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INSULATION TESTING

Invisible insulation boundaries
must be proven with measurable evidence

From cell, module, pack, and rack to the system DC/AC boundary, verify insulation partitions, creepage, clearance, insulation resistance, dielectric withstand, leakage current, protective earthing, and safe discharge layer by layer.

Insulation is not a single-point test, but a complete boundary covering materials, structures, interfaces, testing and human security.

01 Insulation zoning map

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2
3
4
5
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7
Regional ① Cell ② Module ③ Pack ④ Rack ⑤ DC Bus ⑥ PCS DC/AC ⑦ Enclosure / PE
Working voltage 3.2–3.6 VDC 12.8–57.6 VDC 102.4–921.6 VDC 1075.2 VDC 1075.2 VDC 1075.2 VDC / 400VAC —
Insulation system Dust / flame retardation PET / frame / insulation Insulation / Shell Busbar insulation / mica Busbar support / insulation DC/AC isolation structure Paint / Ground Structure
Test Record Cell-shell. Module - Shell Pack - Shell Rack–Frame DC+/- → PE DC → AC / PE Shell PE
Authentication Properties ● ● ● ● ● ● ●
Insulation layers / boundaries HV path / busbar PE / level connection Signal / monitoring boundary
Cell: The working voltage of single-body cores is approximately 3.2-3.6 V, with a focus on control of the basic insulation boundary between the electrocrusts, polar columns and sampling interfaces.

02 Climbing the distance and the electrical gap 64 / 64 VERIFIED

Busbar and enclosure Clearance 8.0 mm
Creepage 10.0 mm
Busbar insulation support Clearance 8.0 mm
Creepage 8.0 mm
Service isolation switch Clearance 6.0 mm
Creepage 6.0 mm
Cable Header Clearance 8.0 mm
Creepage 8.0 mm
High pressure end row Clearance 6.0 mm
Creepage 8.0 mm
PCB/ Interface Local spacing and material rules
Validate by Design
Basis Busbar / enclosure Busbar support Switches Seal Head Port platoon
IEC 60664-1 ✓ ✓ ✓ ✓ ✓
Minimal Electrology Distance 10.0 mm 8.0 mm 6.0 mm 8.0 mm 8.0 mm
Minimum electrical gap 8.0 mm 8.0 mm 4.0 mm 6.0 mm 6.0 mm
Number of validation points 12 8 10 14 20
Busbar and enclosure: From HV busbar to grounded metal structure, check both clearance and creepage along insulation surfaces; each must meet its requirement.

03 Fifteen-rack and system-branch insulation scan

Rack-Frame Request ≥500 MΩ @1000VDC Minimal: 1.10 G
DC Bus-PE request ≥500 MΩ @1000VDC System result: 820 M

Controlled anomaly: R07 terminal area moisture ingress; low insulation reading

Initial Insulation 160 MΩ Process Clean / Dry / Revertend Repeated results >1.00 GΩ · PASS Scope of impact Rack R07 NCR TC-DEMO-NCR-2608-0096 · CLOSED

04 Dielectric withstand test sequence

05 Protective earthing and insulation monitoring

Protective earthing point continuity 48 / 48 Max. Connection resistance. 36 mΩ Conclusions PASS
IMD-100
DC+
DC-
PE
Injected insulation resistance 100 kΩ
Measurement results 96 kΩ
Alarm threshold 100 kΩ
Response Time 420 ms
Status PASS
Action logic: Insulation decline → alarm raised → control commands restricted → contactors must not re-close until insulation recovers and reset criteria are met.

06 Safe discharge and entry permit

Permission status: SAFE TO ENTER

07 Dielectric evidence map

Request / Object Insulated border Test Configuration Instruments Original Wave / Data Result Audit
Design insulation boundary System partition/ voltage level Design baseline — 64/64 VERIFIED
✓
Rack and Frame 15 Rack / DC Bus 1000 VDC IR Test IRM-1000 15/15 PASS
✓
DC Bus Insulation System DC-PE 1000 VDC IRM-1000 820 MΩ PASS
✓
PCS AC/DC Pressure Resuscitation DC/AC segregation 2500 VDC / 60 s HVT-2500 PASS
✓
PE continuity Shell PE point ≤200 mΩ MET-1600 48/48 PASS
✓
Insulation monitoring IMD-100 100 k injections. IMD-100 420 ms PASS
✓
Safe discharge record. DC-Link The discharge curve HVT-2500 <60V / 42s
✓
Witness log HVT-01 Area Controlled license System Log VALID
✓
Calibration records All instruments Calibration duration Calibration Certificate VALID
✓
NCR Closed R07's in shock. NCR-2608-0096 — CLOSED
✓
Insulation zone design: Design baseline first defines insulation boundaries among cell, module, pack, rack, DC bus, PCS, and PE, then validates layer by layer through testing.
✓
Insulation boundary verification status DIELECTRIC BOUNDARY VERIFIED
Insulation partitions, climbing distance, electrical gapes, secondary insulation, stress tolerance, leaking currents, PE continuity, insulation monitoring and safe discharge evidence have all been closed. The current state only proves that a safe boundary between the insulation and the insulation is in place, and allows access to the subsequent controlled system;

09 Standards and norms Insulation test engineering background

60664 IEC 60664-1 Low-pressure system equipment insulation, climbing distance and electrical gap base.
62477 IEC 62477-1 Security and insulation background for electrical electronic transformation systems.
60204 IEC 60204-1 Mechanical and electrical equipment protection, safe circuits and electrical safety requirements.
61557 IEC 61557 (c) The background of the equipment for testing and monitoring the protective measures of the low voltage distribution system.
UL UL 9540 Energy Storage Systems Product Integration and System Security Assessment Background.
INT Internal dielectric specification TIANCHU insulation, stress tolerance, safe discharge and high-pressure area operating specifications.
Engineering principles: The insulation test proved to be insulation, the stress-resilient test tested was insulation, the PE continuity confirmed failure of current safety pathways, the online insulation monitoring verified insulation degradation detection in operation; the four had different purposes and could not replace each other.