High Potential Testing: Achieve Accurate, Reliable Dielectric Testing with Reed Relays

Ensure safety, reliability, and performance in high-voltage testing applications

Hipot testing verifies the effectiveness of insulation in electrical products and systems. It includes two related methods: dielectric breakdown testing, which raises voltage until failure to establish true limits, and dielectric withstand (Hipot) testing, which applies a defined overvoltage and confirms leakage remains within safe limits. Both require accurate low-current measurement while applying high voltage, and both are influenced by real-world insulation choices and ageing factors such as temperature, humidity, dust, chemicals, flexing and thermal cycling.

High-voltage reed relays are a natural fit for this environment. Hermetically sealed contacts in an inert atmosphere or near-vacuum avoid the oxidation and contamination issues that affect open-air electromechanical relays. Compared with solid-state switches, reed relays offer very low leakage thanks to high insulation resistance and careful pin spacing, along with stable contact resistance and fast operate times that support repeatable test results.

As the graph below shows, leakage currents in electromechanical relays (EMRs) and solid-state relays (SSRs) rise quickly as voltage increases, often reaching the microamp range. By contrast, reed relays — and particularly Pickering’s high insulation resistance designs — maintain leakage in the sub-nanoamp region even at kilovolt levels. This stability is critical for producing reliable Hipot test results across dielectric withstand and breakdown methods.

Finding this guide interesting?

Download the full guide now to learn more about utilizing reed relays in Hipot Testing applications.

What you’ll learn in this guide:

High Potential Testing
Insulation: Its Role & Testing
Why High Voltage Reed Relays Outperform EMRs and SSRs
Reed Relay Terminology
Recommended Products for Demanding Hipot Testers
Why Pickering Electronics for Reed Relays?

Why read the guide?

This application guide not only explains the theory behind dielectric testing but also gives you practical insight into how the right reed relay can improve test accuracy, reduce leakage, and deliver long-term reliability. Whether you’re working in semiconductor test, EV charging, solar, or medical electronics, this resource will help you design safer, more effective systems.

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