Hello safety colleagues, We are looking at some changes for End of Line dielectric test for a 240-V rated residential appliance - not medical! - for N. American residential applications. Interestingly, the appropriate UL standards detail test voltages and duration, are a bit vague about legal removal of solid state components "that are capable of being damaged" and absolutely silent on the level of allowable leakage current. I have looked at 3 different safety standards for north american products, and not one specifies a failure limit. This includes the main BESS/PV inverter standard, UL 1741, which is typically very precise. Past experience at an NRTL involved setting the HiPot to 5 or perhaps 10 mA for the test, but I can't remember what mandated the successful test level. My friendly AI bot a few weeks ago suggests 3.5 or 5 mA as allowable for residential appliances, but not what requirement(s) there may be apart from perhaps 60335. UL 60335 is not cited in any of the product safety standards that cover our current products. That same bot is now telling me 100 mA is allowed during dielectric withstand testing. So, if we can find a HiPot tester with 100mA or more capacity, we can speed up our production line by not having to remove Y-caps and/or MOVs, or go to the 1-second test levels, or both, and still get a base level check that a board's insulation system wasn't compromised during production or assembly. This brings up some interesting questions as we evaluate bringing up a new production line. - is there an actual requirement for the mA draw, or is it just what one can find in a hipot device? The testers we've bought & rented stop at 10 or 20 mA.- are there stated mA limits for dielectric breakdown detection? If the bot is right and 60335 is correct, what's the specific clause?- is there anything besides board level defects the dielectric test is supposed to catch?- could one include calculations for mA draw from a device's Y-caps and/or MOVs in an allowable EoL test plan, in case the inspector doesn't trust some chinese-made hipot with 200 mA capacity and asks us to justify a given limit? thanks all, stay safe. Colorado Brian
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