HIOKI BT5525 Battery Insulation Tester – High-Speed, Reliable Testing

Overview

The HIOKI BT5525 is engineered to meet the rigorous demands of modern battery cell and module production lines. Prior to electrolyte filling, battery cells must be checked for insulation defects—including minute, latent defects caused by contamination or internal shorting—which if unchecked, can degrade performance or even cause safety hazards. The BT5525 provides reliable, repeatable insulation resistance testing with several specialized functions (such as BDD and contact check) that help detect these defects early, reduce false negatives or false positives, and increase line throughput. With its high-voltage capability (up to 500 V), fast charge/discharge, and multiple interface options, it can be embedded into automated test systems or operated stand-alone as required.

Key Features

• Break-Down Detect (BDD) Function: Proprietary detection of tiny internal short circuits caused by contamination (metal particles etc.), even before the cell is filled with electrolyte. Helps prevent latent defects that can lead to heating or fire.

• Contact Check Function: Ensures measurement leads/electrodes are properly connected by measuring stray capacitance and capacitance of the DUT (device under test), reducing measurement errors due to poor contacts.

• High Test Voltage Range: 25 V to 500 V, adjustable in 1 V steps, enabling testing across a wide variety of battery types and modules.

• Fast Charging / Discharging: Up to 50 mA charging current; ≥ 40 mA discharge current for rapid removal of residual charge. Compared to older models (e.g. ST5520), charging speed ~25× and discharging ~4× faster.

• Stable under Noisy Conditions: Designed to reduce influence from external noise, enabling accurate measurements in industrial environments.

• Wide Resistance Range: From 0.050 MΩ up to 9999 MΩ, with multiple auto/manual ranges (2 MΩ, 20 MΩ, 200 MΩ, 2000 MΩ, AUTO) to suit different insulation levels.

• Memory & Data Features: Stores up to 15 sets of test condition presets; up to 999 measured values in internal memory. Export via USB/LAN/RS-232C. PC-application support for waveform viewing; CSV export.

Applications

• Pre-electrolyte filling inspection of battery cells to detect insulation defects and contaminants.

• Insulation testing between electrodes and enclosure in battery modules / packs.

• Inline or end-of-line quality control in Li-ion battery manufacturing, EV battery pack assembly.

• Integration into automated test systems, production lines, PLC-controlled environments.

• Situations where measurement reliability in noisy electrical environments is critical.

Technical Specifications

Here is a specification table summarizing all the verified parameters:

Package Contents

Typically, the BT5525 package includes:

• BT5525 Main Unit (Battery Insulation Tester)

• Power cord

• EXT.-I/O male connector

• EXT.-I/O connector cover

• Interlock cancellation jig (for safety/producing environments)

• Startup guide / User manual

Optional accessories / cables:

• RS-232C communication cable (9-pin to 9-pin) (~1.8 m)

• Output lead L9094 (banana type, ~1.5 m)

• High test lead (clamp / banana / coax etc.)

• Low test lead likewise

• PC application software for waveform viewing & CSV export

Call to Action

Don’t let latent insulation defects compromise your battery product’s performance or safety. Order the HIOKI BT5525 today — enhance your production line’s QA, reduce rejects, and protect end-users. Contact us for pricing, lead time, or to arrange a demo.

【FAQ】

以下是可用于 Rank Math FAQ Schema 的问答：

1. Q：What is the maximum test voltage of the BT5525?
   A： The BT5525 supports output test voltage from 25 V up to 500 V, with 1-V resolution. Q：What is the BDD function in BT5525 and why is it important?
   A： BDD (Break-Down Detect) is a function that detects tiny internal short circuits caused by contamination (e.g. metal particles), even before electrolyte filling. It helps prevent defects that could lead to fires or premature battery failure.

2. Q：How fast can BT5525 charge/discharge for testing?
   A： The device can charge at up to 50 mA, and discharge residual charge at ≥ 40 mA, significantly faster than previous models (≈25× faster charging, ≈4× faster discharging vs Hioki ST5520).

3. Q：What interfaces does BT5525 provide for automation or data export?
   A： Standard interfaces include USB, LAN, RS-232C, and EXT. I/O. It also supports PC-application with waveform viewing and CSV data export.

4. Q：What are the dimensions and weight of the BT5525?
   A： The unit measures approximately 215 × 80 × 306.5 mm and weighs about 2.8 kg.