Feature

The Basics of Insulation Testing

by Jim Gregorec
IDEAL Industries, Inc.

What Is Insulation Testing? The simple equation of Ohm’s

law enables us to attach a numerical
In a perfect world, all the electrical current sent along a conductive wire would value to our resistance measure-
reach its intended destination. For various reasons, some of it is lost along the ments. It states that resistance
(ohms) equals voltage (volts) di-
way. Wires are insulated with a resistant sheathing to contain the conductivity vided by current (amperes). Using
of the typically copper or aluminum core. But even with this insulation in place, Ohm’s law, insulation resistance
some of the current still manages to escape. is determined by pressurizing the
conductor with a given voltage
Much like a leak in a water pipe, an imperfection in the insulation of a wire and dividing it by the current that
allows a steady flow of electricity to escape. This can be a detriment to electrical escapes through the insulation and
circuits and machinery. The purpose of testing is to determine whether the in- returns to the meter. This total cur-
sulation is performing at an effective and safe level. Routine testing can identify rent that flows through and along
problems before they result in injury or equipment failure. the insulation during a test is the
As you’ll learn from this guide, insulation is subject to many elements that can result of three different components:
cause it to perform at a less than acceptable level. Excessive heat or cold, moisture, capacitive current, absorption cur-
vibration, dirt, oil, and corrosive vapors can all contribute to deterioration. For rent and leakage current.
this reason, routine insulation testing is necessary.
Capacitive Current
The initial surge of current that
occurs when voltage is first applied
to a conductor is called capacitive
current. Like the first rush of water
flowing through a hose, it typi-
cally starts out high and then drops
quickly once the conductor is fully
charged.

Absorption Current
Absorption current also starts
out high and then drops, but at a
The flow of electrical current through a conductive wire is similar to the flow of water through
a pipe.
much slower rate than capacitive
current. As the voltage builds up,
the absorption level in the insula-
Total Current in Insulation Testing tion changes from high to low. This
Testing the integrity of insulation requires measuring its resistance to current gradual change reflects the storage
flow across it. A high level of resistance means that very little current is escaping of potential energy in and along the
through the insulation. Conversely, a low level of resistance indicates a significant insulation. Absorption current is an
amount of current may be leaking through and along the insulation. important part of the time resistance
method of insulation testing.

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Leakage Current Proof Test (High Potential Test)
The small, steady current present In order to protect against miswired and defective equipment, proof testing
both through and over the insulation is is an important step in the installation of new machinery. A proof test is often
called leakage current, also commonly referred to as a go/no go test because it simply tests the system for errors or in-
referred to as conduction current. Any correct installation. The test is accomplished by applying dc voltage through the
increase in leakage current over time de-energized circuit using an insulation tester. A successful test is one in which no
is usually an indication of deteriorat- failure occurs during the duration of the measurement. Proof testing voltages are
ing insulation. Note that this would much higher than those used in routine maintenance test methods. The general
be read on the meter as a decrease in guideline for deciding on a test voltage is based on the equipment’s nameplate
resistance. rating. Follow the equation below to arrive at an acceptable test voltage.

Types of Insulation Step 1.

(2x nameplate rating) + 1,000V = Factory AC Test
Resistance Tests
Now that we have discussed the Step 2
definition of insulation resistance and 0.8 x Factory AC Test x 1.6 = DC Proof Test Voltage
why it is important to measure, let’s
turn our attention to when and how to
test. The different types of insulation
testing methods can be divided into
two categories: installation (accep-
tance) tests and maintenance tests.

Installation Tests
When installing new electrical
machinery or equipment, testing
insulation resistance is important
for two reasons. It ensures that the
insulation is in adequate condition
to begin operation and it provides a
baseline reading to use as a reference A quick check on a new installation can
for future testing. prevent damage to electrical and electronic
equipment.

Maintenance Tests
Due to fluctuating factors like Short Time/Spot Reading Test
moisture and temperature, insulation In a short time or spot reading test, the tester is connected across the insulation
testing is mostly based on relative of the motor windings. A test voltage is then applied for a fixed period of time
measurements. In other words, today’s (usually 60 seconds). The most important aspect of this test is that it remains
reading of 1.5 megohms is more or less consistent in duration from test to test. Once the time period has elapsed, an
insignificant unless it can be compared insulation resistance measurement can be recorded.
to a previous set of measurements. As discussed earlier, a single maintenance test can act only as a rough guide
Measurements taken during routine for insulation quality. A more effective use of the short time testing method is
maintenance tests can give valuable to establish a series of test results over several months so that long-term trends
information about the quality of may be examined. It is important to understand that a variety of factors such
insulation as conditions vary. In this as temperature and moisture can cause fluctuations in test readings. Typically,
article, we will discuss three such tests: insulation will deteriorate at a very gradual but consistent pace. A significant
the short time/spot reading test, the downward trend over the course of several measurements is usually a sign of
time resistance method and the step insulation breakdown.
voltage (tip-up) test.

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Testing insulation is an integral part of routine maintenance on motors.
When testing a high voltage distribution panel, it is important to use
an insulation tester with high test voltages.
RELATIVE INSULATION RESISTANC

1000
750
500 OIL-FREE MACHINE SHOWING CARBON DUST
ACCUMULATION PLUS VA RYING DEGREES INSULATION
250
100
OF DRYNESS PROBABLY
75
50 OK
25
10
7.5
5.0
2.5
1.0
.75
2 4 6 8 10 12 14 16 18 20

MONTHS ELAPSED
MEGOHMS
RELATIVE INSULATION RESISTANC

1000
750 OIL-FREE MACHINE
500
EXPOSED TO EXCESSIVE MOISTURE
250
100
75 MOISTURE AND DIRT
50
25 MAY BE PRESENT
10
7.5
5.0
MACHINE
2.5 DRIED OUT
1.0
.75
2 4 6 8 10 12 14 16 18 20

MONTHS ELAPSED

0 TIME 10 MIN

Curves from these two time resistance tests show the difference in
Time Resistance Method absorption effect between good and bad insulation. Note that when
insulation is good, the resistance level is considerably higher after ten
Unlike the short time or spot reading test, the time resis- minutes than it is after one minute.
tance method can provide fairly conclusive results without
the luxury of past test measurements. It is accomplished by
taking successive readings at fixed time intervals and plotting Dielectric Absorption Ratio
them. This is an especially effective method when moisture
and other contaminants might be present. The best way to quantify the results of a time resistance
test is through a dielectric absorption ratio. It is simply a ra-
As mentioned earlier, absorption current starts out high tio of two time resistance readings. A commonly used set of
and gradually decreases over time as voltage is applied. In a intervals is a 60-second reading divided by a 30-second read-
machine with healthy insulation, this trend will continue for ing. Another frequently used set is 10 minutes divided by 1
several minutes and show an increasing level of resistance. minute. This resulting value is referred to as the polarization
On the other hand, if the insulation is poor, the level of index. The following chart provides general guidelines for
resistance will flatten out after the initial capacitive charg- how to interpret dielectric absorption ratios.
ing current.

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 Condition Of Insulation Indicated TEST MADE
By Dielectric Absorption Ratios WITH 500V
Insulation 60/30-Second 10/1-Minute Ratio
Condition Ratio (Polarization Index)

Dangerous – Less than 1

Questionable 1.0 to 1.25 1.0 to 2

TEST MADE
Good 1.4 to 1.6 2 to 4 WITH 2500V
(SHOWS INSULATION
Excellent Above 1.6 Above 4 WEAKNESS)

It is important to remember that these values are relative and can vary
based on environmental conditions. Basic maintenance measures TIME 60 sec
such as cleaning the motor windings will help produce more accurate
results.
Results from this step voltage test indicate a weakness in insulation.

Step Voltage (Tip-up)Test

A step voltage test involves testing the insulation at two Testing Preparation
or more voltages and comparing the results. Good insulation Preparing the equipment and your insulation tester cor-
will show a relatively consistent resistance reading regardless rectly is crucial to your safety and the well-being of wiring
of the voltage applied. On the other hand, when the resis- and machinery. Outlined below is a process that you should
tance level drops as the voltage level increases, it is usually make routine before every test.
an indication that the insulation is aging, contaminated or
brittle. This occurs because small imperfections such as pin- 1. Take equipment out of service
holes and cracks reveal themselves under increased electrical Shut down the apparatus, open switches, and de-energize.
stress. When performing a step voltage test, it is important Disconnect the equipment under test from all other equip-
to start with the lowest test voltage and then proceed to the ment and circuits including neutral and protective ground
next voltage level. Test duration is typically 60 seconds. The connections. Make sure proper lockout/ tagout procedures
graph below provides an example. are followed during this step.

Setting Up a Maintenance Program 2. Check what will be included in

The key to establishing a reliable maintenance program the test
is consistency. Periodic tests should be performed with the The more equipment included in a test, the lower the
same test equipment, with the same connections, and for resistance reading will be. For this reason, it is very important
the same length of time. It is also advantageous to test at to inspect the installation and understand exactly what is
the same temperature, but changing seasons and weather included. You do not want a reading to be affected by ad-
conditions can make that unrealistic. Correcting your read- ditional equipment not included in previous tests. However,
ings to a given temperature might be necessary. if a complete installation with several pieces of equipment
How often you test depends on the type, location, and yields a high reading, it is safe to assume that each individual
importance of the equipment. Experience will give you a apparatus will yield an even higher reading. Consequently,
feel for how quickly a specific machine’s insulation can de- sometimes separating components is unnecessary.
teriorate. Monthly, semiannual, and annual intervals are all
common for motors and other machinery. For basic wiring, 3. Discharge capacitance
once a year is probably sufficient. The important thing is to Both before and after an insulation resistance test, it is
test with enough frequency to catch insulation weakness important to discharge capacitance. Discharge time should
before it becomes hazardous. be approximately four times as long as the test voltage was
Deciding which testing method to employ also depends applied during the test.
on the equipment. For a relatively small motor with little
or no capacitance, a spot reading test may be all that is
necessary. Conversely, a large motor running at high volt- Interpreting Results
age probably requires both a spot reading and a step volt- What to do with the results of an insulation test can often
age test. And for a machine in which moisture is a factor, a be more complicated than the test itself. Every piece of equip-
time resistance test is probably in order. When it comes to ment has a general insulation “personality.” In other words, if
determining a specific regimen of testing, every facility is a machine is behaving in accordance with its normal tenden-
different. Experience is the best guideline you have. cies, there is usually no cause for concern. However, a mini-
mum value below which equipment should not be energized is

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 Potential Conditions Discovered During Testing
Condition What To Do

Fair to high values, and well maintained No cause for concern

Fair to high values, but showing a Locate and remedy the cause and
constant tendency toward lower levels check the downward trend

Low, but well maintained Condition is probably all right, cause of low values
should be checked

Very low values Clean, dry out, or otherwise raise the values
before placing equipment in service
(test wet equipment while drying out)

Fair to high values, previously well Make tests at frequent intervals until:
maintained, but showing sudden drop 1. Cause of low values located and remedied
2. Values become steady at a lower level safe for operation
3. Values become so low that it is unsafe to keep
the equipment in operation.

1 megohm per 1000 volts. Use the chart on the next page as AC Motors and Starting Equipment
a rough guideline for what to do with your readings.
It is extremely important to consult the operating
handbook and the manufacturer for specific information
and guidance as to whether a particular value as measured
between two points should be considered acceptable or
questionable. Test equipment is capable of providing ac- MOTOR

curate readings, but one must determine if a particular

measured value indicates that a piece of equipment meets STARTER
the manufacturer’s specification for insulation integrity. MAIN
SWITCH
L E

Connection Diagrams
G

MEGGER
INSULATION
The following four diagrams provide general guidelines SOURCE TESTER

to connect an insulation tester to most of the electrical

equipment encountered. Remember that every piece of When testing ac motors and starters, connect the insulation tester in
equipment is different. It is always wise to closely examine parallel to the circuit. If a weakness exists, disconnect and test each
component of the system separately.
a specific apparatus to determine exactly what is included
between the connected terminals.

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DC Generators & Motors Control, Signaling
and Communication Cables

G L E

With the brushes raised as indicated, the brush rigging and field coils
can be tested separately from the armature. With the brushes lowered,
the insulation resistance of the entire system will be tested.
By connecting a communication cable, a single wire can be tested
against all other wires and the cable jacket at the same time.

Wiring Installation

Jim Gregorec is a Group Manager for the Test & Measurement Di-
vision of IDEAL INDUSTRIES, INC. Jim has a B.S. in Engineering
from the Milwaukee School of Engineering and an MBA from Northern
Illinois University. Jim has been with IDEAL for the past 16 years - half
of which were spent in quality, process, and manufacturing engineering
functions in a plant environment before transferring to product marketing.
Jim has been responsible for developing IDEAL’s innovative test and
measurement product line, that has received various product of the year
awards from notable electrical trade circulations.

By testing at the main panel, the entire system can be tested to ground
at one time, providing all switches in the distribution panel are closed.
If weakness is detected, test each circuit separately.

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