Industrial Hipot Testers for High-Voltage Insulation Testing
Reliable dielectric withstand testing equipment designed for power transformers, switchgear, cables, and electrical machinery. Built with heavy-duty HV transformers and microprocessor-controlled tripping systems to ensure strict compliance with IEC, IEEE, and ASTM insulation standards.
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Product Series
AC Hipot Test Set (Dry-Type / Oil-Immersed / Inflatable)
Voltage Range: Up to 300 kV AC
Capacity: 5 kVA - 500 kVA
Primary Use: Standard factory acceptance testing (FAT) for distribution transformers, insulators, and switchgear.
AC/DC Dual-Output Hipot Tester
Voltage Range: Up to 300 kV AC / 400 kV DC
Capacity: 5 kVA - 100 kVA
Primary Use: Field insulation diagnostics for underground cables, DC power supply units, and capacitive loads.
Automated Microprocessor-Controlled Hipot Test Bench
Voltage Range: Customized per rating (10 kV - 500 kV)
Features: Automated voltage ramping, leakage current graph plotting, RS485/Modbus data integration, PLC remote control.
Primary Use: Automated transformer production lines and accredited third-party testing laboratories.
Technical Specifications
|
Specification Parameter |
Dry-Type AC Hipot Set |
Oil-Immersed AC/DC Set |
Automatic PLC Test System |
|
Output Voltage Range |
0 - 50 kV AC |
0 - 100 kV AC / 0 - 120 kV DC |
0 - 300 kV AC (Customizable) |
|
Rated Output Capacity |
5 kVA - 50 kVA |
10 kVA - 100 kVA |
20 kVA - 500 kVA |
|
Output Voltage Accuracy |
plus-minus 1.5% Full Scale |
plus-minus 1.0% Full Scale |
plus-minus 0.5% Full Scale |
|
Leakage Current Measurement Range |
0.1 mA - 500 mA |
0.1 mA - 1000 mA (DC) |
0.01 mA - 2000 mA |
|
Tripping Response Time |
less than 20 ms |
less than 15 ms |
less than 10 ms |
|
Output Waveform Distortion (THD) |
less than or equal to 3% (Resistive/Inductive); less than or equal to 1.5% for low-partial-discharge customized test benches. (Note: Capacitive load testing may require optional series damping reactors) |
less than or equal to 2.5% |
less than or equal to 1.5% |
|
Duty Cycle |
30 min ON / 15 min OFF (at max load) |
Continuous operation at 80% load |
Continuous heavy-duty |
|
Input Voltage Options |
220V / 380V / 415V (50/60 Hz) |
220V / 380V / 415V (50/60 Hz) |
380V / 480V 3-Phase |
|
Operating Temperature |
-10 degrees C to +50 degrees C |
-20 degrees C to +55 degrees C |
-10 degrees C to +50 degrees C |
Standards & Calibration
Design & Safety Compliance:
Built in accordance with IEC 60060-1 (High-voltage test techniques), IEC 60076 (Power transformers), and IEEE Std 4.
Calibration Traceability:
Every unit is supplied with a factory routine test report traceable to ISO/IEC 17025 accredited calibration standard laboratories.
afety Interlocks:
SPhysical zero-start protection (prevents HV energization unless the regulator is at zero position), emergency trip buttons, external safety cage contact loops, and automated grounding discharge rods for capacitive loads.
Applications
Power & Distribution Transformers:
Insulation integrity testing between primary/secondary windings and ground core during manufacturing and overhaul.
High-Voltage Switchgear & GIS:
Dielectric withstand verification across open contacts and busbar compartments.
Power Cables & Accessories:
High-voltage DC withstand testing and leakage current profiling on XLPE insulated cables.
Electrical Motors & Generators:
Stator winding insulation quality assurance for OEM production lines.
Configuration & Manufacturing Quality
Core Components & Dielectric Integrity: High-permeability cold-rolled silicon steel cores with optimized gradient winding structures. Dry-type units feature vacuum epoxy casting, while oil-immersed models undergo multi-stage vacuum degasification and oil filling to maintain partial discharge levels below 10 pC at rated voltage.
Control Console Modular Architecture: Digital display meter units separated from high-voltage step-up transformers via isolated control cabinets to guarantee operator safety.
Factory Testing & QC Inspection: Each hipot system undergoes 120% over-voltage endurance testing, short-circuit breakdown tripping tests, and thermal imaging checks prior to shipment.
Our Certificate
ISO9001, ISO14001, ISO45001
FAQ
Q: What capacity (kVA) rating do I need for my hipot testing application?
A: Required capacity depends directly on the test voltage (V) and the capacitive reactance (C) of the test object (I = 2 * pi * f * C * V). For example, testing long power cables or large transformers requires higher kVA due to large capacitive charging currents. Contact our engineering team with your specimen details to calculate exact kVA requirements.
Q: What is the difference between dry-type, oil-immersed, and SF6 gas-filled transformers?
A: Dry-type units utilize epoxy resin casting; they are lightweight and maintenance-free, ideal for field use up to 50 kV. Oil-immersed units offer superior heat dissipation and higher voltage limits (up to 300 kV+) for heavy factory testing. SF6 inflatable units provide compact size and high dielectric strength without oil contamination risks.
Q: Does the system include automatic over-current and zero-start protection?
A: Yes. The control console prevents high-voltage output startup if the voltage regulator is not at the zero position. Furthermore, if the specimen breaks down and leakage current exceeds the set threshold, the main circuit breaker trips within 10-20 milliseconds.
Q: Can the hipot tester perform both AC and DC insulation tests?
A: Our dual-output series includes a built-in high-voltage silicon rectifying stack. Switching between AC and DC output is managed either via a high-voltage selector rod or through terminal reconnects on the control panel.
Q: What documentation is supplied with the equipment?
A: Each unit ships with an Operating Manual, Factory Routine Test & Inspection Certificate, Schematics Wiring Diagram, and a Calibration Report. Third-party ISO/IEC 17025 calibration certificates are available upon request.
Q: What is the lead time for customized high-voltage hipot systems?
A: Standard dry-type and oil-immersed models (up to 50 kV / 10 kVA) ship within 7-10 business days. Custom engineering designs (above 100 kV, automated PLC test rigs, or multi-channel acquisition) typically require 3-4 weeks for manufacturing and factory testing.
Request a Technical Quote
Need a tailored hipot testing system for your production line or testing facility? Provide your testing parameters below, and our application engineers will send technical drawings and pricing within 24 hours.
Required Test Voltage (kV): [ AC / DC ]
Specimen Type: [ Transformer / Cable / Switchgear / Motor / Other ]
Power Supply Specification: [ Voltage / Frequency ]
Control System Preference: [ Manual Dial / PLC Touchscreen / Computer Automated ]
Contact Email: wang@transformer-test.com
Technical Support Line: +8616630291792
Factory Location: Mancheng District, Baoding City, China
Refine On (Hebei) Electric Power Technology Co., Ltd. is one of the most reliable hipot tester manufacturers and suppliers in China, also supports customized service. Please feel free to wholesale advanced hipot tester at competitive price from our factory. Contact us for quotation.
Smart DC Withstand Voltage Tester, Intelligent HV DC Test Set, Intelligent Digital DC Hipot Tester
