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December 16, 2017 GMT
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About Hi-Pot Testing

Caution: We make no claims as to the safety of any of our products for high-voltage use. These voltages can kill. Do not handle or approach any cable or conductor carrying high voltage; this includes insulated cables, nearby metal parts, water, and other conductive materials. Engineering and design for safety in your application are your responsibility. The hi-pot test results mentioned here are not an indicator of human, animal, or equipment safety around these cables when carrying high voltage.

We hi-pot (high voltage) test our cable assemblies for high-voltage breakdown between core and braid only. This is a QA test, not a safety certification. We do not test for high-voltage breakdown of the external insulating jacket, which is why these cables are not rated for safety at high voltages. Please contact us for the exact voltage we use when testing a particular cable and connector combination.

Background

High voltages in physics applications, high transmit power in radio, or composite materials, air-coupled scanning, and other high power domains in industrial ultrasound, can cause radio transmitters or NDT pulser-receiver equipment to drive cables in excess of 1000 volts. But the connectors made for small-diameter cable are typically designed and rated by manufacturers for as little as 30 volts. Too often the result is arcing, dielectric breakdown, poor signal performance, and in most cases an eventual total cable or connector failure, as carbon traces build up and cause a short between conductors. But entire industry segments use these low-voltage components anyway, often for historical reasons dating back to times when power demands were not as high.

In order to support these applications, we test to destruction when selecting suppliers and connector designs. During assembly, we use techniques and materials that we've evolved over time to greatly improve the voltage-carrying capacity of these parts. Before shipping, we test each and every cable assembly we build -- we don't simply pull a few out for an audit check. Even with this added cost in our manufacturing process, we still ship some of the least-expensive cables in the industry, and we're content knowing that these cables will perform reliably in the field.


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