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Dielectric Testing

Dielectric testing on batteries also known as high potential test, hipot test, or insulation test applies a high level of voltage to the insulation barrier and measure the reaction of the material to assess the insulation of electrical components, including batteries, by applying high voltage to them.  

Dielectric testing is important for ensuring the safety and reliability. It verifies that the insulation or battery cell barrier can withstand the transients that can occur during surge events, and that it has enough performance "headroom" to prevent failure due to aging, moisture, or vibration.  

During the dielectric test a high voltage is applied between the two conductors that are designed to be electrically insulated from each other. If the insulation is adequate, the voltage difference will not cause current to flow between the conductors.  The battery passes the  hipot or dielectric test if the current through it is less than a specified limit at the required test potential and time duration.  

In conducting the dielectric test, the Clark test team will prepare the battery and ensure it is in a stable condition and fully assembled charged as it would be during normal operation.  We utilize a high-voltage insulation tester to apply high voltage to the insulation and measure leakage current while adjusting the voltage settings and are essential for performing dielectric strength tests. 

A digital multimeter is sometimes used to take initial voltage and resistance measurements before the high-voltage test is performed. It can also measure leakage currents during the test.  The insulation resistance tester is used to measure the resistance of insulation materials. It can provide readings that indicate the quality of insulation before applying high voltage.  Finally, we use a clamp meter to measure leakage current without direct contact. It’s useful for monitoring currents in live circuits and ensuring safety during testing. 

The multimeter, resistance monitor, and clamp meter are monitored for key parameters including:   

  • Leakage current
  • Voltage levels 
  • Duration of the test 

Records of leakage currents and breakdown occurrences are maintained to evaluate the insulation's effectiveness.  After testing, the battery is inspected for any signs of damage, and the data collected is analyzed to assess insulation integrity and compliance with safety standards. 

“As one of the most experienced and capable battery test laboratories in the US, our customers recognize the Clark Battery Lab as a critical resource in their technical development and market advancements in battery technology. Partner with Clark Testing to ensure your products meet the highest safety and performance standards.”

Paul Heffernan