Bengaluru · Electrical safety testing
EV Battery Pack and Charger Hipot Testing in Bengaluru
Star Automations runs withstand and insulation resistance checks on EV battery packs, chargers and BMS or controller assemblies from our Bengaluru office. Every unit gets a test record with the voltage applied, the current limit, the duration and a pass or fail result.
Important: This is an in-house electrical safety test and test record service for pre-compliance, production and post-repair testing. It is not NABL-accredited testing, and it is not BIS or CE certification. Our records do not replace a certified laboratory's report. For accredited certification, please use a NABL- or BIS-recognised laboratory.
Why insulation checks matter on EV packs and chargers
An EV pack or charger carries high voltage close to metal enclosures, cooling parts and surfaces a user can touch. If the insulation between live parts and the chassis is weak, a functional test may not show it, but it can appear later as leakage or a safety trip. A withstand test and an insulation resistance (IR) reading check the insulation directly, before the pack or charger moves on to the next stage.
What we test
- Battery packs: positive and negative to the enclosure or chassis.
- Chargers: input and output to earth.
- BMS and controller boards: between isolated sections and to the chassis.
- Repeat batches: per-batch checks on later builds, logged unit by unit.
- Instrument range: AC to 5 kV, DC to 6 kV and insulation resistance to 1 kV.
Where this fits before AIS-156 or IS 17017 testing
AIS-156 and IS 17017 / IEC 61851-1 are named here only as context. Many teams run their own insulation checks before booking a slot at an accredited laboratory, to find problems early. The test voltage, current limit and time for your product come from your own specification or the standard you follow; we do not quote limits from those standards.
Handling and safety
The pack or charger is isolated and discharged before testing. Testing is done by trained staff in an interlocked area, with a discharge procedure after every test.
What we cannot do
- Type approval of a pack or charger.
- Thermal tests and cycling tests.
- Full AIS-156 certification. These need an accredited laboratory.
How it works
Sample intake
Send us the product type, quantity, test specification and the voltage and current limit you need. Ship samples to us or book an on-site visit in Bengaluru.
Test plan
We agree the test type (AC, DC, IR or a combination), voltage, current limit, duration and where to connect, in writing, before testing.
Test
Trained staff run the test with interlocks and a discharge procedure. Every unit is tested and logged individually.
Report
You receive a test record, with unit ID, applied voltage, current limit, duration, measured value and pass or fail.
What you receive
A test record (PDF) that lists, for each unit:
- Unit ID or serial number
- Test type (AC withstand, DC withstand, insulation resistance)
- Applied voltage and current limit
- Test duration
- Measured leakage current or insulation resistance
- Pass or fail
- Instrument model used, test date and operator name
Questions
Do you test EV battery packs and chargers?
We can run withstand and insulation resistance checks on EV battery packs, chargers and BMS or controller assemblies within the instrument range of 5 kV AC, 6 kV DC and 1 kV IR. Full type approval, thermal or cycling tests and AIS-156 certification need an accredited laboratory.
Is this AIS-156 certification?
No. We run in-house withstand and insulation resistance checks and issue a test record. We are not a NABL-accredited or BIS-recognised laboratory, and our records do not replace an accredited report. Use an accredited laboratory for AIS-156 or any certification you need.
What should I send for an EV pack or charger test?
Send the product type, quantity, the test specification and the voltage and current limit you need, on WhatsApp at +91 97866 22233 or through the form below. We agree a test plan with you before testing, then you ship samples or we arrange an on-site visit.
Get a test plan
Tell us what you need to test: product, quantity, standard or specification, voltage and current limit.
WhatsApp: +91 97866 22233. Website: www.starautomations.com. Address: 1st Floor, 40, Goshala Rd, Garudachar Palya, Mahadevapura, Bengaluru, Karnataka 560048.
Message received
Our team replies by email or WhatsApp. For urgent requests, WhatsApp +91 97866 22233.
Star Automations provides in-house safety testing and test records. We are not a NABL-accredited or BIS-recognised laboratory. Star Automations is an independent multi-brand repair company and is not an OEM service centre.