High Voltage (HiPot) Cable & Harness Testers CableEye ® HVX ...

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High Voltage (HiPot) Test Parameters

This control screen sets the desired test types, voltages, and limits, and holds default values when you learn or enter a new cable. You may override these default values with custom values unique to that cable and store any changed settings with the cable in the database.

Select the test you wish to perform, and set the voltage and current limits as desired. Test voltage may be adjusted from 10V in 1V increments to the model's maximum voltage:  Vdc and  Vac for HVX, and  Vdc and  Vac for HVX-21.

The current may be adjusted from 5µA (ac/dc) to 3.3mA, and the isolation threshold set up to 1GΩ (HVX), 5GΩ (HVX-21). Choose the lowest trip current possible for cable under test to minimize insulation damage in the event of dielectric failure.

The Ramp times specify how fast the test voltage is reached when starting a test and how fast the cable is discharged when the test finishes. This may be adjusted between 150 V/s to  V/s. Smaller ramp rates are needed for assemblies that exhibit high capacitance.

Choose the test frequency to correspond with the power line frequency under which the cable will be operated.

Electrically Testing Long Cables
Learn how parasitic capacitance can affect your safety and the accuracy of your results when testing cables longer than 10ft. Click to read.

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Safety & Electromagnetic Compatibilty

The HVX System has undergone a rigorous series of tests at the Littleton, Massachusetts laboratory of Curtis-Straus, a division of Bureau Veritas, to confirm our product meets the safety and electromagnetic compatibility standards for the CE Mark. This certification is required on any electronic equipment imported into the European Union. In addition to satisfying requirements for the CE mark, customers using the HVX system can feel secure in knowing that this equipment was thoroughly reviewed and tested by engineers in an independent lab and found to meet all applicable standards.

Safety testing ensures that the design complies with regulations governing 120V/240Vac power distribution inside the equipment to adequately protect operators from electric shock under various operating conditions, and that in the event of a component failure or internal electrical short, the system will automatically shut down by fusing or other means, and will not create a fire hazard. Part of this testing involved shock testing. This consisted of dropping a 0.5 kG steel ball from a height of 1 meter onto the case during operation, applying a similar force to the unpowered power jack, and dropping the tester on each corner of the case. Other tests involved placing it in a 97% relative humidity environment to see if internal shorts were created, checking the Lexan labels applied to the case to be sure they did not burn, measuring leakage current from the DC power supplies, and installing 60 temperature probes inside the equipment to monitor internal temperature during operation.

Because of the hazardous voltages produced by this equipment, the lab required additional testing to ensure that, in the event a short developed on the high voltage board, the system would immediately shut down without creating an electric shock or fire hazard. They accomplished this by intentionally introducing a short on the board during high voltage operation and monitoring the response. Also, because our high voltage board uses a custom-designed transformer to generate the AC test voltage, they needed to disassemble one of these transformers to confirm that the firm who built it allowed adequate spacing and insulation.

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Electromagnetic compatibility testing ensures that the HVX tester does not emit interfering levels of electrical noise that might affect other equipment, and that the system will not be adversely affected by environmental electrical noise, conducted electrical noise through the power lines, or electrostatic discharge.

To prove that the system did not emit noise above the allowed limit, the test lab placed it in a sealed room and slowly rotated it in front of a sensitive antenna while it performed a high voltage test. Immunity testing involved focusing a radio beam at the unit, also on a rotating table, while a transmitter swept through a wide range of frequencies as the unit was performing a high voltage test. The unit must run its test to completion without interruption to pass this test.

Electrostatic discharge (ESD) testing posed the greatest risk to the equipment. For this test, the test lab used a special ESD simulator "gun" to apply +/– 4kV discharges to the case, switches, control panel, USB cable, and other places all over the equipment while the HVX performed a test to confirm that the system would not stop functioning given these environmental insults.

CableEye® Testers: Environmental, EMC, & Safety Specifications
A reference document. Click to read.

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