Understanding Insulation Resistance Testing Why have an insulation testing program? A tegular program of testing insulation resistance is strongly recommended to prevent electrical shocks, assure safely of personnel and to reduce or eliminate down time. I helps to detect deterioration of insulation in order to schedule repair ‘work such as: vacuum cleaning, steam cleaning, drying and rewinding. Itis also helpful when evaluating the quality of the repairs before the equipment is put back into operation What causes insulation fallure? ‘Some of the more common causes of insulation failure include: excessive heat or cold, moisture, dit, corrosive ‘vapors, oil, vibration, aging and nicked wiring, What tests are used to detect insulation deterioration? There are numerous maintenance tess for assossing insulation qualty. The three tests discussed here are used primarily to test motor, generator and transformer insulation, What equipment is necessary for conducting Insulation resistance tests? + Megohmmeter with a timed test function + Temperature indicator + Humidity metor (not necessary i equipment temperature is above the dew point) Test Currents in Insulation Total current inthe body of the insulation is the sum of three components + Capacitance Charging Current + Absorption Current + Leakage or Conduction Current Test Gurrente Tasulation One Line Diagram © = Represents charging eurent Ra = Represents k absorption oevarrace current RL = Represents nL volumetric TUAEMG" Technical Assstance (600) 343-139 Insulation Resistance Readings Readings are ime dependent + al the start, capacitance is whal you see frst + at or about one minute, absorption + at 10 minutes, reading is mainly leakage current ‘These changing readings are best seen with analog bargraphs on cigital instruments or needle movement (on analog instruments. Spot Reading Test Method For this test, the megohmmeter is connected across the insulation of the windings of the machine being tested, ‘test voltage is applied for a fixed period of time, usually 60 seconds and a reading is taken. The spot reading test ‘should only be carried out when the winding temperature is ‘above the dew point. The operator should make a note of the winding temperature, so that it wll be possible to correct the reading to a base temperature of 20°C. Test Duration ‘To obtain comparable results, tests must be ofthe same duration. Usually the reading is taxen after 60 seconds, Interpretation of Results Proper interpretation of spot reading tests requires access to records of results from previous spot reading tests. For Conclusive results, only use results from tests performed at the same test voltage for the same amount of time, and under similar temperature and humidity conditions. These readings ‘are used to plot a curve of the history of insulation resistance. ‘Acurve showing a downward trend usually indicates a loss of insulation resistance due to unfavorable conditions such as: humidity, dust accumulation, ete. A very sharp drop indicates ‘an insulation failure. See Figure 1 nlestng tel Reine eth 0 Ri 2 ToreExample ofthe variation of ineultonresitance over «period of yre: ‘8, to sharp drop nests an incl fare ‘AG. the meuntonrecctance vue aor te motor hasbeen ren. (1) Dew pot tmpoature i te temperature at whch te mature waporin the at condenses as 2 gu Time-Resistance Testing Method This method is fairly independent of temperature and often can give you conclusive information without records of past tests. Itis based on the absorption effect of good insulation Compared to that of moist or contaminated insulation. ‘Simply take successive readings at spectfic times and note the differences in readings (see curves, Figure 2). Tasts by this method are sometimes referred to as absorption tests, Good insulation shows a continual increase in resistance (see curve D) over a period of time (in the order of 5 to 10 minutes), Ths is caused by the absorption; good insulation shows this charge effect over a time period much longer that the time required to charge the capacitance of the insulation, It the insulation contains moisture or contaminants, the absorption effect is masked by a high leakage current which stays at a fay constant value ~ keeping the resist- ance reading low (R = Ei) (see curve E} The time-resistance testing is of value because i is independent of equipment size. The increase in resistance for clean and dry insulation occurs in the same manner whether a motor is large or small. You can compare several motors and establish standards for new ones, regardless of their horsepower ratings. Figure 2 shows how a 60-second test would appear for good {and bad insulation, When the insulation isin good shape, the 60-second reading is higher thal the 30-second reading, Aturther advantage of this two reading testis that it gives ‘you a clearer picture, even when a “spot reading" says the insulation looks ok. Time-resistance tests on large rotating electrical machinery = especially With high operating voltage - requice high insulation resistance ranges and a very constant test volage. GuAEMG’ FAEIVIG | Technica Assstance (600) aaa-1397 ‘Aheavy-duty megohmmeter serves this need. Similarly, such an instrument is better adapted for cables, bushings, transformers, and switchgear in the heavier-duty sizes. ‘Test Methods —Time-Resistant Tests Dielectric Absorption Ratio (DAR) + The ratio of 60 seconds/30 seconds + lass than 1 = failed + 1.00 1.25 = 0K + 14a 1.6 = excellent Note: This isnot a commonly used test Step Voltage Test Method In this tet, the operator applies two or more test voltages in ‘stops. The recommended rato forthe test voltage stops is 110 6. At each step, test voltage should be applied for the same length of time, usually 60 seconds. The application of increased voltage creates electrical stresses on internal insulation cracks. This can reveal aging and physical damage ‘even in relatively dry and clean insulation which would not have been apparent at lower voltages, ‘Test Duration A.sories of "stops," each stop lasting 60 seconds. Interpretation of Results ‘Compare the readings taken at diferent voltage levels, laok- ing for any excessive reduction in insulation resistance values at the higher voltage levels. Insulation that is thoroughly dry, clean, and without physical damage should provide roughiy the same resistance values despite changes in test voltage levels. If resistance values decrease substantially when tested at higher voltage levels, his should serve as a warming that insulation qualty may be deteriorating due to dit, moisture, cracking, aging, et. Polarization Index (Pl) = 10-minute reading, ‘eminute reading ‘The IEEE Std 43-2000 lists the following minimum values for the polarization index for AC and DC rotating machines: Class B:20 Class C:2.0 Class A: 15 Pure 2 Absorption curve of tat conducted on 350 HP Motor: Cure Dinseatae 8 ‘200 insuaon wih an excelent polaraton index of. Cure Eindeatos 2 potential problem The poazaion nex aly Ma, a 147. (2)IEEE St 48-200, "Recommended Practe fo Test nelton Resistance o Retaing Machine?” Avalable forthe Insitute of let and ning elit Reitace Teta a 206 Re BaleBetore and ater ropa: ‘Care F shows 4 dounvad trad ofieuton restace ates a he et volage sineressed. Tis inate 2 potent rien nh the relation Curve stews the same equpment afer it hs ben repaired Utilizing the Guard Terminal “The guard terial is useful when measuring very high resistance values ‘Tho guard terminal isuseful when measuring vaty Conguctor Islaton Shes Expnng high resistance e Shite values, aa, ‘What test voltage should | use? There are two schools of thought regarding the voltage to test insulation at. The first applies to new equipment or cable andi can use AC or DC test voltages. When AC voltage is used, the rule of thumb is 2 x nameplate voltage + 1000, When DC voltage is used (most common on ‘megohmmeters manufactured today) the rule of thumb is simply 2 x nameplate voltage except when higher votlages are used, See chart below for suggested values. Equipment/Cable Rating De Test Voltage 2410 50V '50 to 100V0e 50 to 100V 100 to 250V0e 100 to 240 250 to 500VDe 420 to 550V 500 to 10000 2400V 1000 to 2500V0e 4100¥ 1000 to 5000VDe It'is always advisable to contact the orginal equipment manufacturer to gat their commendation for the proper ‘voltage to use when testing their equipment TUAEMG" NSTRUMENTS Technical Assistance (800) 348-129) ‘Advantages of DC Testing + Lighter size and weight of test equipment + Non-destructve + Historical data can be compiled ‘Transformer Testing “Transformers a tested ator abeve tho rated voltage to be cerain hare are no excessive leakage path to ound tr between windings: These ae conducted with Ye transformer completely discomected fom the ie and foad: However the cage ground should not be removed Single-Phase Transformer ‘Tho following 5 tasts and corresponding wiring diagrams will completely test a single-phase transformer. Allow at least 1 minute for each test or until the reading stabilizes. 1 High voltage winding to low voltage winding and ground ». Low voltage winding to high voltage winding and ‘ground ©. High vottage winding to low voltage winding 4. High voltage winding to ground 2. Low voltage winding to ground ‘Three-Phase Transtormor ‘The following 5 tests and corresponding wiring diagrams will completely test a three-phase transformer. {a High voltage winding to low voltage winding and ground ». High voltage winding to ground with low voltage winding to guard ©. High vottage winding to low voltage winding 4. Low voltage winding to ground and high voltage winding to guard «©. High vottage winding to low voltage windingSingle-Phase Transformer Three-Phase Transformer $= Ean Terminal = = Line Terminal G= Guard Terminal, uAemc” iat tl Pte To 28 Re 2 iisrruments Tachnical Assistance (600) 2a-1397 aer6Cable Testing Transformers are tested at or above the rated voltage to be certain there are no excessive leakage paths to ground or between windings. These are conducted with the transformer completely disconnected from the line and load. However, the case ground should not be removed. Single Conductor Connect as shown in the diagram € Conductor to Line (-) terminal and sheath to Earth (+) Multi: Conductor 2. Single conductor b.One conductor to all ©. One conductor to earth 1d, One conductor to others minus ground Motor and Generator Testing Boore testing the above lit the rotor brushes, ground the saror terminal and frame and ground the motor shat. Discharge the field winding by grounding. Then remove the field winding from ground and connect to the () Line ‘connection on the megohmmeter. Connect the (+) Earth terminal to ground. The diagram shows the connection for testing the field insulation resistance. The stator winding may also be measured in a similar manner. = xe Terminal G= cues Temas DAM? eo 162002 Chauvin Amu, ne. dia. AEM nsturents BoleJ AEMG" INSTRUMENTS, [HRUVIM ARNOUX GROUP ss Contact Us United States & Canada: Chauvin Amoux*, Inc. d.b.a, AEMC® Instruments 200 Foxborough Blvd. Foxborough, MA 02035 USA (508) 698-2115 - Fax (508) 698-2118 www.aeme.com Customer Support - for placing an order, obtaining price & delivery: [email protected] Sales Department - for general sales information: [email protected] Repair and Calibration Service — for information on repair & calibration, obtaining a user manual: [email protected] Technical and Product Application Support - for technical and application support: [email protected] Webmaster - for information regarding www.aeme.com: webmaster @aeme.com South America, Central America, Mexico, Caribbe: , Australia & New Zealand: Chauvin Arnoux’, Inc. dib.a, AEMC® Instruments 15 Faraday Drive Dover, NH 03820 USA (978) 526-7667 - Fax (978) 526-7605 [email protected] www.aeme.com All other countries: Chauvin Arnoux SCA 190, rue Championnet 75876 Paris Cedex 18, France 83 1 44 85 45 28 - Fax 83 1 46 27 73 89 [email protected] www.chauvin-aroux.com, BAemc’ nd an eine a 08 INSTRUMENTS Technical Assistance (800) a43-1397 Sore