Insulation Resistance and Dielectric Withstanding Voltage Testing

8 月 21, 2023 CONNECTOR

That’s shocking! Insulation Resistance and Dielectric Withstanding Voltage are two of the qualification tests that Samtec performs in-house during part qualification testing.

These tests will ensure that when a connector is used in environmental conditions at the rated working voltage (de-rated from the test voltage) the product will not fail, and there will not be current leakage.

Insulation Resistance Testing

The purpose of the Insulation Resistance (IR) test is to determine the resistance of the insulation materials to leakage of current. This is measured on the surface while DC potential is applied at 500 VDC. 

There are several variables that can cause a part to fail prior to its calculated results; condensation on the part,  a crack in the body, and damage to the insulation.

Samtec tests it parts according to EIA-364-21 “Insulation Resistance Test Procedure for Electrical Connectors, Sockets, and Coaxial Contacts.”

Dielectric Withstanding Voltage Testing

The Dielectric Withstanding Voltage (DWV) test is intended to take into account momentary over potentials caused from switching, surges,and other phenomenon. This establishes the proper operation at a test voltage that is three times the rated working voltage of the system under the test. 

DWV is determined from the breakdown voltage (BDV) of a part (DWV = 0.75 x BDV). The BDV is the voltage where the part arcs across the metallic interface; think pin-to-pin or pin-to-hardware, and working voltage is = 1/3 x DWV or 0.25 x BDV.

For example: if the breakdown voltage is 1000 VAC the Test Voltage will be 750 VAC, and Working Voltage will be 250 VAC.  DWV is tested by applying the calculated test voltage for 60 seconds.  The part will pass if there is no indication of arcing. 

For DWV, Samtec uses EIA-364-20 “Withstanding Voltage Test Procedure for Electrical Connectors, Sockets, and Coaxial Contacts.”

Why test IR/DWV?

Bottom line, IR /DWV are part of determining a connector’s performance in varying conditions.  The test sequence for both IR/DWV involves using thermal shock and humidity cycling.  By testing under these conditions, Samtec is confident that its parts will perform in less than ideal environments.


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