, no breakdown of either the air insulation or the solid insulationshould take place. Therefore, the current of interest is the current that is theresult of a partial discharge or breakdown, rather than the current due tocapacitive coupling.
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TopTime Duration for HIPOT Test
The test duration must be in accordance with the safety standard being used.The test time for most standards, including products covered under IEC 60950, is1 minute.
A typical rule of thumb is 110 to 120% of 2U + 1000 V for 1–2seconds.
TopCurrent Setting for HIPOT TestMost modern hipot testers allow the user to set the current limit. However,if the actual leakage current of the product is known, then the hipot test currentcan be predicted.
The best way to identify the trip level is to test some product samples andestablish an average hipot current. Once this has been achieved, then the leakagecurrent trip level should be set to a slightly higher value than the averagefigure.
Another method of establishing the current trip level wouldbe to use the following mathematical formula: E(Hipot) / E(Leakage) =I(Hipot) / 2XI(Leakage)The hipot tester current trip level should be set high enough to avoid nuisance
failure related to leakage current and, at the same time, low enough not to overlooka true breakdown in insulation.
TopTest Voltage for HIPOT TestThe majority of safety standards allow the use of either ac or dc voltage fora hipot test.
When using ac test voltage, the insulation in question is being stressed mostwhen the voltage is at its peak, i.e., either at the positive or negative peakof the sine wave.
Therefore, if we use dc test voltage, we ensure that thedc test voltage is under root 2 (or 1.414) times the ac test voltage, sothe value of the dc voltage is equal to the ac voltage peaks.For example, for a 1500-V-ac voltage, the equivalent dc voltage to produce thesame amount of stress on the insulation would be 1500 x 1.414 or 2121 V dc.
TopAdvantages and Disadvantages of use DC Voltage for Hipot TestOne of the advantages of using a dc test voltage is that the leakage currenttrip can be set to a much lower value than that of an ac test voltage. This wouldallow a manufacturer to filter those products that have marginal insulation, whichwould have been passed by an ac tester.
When using a dc hipot tester, the capacitors in the circuit could be highlycharged and, therefore, a safe-discharge device or setup is needed. However, itis a good practice to always ensure that a product is discharged, regardless ofthe test voltage or its nature, before it is handled.
It applies the voltage gradually. By monitoring the current flow as voltagesincrease, an operator can detect a potential insulation breakdown before it occurs.A minor disadvantage of the dc hipot tester is that because dc test voltages are
more difficult to generate, the cost of a dc tester may be slightly higher thanthat of an ac tester.
The main advantage of the dc test is DC Voltage does notproduce harmful discharge as readily occur in AC.It can be applied at higher levels without risk or injuring good insulation.This higher potential can literally “sweep-out” far more local defects.
The simple series circuit path of a local defect is more easily carbonized orreduced in resistance by the dc leakage current than by ac, and the lower the faultpath resistance becomes, the more the leakage current increased, thus producinga “snow balling” effect which leads to the small visible dielectric puncture
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usually observed. Since the dc is free of capacitive division, it is more effectivein picking out mechanical damage as well as inclusions or areas in the dielectricwhich have lower resistance.
TopAdvantages and Disadvantages of use AC Voltage for Hipot TestOne of the advantages of an ac hipot test is that it can check both voltagepolarities, whereas a dc test charges the insulation in only one polarity. Thismay become a concern for products that actually use ac voltage for their normaloperation. The test setup and procedures are identical for both ac and dc hipottests.
A minor disadvantage of the ac hipot tester is that if the circuit under testhas large values of Y capacitors, then, depending on the current trip setting ofthe hipot tester, the ac tester could indicate a failure. Most safety standardsallow the user to disconnect the Y capacitors prior to testing or, alternatively,to use a dc hipot tester.
The dc hipot tester would not indicate the failure of a unit even with highY capacitors because the Y capacitors see the voltage but don’t pass any
current.
TopStep for HIPOT Testing
Only electrically qualified workers may perform this testing.Open circuit breakers or switches to isolate the circuit or Cable that willbe hi-pot tested.Confirm that all equipment or Cable that is not to be tested is isolated fromthe circuit under test.The limited approach boundary for this hi-pot procedure at 1000 voltsis 5 ft. (1.53m) so place barriers around the terminations of cables andequipment under test to prevent unqualified persons from crossing thisboundary.Connect the ground lead of the HIPOT Tester to a suitable building ground orgrounding electrode conductor. Attach the high voltage lead to one of the isolatedcircuit phase conductors.Switch on the HIPOT Tester. Set the meter to 1000 Volts or pre decide DC Voltage.Push the “Test” button on the meter and after one minute observe the resistance
reading. Record the reading for reference.At the end of the one minute test, switch the HIPOT Tester from the highpotential test mode to the voltage measuring mode to confirm that the circuit phaseconductor and voltage of HIPOT Tester are now reading zero volts.Repeat this test procedure for all circuit phase conductors testing each phaseto ground and each phase to each phase.When testing is completed disconnect the HIPOT Tester from the circuits undertest and confirm that the circuits are clear to be re-connected andre-energized.To PASS the unit or Cable under Test must be exposed to a minimum Stress ofpre decide Voltage for 1 minute without any Indication of Breakdown. For Equipmentswith total area less than 0.1 m2, the insulation resistance shall not be less than
400 MΩ. For Equipment with total area larger than 0.1 m2 the measured insulationresistance times the area of the module shall not be less than 40 MΩ⋅m2.
TopSafety precautions during HIPOT Test
During a HIPOT Test, There may be at some risk so to minimize risk of injuryfrom electrical shock make sure HIPOT equipment follows these guidelines:
The total charge you can receive in a shock should not exceed 45uC.
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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 safetyinterlock system that guarantees you cannot contact the cable while it is beinghipot tested.
For Cable:
Verify the correct operation of the safety circuits in theequipment every time you calibrate it.Don’t touch the cable during hipot testing.Allow the hipot testing to complete before removing the cable.Wear insulating gloves.Don’t allow children to use the equipment.If you have any electronic implants then don’t use the equipment.
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Jignesh Parmar
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mailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-testmailto:?subject=Check%20out%20this%20article:%20What%20is%20HIPOT%20Testing%20%28Dielectric%20Strength%20Test%29?&body=http://electrical-engineering-portal.com/what-is-hipot-testing-dielectric-strength-test
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Jignesh Parmar has completed M.Tech (Power System Control),B.E(Electrical). He is member of Institution of Engineers (MIE),India. MembershipNo:M-1473586.He has more than 13 years experience in Transmission-Distribution-Electrical Energy theft detection-ElectricalMaintenance-Electrical Projects (Planning-Designing-TechnicalReview-coordination -Execution). He is Presently associate with one of the leadingbusiness group as a Deputy Manager at Ahmedabad,India. He has published numbersof Technical Articles in "Electrical Mirror", "Electrical India", "LightingIndia", "Industrial Electrix"(Australian Power Publications) Magazines. He isFreelancer Programmer of Advance Excel and design useful Excel base ElectricalPrograms as per IS, NEC, IEC,IEEE codes. He is Technical Blogger and Familiar withEnglish, Hindi, Gujarati, French languages. He wants to Share his experience &Knowledge and help technical enthusiasts to find suitable solutions and updatingthemselves on various Engineering Topics.
RSS Feed for Comments
51 Comments
irfan ullah
Mar 23, 2016What is the allowable leakage current during hipot test
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(reply)
kalaiyarasan
Feb 01, 2016why we have to use DC Voltage For Hi-Potential Test? do we have any strong reason?
(reply)
NIRMAL
Jan 19, 2016
Dear Sir,
Is there any Standard for the amount of allowable leakage current during theHigh-Pot testing of Switchgears?. For Eg. We have 33kV GIS Switch Gear(2 Verticles)and during High Pot Testing (A/C) whether a leakage current of 20-25mA is acceptableor not ?
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(reply)
Anbu
Dec 18, 2015Hi Sir,
I want to know HI-POT testing charges for below spec
Part Name – Bus Bar
Voltage – 1KVDC
Part Length – 380mm
Width – 15.24mm
Thick – 2mm
Quantity – 20,000 PiecesRegards
Anbu(reply)
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ages/default-avatar.png' class='avatar avatar-60 photo' height='60' width='60'/>
Joey
Dec 15, 2015
Considering high-pot testing is somewhat distractive specially for old andexisting electrical equipment, what do you recommend as an alternative test forhigh-pot testing?
(reply)
Manohar
Nov 18, 2015Dear Sir
Pl let us know what is the limit of leakage current while doing Hi-POT testfor cable and HT busbar
(reply)
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Jitu
Oct 22, 20151. At what max KV we can go HI POT for CAT 5E cables?
2. Enlist requirement to make 2KV HI POT tester for cable harness ranging from1 M Length to 20 M length
3. Approximate cost.
4. Any special care required for operators while handling this test?
5. Please provide details for safety/controls/special tool requirement/matingparts requirement while performing HIPOT test for cable harness.
6. This can be done on both types of cables? shielded and un-shielded?7. Approximate what will be the total time required to conduct 2 sec HIPOT testfor cable having approximate length of 2 M and connector at both ends?
8. provide supplier details who make this type of tester.(reply)
edwin
Oct 04, 2015As per IEC 60950, The Basic test Voltage for Hipot test is the 2X (OperatingVoltage) + 1000 V
Please send standard or part of this standard where support this assertion.
according to this standard for a 5K cable is applied as hom
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(reply)
Adrian
Sep 17, 2015
hipot dc surges tester are equal?????
and dc withstand(reply)
siva
Sep 14, 2015Hi Sir,
I’m design inductance coil, I need perform hipot test for 60sec underlow current limit 0.7mA and upper current 5.0mA with load voltage test range 2.5kV,
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test voltage 0.5KVac Now my problem is i market return unit fail hipot but duringlab test without load the unit pass hipot using test range 0.5KVac and leak currentonly 0.01mA…Pls help
(reply)
Iqbal Abbasi QA E&I
Sep 19, 2015Siva
Your question is not very clear.
Hipot test are very simple depending what you are testing.(reply)
hossein
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Aug 25, 2015
hi,
I need to the test sheet for hi pot test for 20 kv cable & bus duct and 6 kvmotors.
thank you(reply)
aby
Sep 01, 201512/20(24)||U0/U(Um)-
Test voltage to be 50kV dc(reply)
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ages/default-avatar.png' class='avatar avatar-60 photo' height='60' width='60'/>
Iqbal Abbasi QA E&I
Sep 19, 2015Hossein
It is easy, go on spread sheet, design your sheet.
Applied voltage Duration Result ie in Ohm’s valve(reply)
vinod
Aug 21, 2015Dear Sir,
Pl suggest me for the voltage range apply for HV test for high rating UPS like100kva to 600kva(reply)
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Iqbal Abbasi QA E&I
Sep 19, 2015Vinod
The test voltage always depend on what your testing.
It dosen’t matter 100 KVA or 600 KVA power, but what is
equipment voltage.
for examlpe UPS is for 125V then you can go upto 500V Testing.(reply)
Chickenhawk
Aug 12, 2015What settings do you set the Fluke Multimeter to? I’m trying to capturecheck for leakage and record the results in mA. Any help would be appreciated!
(reply)
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karthick
Jun 10, 2015If I get less value in IR test after hi-pot then before hi pot what could be
the reason.
(reply)
Manikandan
Jun 28, 2015Usual problem, but still I am not cleared…If there is any acceptableleakage current value is there during Hi-pot test, please share with us.. In modernday test kit, we could find many options, 25mA, 50mA, 75mA… I heard,insulation should not get breakdown or kit should not trip. I kept in 25mA optionand it is tripped, but same way I kept it in 100mA, and it is not tripped. I amsure it is less than 100mA. But I need to know what is the acceptable range ofleakage current.
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(reply)
anbu
Apr 07, 2015Dear sir
What are the drawbacks of injecting DC voltage( for testing purpose) in GasInsulated Switchgear. what is the limitation.
(reply)
Surat
Apr 06, 2015 -
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Dear Jignesh,
If I need to test Hipot test with the product. Do we need to test Hipot test beforeFunctional test or after Functional test? Why?(reply)
Steve
Mar 09, 2015Is there a conversion from DC microamps to AC microamps?
(reply)
jignesh panchal
Feb 01, 2015 -
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Hello sir
What is the difference between high voltage test and insulation resistance testAnd how class of equipment decide
(reply)
RODEL VALENCIA
Feb 08, 2015Dear Mr. Jignesh Parmar,
We have a new AC Hipot equipment for our instrument transformers 5kv, 15kv, 35kv.My question: Is there a table of all different voltages of transformer and thevoltages to apply to hipot transformer.(reply)
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Jonhny Magtulis
Jan 15, 2015Thanks alot for this very usefull idea
(reply)
Test On 110kV Power CableAfter Installation (2) | EEPDec 26, 2014
[…] The DC HV 25kV Tester, Model No. PGK 25 manufactured by BAUR Germany.The test is applied only to cables covered with conductive layer over outer sheath.(Read more about Hipo Testing) […]
(reply)
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Andhika
Dec 18, 2014Dear Mr.Jigner,
Nice info sir,
If i want to do DC Hipot testing for panel 6 kv, this panel contains cable 6 kV,VCB, Busbar, PT, CT, Surge Absorber, and etc.
Before perform hipot test for this panel, i’m open fuse on the PT and drawoff VCB. Surge absorber, CT, and busbar still connecting to cable.
is it right?
I gave 13,5 kV for 10 mins and the leakage current is 500ms. Is it cause by i’mnot disconnecting the surge absorber?(reply)
Seran raj.m
Apr 18, 2015Nice work for engineer to learn.
(reply)
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Aniel
Nov 26, 2014Neatly explained, step by step. Nice job .Keep it up Jigneshji
(reply)
mohamed
Nov 02, 2014Dear Jignesh,
Please send me the details for Lightining Arrestor testing method and for thecapacitor banks used in HV/MV ( 60KV/30KV) network and if you dont mind the allthe test that shall be done in commissionning phase for power transformer, GIS,and LV switchgear
thanks a lot
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(reply)
Bhadresh Patel
Oct 19, 2014Dear Jignesh,
Please send me the details for Lightining Arrestor testing method and the Earthresistance value for LA ( Used for building protection). Also is it possible tohave damage in Electrical lighting DB by lighting stricke or Surge form HT linesas we observed one HT fuse blown during lighting stricke and electrical burninghin LDB.(reply)
Shaukat Ali Khan
Sep 11, 2014 -
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JP, excellent! I had an Indian EE friend in America. He worked in Gujarat,Rajasthan, and Maharashtra states of India before coming to America for M.S inEE. A very nice friend of mine then in mid1990’s. I know how the hi-pot testworks and the setup. Please include the test equipment diagram in your paper. Also,I don’t see someone from your group side to be responding to the commentsput out by the readers? Why is that? Another things is that your query down belowlike 6 x three = ? That’s 6 is in digit and three non-digit, could bequestionable in some where down the line. It has to be all in digits, not?
(reply)
Hemant
Oct 26, 2014Shaukat Ali : 6 x Three types questions are to block spam programs imitatinghumans and flooding the website. Normally a spam is not supposed to recognize suchthing, and will not be able to proceed further.
(reply)
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James Mazarello
Aug 29, 2014Dear Jigu,
I want an insulation for instrumentation purpose from readily availableinsulation polymers that can be molded which has very low leakage in the rangeof femtoamps, I am basicaly interested in measuring current in that range,Operating voltage is in the range of 300Vdc to 1000v DC. what would be the besttest in this range and which insulation can be used.
(reply)
aimee
Jul 22, 2014Im curious to how you came up with the rule of thumb for the test voltage. Ilooked at the IEC spec and couldnt quite figure it out. please advise
(reply)
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chandrshekar.g
Jun 11, 2014
Dear sir,
pl send solar motar caulation excel sheat.
(reply)
Manuel Montiel
Jun 09, 2014Your article of hipot is very good and easy to digest, I would like to contactyou to ask some direction to solve an issue. We are seeing VSWR large spikes in
coaxial at 2.5 GHz and wonder if the standard concept of a hipot can be appliedby changing the frequency of the ac (60 GHz) to other frequency as the one of theVSWR, in the range of 2 – 8 GHz and if will be possible see the physicalissue (sparks) in the conductor or overlap of dielectric or the shield. Basedin our calculation we can correlate the periodicity in inches of the spikes
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(reply)
rahimi
Apr 14, 2014we have a cantractor and they wanna start this test according to iec60502-2standard but this standard talk about cable. i wanna know procedure of hipot testfor panel busbar
(reply)
rahimi
Apr 14, 2014hi,i have a question?
we want to start hipot test for panel busbar in sub station,how we do it? -
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(reply)
Himanshu Behera
Mar 29, 2014purpose of fault indication and advantages.
(reply)
Palwinder Singh
Jan 30, 2014If we use core balance current transformer for earth fault protection then dowe need to connect S2 terminal of CBCT to the ground terminal .Please send me somepictures of circuit diagrams of cbct +efr for earth fault protection.
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(reply)
AVINASH KUMAR
Jan 15, 2014this website is very very helpful to electricalengineers………………………
thank you,(reply)
How to Protect Capacitor Banks? |EEPSep 14, 2013
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[…] of a capacitor bank step. Overloads result in overheating whichhas an adverse effect on dielectric withstand and leads to premature capacitoraging. 2. Short CircuitA short-circuitis an internal or […]
(reply)
Inspection andTest Procedures for Metal-Enclosed Busways | EEPDec 22, 2012
[…] and phase-to-ground for one minute, in accordance with Table 100.1below.3. Perform a dielectric withstand voltage test on each busway,phase-to-ground with phases not under test grounded, in accordance with[…]
(reply)
The Good, The Bad and The Ugly CableInsulation | EEPOct 23, 2012
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[…] a Megger Insulation Tester.Current flowing through this resistanceis measured when performing a DC Hipot Test as shown in Figure 1.The combinedinductance (L), series resistance (RS), capacitance (C) and […]
(reply)
jayu
Nov 07, 2012i see this web site its amazing & very useful for electrical engineer
(reply)
How to locate underground faultson cable? | EEPAug 21, 2012
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[…] fault on two cablesA common approach to test cable and determineinsulation integrity is to use a Hi-pot test. In a hi-pot test, a DC voltage isapplied for 5 to 15 min. IEEE-400 specifies that the hi-pot […]
(reply)
Dielectric Strength Of InsulatorMaterials | EEPJun 14, 2012
[…] a localized ”puncture” of the insulating medium where the electronsflowed during breakdown. Dielectric strength comparison between materialsMaterial*Dielectric strength (kV/inch)Vacuum20Air20 to 75Porcelain40 […]
(reply)
Measurement of insulationresistance (IR) - Part 1 | EEPApr 28, 2012
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[…] IR Test are not intended to be useful in finding localized defectsin the insulation as in a true HIPOT test, but rather give information on the qualityof the bulk material used as the insulation.Even when […]
(reply)
Megger Insulation Resistance Test |EEPMar 13, 2012
[…] it should resist current and keep the current in its path along theconductor.To understand insulation testing you really don’t need to go into the
mathematics of electricity, but one simple equation – […]
(reply)
Maintenance Of SF6 Gas CircuitBreakers | EEP -
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Feb 24, 2012
[…] of the outstanding properties of SF6 making it desirable to use inpower applications are:High dielectric strengthUnique arc-quenchingabilityExcellent thermal stabilityGood thermal conductivityTopProperties Of SF6[…]
(reply)
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