ARS Highpot Testing

21 Mar ARS Highpot Testing

How to Test Cables:  Location is Only Half the Story!
By Rich Weinberg
Senior Electronics Designer
American Rheinmetall Systems

It goes without saying that a cable assembly needs to be checked for continuity and shorts, however checking for conductors in the right place, and not in the wrong place is only half the story. All cables should be tested for “leakage” as an indicator of manufacture quality. During High Potential, or “Hipot” testing, each conductor of a cable assembly is raised to a high voltage or potential for a specified period of time (Dwell) while the rest of the conductors are kept at ground potential. The flow of current is measured from the high voltage source to ground. In a production environment, “Dielectric Withstand Testing” as described here is most commonly used. Because this method measures the leakage current at a potential less than the expected breakdown voltage, it will not shorten the life of the cable assembly. Withstand Test will indicate failures for, assembly defects, contamination, insulation damage, spacing, tolerance, or moisture problems.

Example: For low voltage systems, Hi Pot testing at 300V Peak AC/DC is typical, dwell times vary from 100 to 1000mS depending on the cable.

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About American Rheinmetall Systems

American Rheinmetall Systems (ARS) was established under the name of Vingtech in January 2007. Since June 2010 the company has been a member of the Rheinmetall group and forms part of the Mission Equipment business unit.  American Rheinmetall Systems is a mechanical and electro-optical engineering company specializing in sophisticated system integration, assembly and R&D, working in close cooperation with customers worldwide. The company is a key sub-supplier to Kongsberg for the US Army’s CROWS II remote weapon station program, producing mounts, firing mechanisms and video imaging modules, and is currently under contract for multiple fire control programs supporting the US military. For more information, visit

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