High-voltage hipot tester

electrical conformity

Overview
Sensors manufactured for electrical applications require end-of-line insulation testing. This water-bath hipot test system performs full-immersion dielectric tests to verify casing insulation for position sensors across protection classes I, II and III.

Industry
electrical / electrotechnical industry

Task
The customer needed an automated, highly flexible test system able to handle more than 100 product variants and increasing volumes. The system had to allow multiple DUTs per loading operation and guarantee 100% verification of housing insulation by testing in a water bath.

Solution
A high-voltage test system with an adjustable-depth water bath was developed. Products are fully tested by immersion; immersion depth is precisely adjustable with a stepper motor to cover existing and future variants. Automatic water-level control and a recirculation pump with UV clarifier reduce contamination. A light curtain provides safety. Up to four DUTs mounted on pneumatic line terminals can be tested simultaneously. Integrated drying is performed via a dedicated air-vent system. The PC-based test system stores an unlimited number of test programs; customers can create and assign programs per product. Test results are logged automatically in XML or Access format to a network location. A separate test dummy enforces a mandatory automatic system check at daily start-up; the system blocks further testing if the dummy test fails.

Benefits

• Turnkey solution including DUT support, adaptation and workplace layout
• Simple, intuitive operation for semiskilled personnel
• DUT connected once; full test sequence runs automatically
• Network operation: automatic storage of test data to specified location/database
• Long service life and service-friendly design
• All parameters and settings adjustable via software
• Automatic dummy test for daily verification
• Workplace safety compliant with EN 50191
• High flexibility for test scope and DUT variants
• Simple handling, mounting and multiple testing capability

Technical characteristics / specifications

• Hipot AC range: 500 V AC to 5,500 V AC; trip current: 0.1 mA to 100 mA
• Hipot DC range: 1 V DC to 6,000 V DC; trip current: 0.1 mA to 100 mA
• Testing method: full immersion in adjustable-depth water bath (stepper motor control)
• Water management: automatic water-level regulation, recirculation pump, UV clarifier
• Concurrent testing: up to 4 DUTs simultaneously on pneumatic line terminals
• Drying: integrated drying via dedicated air-vent system
• Safety: light curtain and workplace protection per EN 50191
• Software: unlimited test programs stored on test system PC; program assignment per product list
• Data logging: automatic storage of test results in XML or Access format to network locations
• Quality assurance: mandatory automated dummy test before production testing