Hi Brian:

Most hi-pot failures are clearances and sometimes
creepage distances and seldom solid insulation.  See
Joe Randolph's paper at the May PSES Symposium on
breakdown of ethernet connectors.

All breakdowns are due to the peak voltage, whether
ac or dc. The results are the same voltage (peak).

If ac, then the tester must have sufficient current
to drive the capacitance of the line filter.  The
minimum ac current is a multiple of the leakage
current, either 1x or 2x the voltage ratio between
the leakage current voltage and the hi-pot test
voltage.  (If the neutral was open during the
leakage current test, then 1x; if the neutral was
closed, then 2x.)

If dc, then the rate of rise, dV/dt, must be adjusted
to limit the line filter charging current to less than
the hi-pot current rating.

Failure is evidence of an arc, not necessarily a current
trip of the hi-pot tester.  An arc can occur, but not
trip the hi-pot tester.  Some hi-pot equipment includes
an arc detect circuit as sometimes the arc is difficult to
detect by a human.

If there is a breakdown, repeat the test with a higher
current to find the breakdown site.  Sometimes, components
must be removed one at a time repeating the hi-pot test to
find the breakdown site.


Rich

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