Electrical Safety & Compliance Testing

High-voltage testers are an integral part of the manufacturing process for electrical and electronic equipment. High-voltage testers get their name from the high potential (high voltage) they generate to perform dielectric strength and insulation resistance tests. For these tests, high-voltage testers offer advanced performance and accurate measurements with low-impedance and low-impedance/high-current outputs.

HiPot Testing of Military/Aerospace Interconnect Components

Electrical safety and compliance testing is essential for consumer, industrial, and avionics product testing. These tests directly address “product safety,” as defined by UL and international safety organizations. In addition to the necessary safety tests on the equipment itself, the cables and connections used also deserve special attention. See the image below.

Operational performance and safety are of the utmost importance in determining the acceptability of a range of cable and connector products in military and aerospace applications. Connectors and relays, wires, and wires bundled into cables and harnesses must all be tested according to strict standards. These tests take on added significance, as product failures can be costly, if not fatal.

The range of tests and standards pertaining to wiring, cabling, and connectors in military and aerospace applications is quite extensive. Below is a selection of these standards:

Wires: MIL-STD-2223 – Electrical Tests – Class 3000

  • Test 3001 – Spark Test of primary insulation
  • Test 3002 – Impulse Dielectric
  • Test 3003 – Insulation Resistance
  • Test 3004 – Surface Resistance
  • Test 3005 – Wet Dielectric

Connectors

The scope and complexity of connector standards are simply beyond the scope of this article. Here is a brief overview of these proposals, each focused on a specific type.

  • MIL-DTL-5055 – Circular with solderable or crimpled contacts
  • MIL-DTL-12520 – Centerlock screw coupling, waterproof,  polarized multi-contact
  • MIL-DTL-22292 – Multi-contact, heavy-duty, quick  disconnect electrical plug/receptacle
  • MIL-DTL-24308 – Polarized shell, miniature, rack and panel
  • MIL-DTL-26482 – Environmental resisting, quick disconnect,  miniature, circular
  • MIL-DTL-32139 – Nanominiature
  • MIL-DTL-38999 – Miniature, circular, high density, bayonet,  threaded or breach couling

Electrical safety test equipment is used to perform the series of prescribed tests covered in this document and is required to carry out one or more of the following test procedures:

  • Spark/Arc Testing
  • Dielectric Withstand (AC or DC)
  • Insulation Resistance/Leakage
  • Ground Continuity
  • Ground Bond

The advanced features of the high-voltage testers are particularly important when testing compliance with civil, military, and aerospace regulations related to avionics.

The advanced electrical safety testers described in this article are necessary for the reliable execution of many of these complex test sequences.

The test equipment can be configured to quickly handle a variety of test setups. It generates high voltages and currents and accurately measures test results, including very high and very low impedances and leakage currents.

TT&MS BV provides consulting services and supplies leading-edge test and measurement equipment for aerospace testing solutions, including specialized AC power supplies for generating and simulating various on-board power supplies in accordance with the required specifications.

For more information, please visit the following pages:

  1. Aerospace, electrical testing solutions
  2. Commercial and military standards
  3. Key electrical tests in the aerospace industry
  4. AC power supplies for avionics applications
  5. 270 VDC in avionics
  6. APS4000 Simulation Software for Aerospace Power Systems
  7. Electrical Safety & Compliance Testing

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