Insulation Resistance Testing

Application Note
Introduction
detailed information on leakage Insulation resistance testers can currents and resistance tests see be used to determine the integ- the following sections: What Is Insulation Resistance & Leakrity of windings or cables in age Currents and Predictive motors, transformers, switchgear, and electrical installations. Maintenance Tests). On the other hand, when the The test method is determined equipment to be tested is a long by the type of equipment being run of cable, large motor, or tested and the reason for testgenerator (high-capacitance ing. For instance, when testing electrical cabling or switchgear equipment) the time-dependent currents will last for hours. (low-capacitance equipment) These currents will cause the the time-dependent capacitive leakage and absorption leakage meter readings to change constantly, making it impossible to currents become insignificant obtain an accurate steady readand decrease to zero almost ing. This condition can be instantly. A steady conductive leakage current flow is reached overcome by using a test that establishes a trend between almost instantly (a minute or readings, such as the step voltless) providing perfect conditions for the spot-reading/short- age or dielectric-absorption test. These tests do not depend on a time resistance test. (For more single reading but on a collection of relative readings. It would be a waste of time to perform these tests on lowcapacitance equipment since the time-dependent currents diminish quickly, resulting in all the measurements being the same.

Installation testing
The most important reason for testing insulation is to insure public and personal safety. By performing a high dc voltage test between de-energized current-carrying (hot), grounded, and grounding conductors, you can eliminate the possibility of having a life-threatening short circuit or short to ground. This test is usually performed after the initial installation of the equipment. This process will protect the system against miswired and defective equipment, and it will insure a high quality installation, customer satisfaction, and protect against fire or shock.

Maintenance testing
The second most important reason for insulation testing is to protect and prolong the life of electrical systems and motors. Over the years, electrical systems are exposed to environmental factors such as dirt, grease, temperature, stress, and vibration. These conditions can lead to insulation failure, resulting in loss of production or even fires. Periodic maintenance tests can provide valuable information about the state of deterioration and will help in predicting possible failure of the system. Correcting problems will result not only in a trouble-free system, but will also extend the operating life for a variety of equipment.

Before measuring
In order to obtain meaningful insulation resistance measurements, the electrician should carefully examine the system under test. The best results are achieved when: 1. The system or equipment is taken out of service and disconnected from all other circuits, switches, capacitors, brushes, lightning arrestors, and circuit breakers. Make sure that the measurements are not affected by leakage current through switches and overcurrent protective devices. 2. The temperature of the conductor is above the dew point of the ambient air. When this is not the case, a moisture coating will form on 3.

4.

5.

6.

the insulation surface, and, in some cases will be absorbed by the material. The surface of the conductor is free of carbon and other foreign matter that can become conductive in humid conditions. Applied voltage is not too high. When testing lowvoltage systems; too much voltage can overstress or damage insulation. The system under test has been completely discharged to the ground. The grounding discharge time should be about five times the testing charge time. The effect of temperature is considered. Since insulation resistance is inversely proportional to insulation tempera-

ture (resistance goes down as temperature goes up), the recorded readings are altered by changes in the temperature of the insulating material. It is recommended that tests be performed at a standard conductor temperature of 20C (68F). As a rule of thumb, when comparing readings to 20C base temperature, double the resistance for every 10C (18F) above 20C or halve the resistance for every 10C below 20C in temperature. For example, a one-megohm resistance at 40C (104F) will translate to fourmegohm resistance at 20C (68). To measure the conductor temperature, use a noncontact infrared thermometer such as the Fluke 65.

Work safely
Safety is everyones responsibility, but ultimately it is in your hands. No tool by itself can guarantee your safety. It is the combination of the instrument and safe work practices that gives you maximum protection. Here are a few safety tips you should follow: Work on de-energized circuits whenever possible. Use proper lock-out/tag-out procedures. If these procedures are not in place or not enforced, assume the circuit is live. On live circuits, use protective gear: Use insulated tools Wear flame resistant clothing, safety glasses, and insulation gloves Remove watches or other jewelry Stand on an insulation mat

Hang or rest the meter if possible. Try to avoid holding it in your hands to minimize personal exposure to the effects of transients. Use the three-point test method, especially when checking to see if a circuit is dead. First, test a known live circuit. Second, test the target circuit. Third, test a live circuit again. This verifies that your meter worked properly before and after the measurement. Use the old electricians trick of keeping one hand in your pocket. This lessens the chance of a closed circuit across your chest and through your heart.

When making voltage measurements on live circuits: Hook on the ground clip first, then make contact with the hot lead. Remove the hot lead first and the ground lead last.

When performing insulation and resistance tests: Never connect the insulation tester to energized conductors or energized equipment and always follow the manufacturers recommendations.

Shut down the equipment to be tested by opening fuses, switches, and circuit breakers. Disconnect the branch circuit conductors, grounded conductors, grounding conductors, and all other equipment from the unit under test. Discharge conductor capacitance, both before and after the test. Some instruments may have automatic discharge functions. Check for any leakage current through fuses, switches, and breakers on de-energized circuits. Leakage current can cause inconsistent and incorrect readings. Dont use an insulation tester in a dangerous or explosive atmosphere since the instrument can generate arcing in damaged insulation. Use insulated rubber gloves when connecting the test leads.

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Insulation Resistance Testing

What are insulation resistance and leakage currents?

The value of insulation resistance read on the meter will be a function of following three independent sub-currents. During the testing procedure, Conductive leakage the high dc voltage generated by pressing the test button will current (IL ) Conductive current is a small cause a small (micro-amps) (micro-amp) amount of current current flow through the conthat normally flows through ductor and the insulation. The insulation, between conductors amount of current depends on or from a conductor to ground. the amount of voltage applied, This current increases as insulathe systems capacitance, the tion deteriorates and becomes total resistance, and the tempredominant after the absorpperature of the material. For a tion current (see Figure 1) vanfixed voltage, the higher the current, the lower the resistance ishes. Because it is fairly steady and time independent, this is (E=IR, R=E/I). The total resistance is the sum of the internal the most important current for measuring insulation resistance. resistance of the conductor (small value) plus the insulation resistance in Ms.

Total Current (IA + IC + IL )

Insulation Resistance (in Megohms)

IL Current (in A) 0

IC

IA

Capacitive charging leakage current (IC ) When two or more conductors are run together in a raceway, they act as a capacitor. Due to this capacitive effect, a leakage current flows through conductor insulation. This current lasts only for a few seconds as the dc voltage is applied and drops out after the insulation has been charged to its full test voltage. In low-capacitance equipment, the capacitive current is higher than conductive leakage current, but usually disappears by the time we start recording the data. Because of this, it is important to let the reading settle out before recording it. On the other hand, when testing high capacitance equipment the capacitive charging leakage current can last for a very long time before settling out. Polarization absorption leakage current (IA ) Absorption current is caused by the polarization of molecules within dielectric material. In low-capacitance equipment, the current is high for the first few seconds and decreases slowly to nearly zero. When dealing with high capacitance equipment or wet and contaminated insulation, there will be no decrease in the absorption current for a long time.

Time (in seconds)

Figure 1. Current components

Figure 2. Conductive leakage current (IL)

IL

IC

Dielectric Insulation

Dielectric Insulation Conductors

Figure 3. Capacitive charging leakage current (IC)

Conductors

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Applications

facturers factory test voltage Proof test procedure (higher than the rated voltage To conduct an installation proof Installation test and is available from the cable test, use the following procedure: manufacturer). If you dont Use a multimeter or the voltProof testing know the factory test voltage, age measurement function on Electricians and engineers per- test using a voltage about twice the MegOhmMeter to make form proof tests to insure proper the cables rated voltage plus sure there is no power applied installation and integrity of 1000 volts. Rated voltage is the to the tested circuit. conductors. The proof test is a maximum amount of voltage Select the appropriate voltage simple, quick test used to indithat the conductor can be exlevel. cate the instantaneous condiposed to for a prolonged amount Plug one end of the black test tion of insulation. It provides no of time, usually printed on the lead to the common terminal diagnostic data and the test conductor. For single-phase, on the meter and touch the voltages used are much higher two-phase, or three-phase systest probe to a ground (earth) than the voltages used in pretems, the cable is rated phaseor another conductor. Somedictive maintenance tests. The to-phase. times it is helpful to ground all proof test is sometimes called This previously mentioned conductors that are not part of GO/NO GO TEST because it tests method should only be used for the test. Alligator clips can cable systems for maintenance testing small and new apparamake measurements easier errors, incorrect installation, tus because of its ability to and more accurate. serious degradation, or contami- withstand higher stress voltages. nation. The installation is For larger or older equipment or Plug one end of the red test declared acceptable if no break- wire use dc test voltages (see lead to the volt/ohm terminal down occurs during testing. table 3). on the meter and connect the Common proof dc test volttest probe to the conductor to Choosing the test voltage ages (not the manufacturers be tested. A proof test can be performed test voltages) used for testing on equipment of any capaci Press the test button to apply rotating equipment are shown tance. It is performed with a single voltage, usually between in Table 1. 500 and 5000 V, for about one Rotating Equipment DC Test Voltages Formula Used minute. It is common to stress Factory AC Test, VAC (only for reference) 2 x (VAC Nameplate Rating) + 1,000 the insulation above normal Maximum DC Installation Test, VDC 1.28 x (Factory AC Test) working voltages in order to Maximum DC After Service Test, VDC 0.96 x (Factory AC Test) detect subtle weaknesses in the insulation. For new equipment, Table 1. Proof test voltage equations for rotating machines the test should be done at about 60% to 80% of the manu-

Metal Conduit Insulation

Figure 4. Conductor under test

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the desired voltage and read the resistance displayed on the meter. It could take a few seconds for the reading to settle. The higher the resistance is the better. Test each conductor against ground and against all the other conductors present in the conduit. Keep a dated record of the measured values in a safe place. If some of the conductors fail the test, identify the problem or re-pull the conductors. Moisture, water, or dirt can create low resistance readings.

Predictive maintenance tests

Maintenance tests can provide important information about the present and future state of conductors, generators, transformers, and motors. The key to effective maintenance testing is good data collection. Examining the collected data will aid in scheduling diagnostic and repair work, which will reduce downtime from unexpected failures. The following are the most commonly applied dc test voltages and maintenance tests performed:
Equipment AC Rating (Volts) 0 100 440 560 2,300 4,100 and above DC Test Voltage (Volts) 100 250 500 1,000 1,000 or higher 1,000 or higher

should notice a steady increase in insulation resistance due to decrease in capacitive and absorption currents. Because temperature and humidity can affect the readings, the measurements should preferably be made above the dew point at standard temperature, about 20C/68F. For equipment rated at or below 1000 volts, the insulation reading should be of a value of 1M or greater. For equipment rated above 1000 volts, the expected resistance should increase to one megohm per 1000 volts applied. Usually, the measured insulation resistance will be a bit less than the values recorded previously, resulting in a gradual downward trend as

shown in Figure 6. The downward slope is a normal sign of insulation aging. A sharp downward slope would indicate an insulation failure or a warning of troubles ahead.
DC Test Voltages For phase-to-phase voltage rating Formula Used DCt = 0.8165 x Ep-p

For phase-to-ground DCt = 1.414 x Ep-n voltage rating Table 3. DC test voltage equations

DCt - dc test voltage related to the maximum insulation stress during normal ac operation Ep-p - Phase-to-phase voltage rating Ep-n - Phase-to-ground voltage rating

Recorded Value (in Megohms) Resistance (in Megohms)

0
Figure 5. Insulation resistance test

Time (in seconds)

60 sec

Table 2. Maintenance test voltages versus equipment ratings

1000

Initial Acceptance Test

Aging of Insulation

After Rewinding

Spot-reading/short-time resistance test During the short-time test, the MegOhmMeter is connected directly across the equipment being tested and a test voltage is applied for about 60 seconds. In order to reach a stable insulation reading in about one minute, the test should only be performed on low-capacitance equipment. The basic connection procedure is the same as for a proof test and the voltage applied is calculated from the dc test voltage formulas. When testing good equipment, you

500

100 Resistance 50 (in Megohms)

10 5 Insulation Failure

1995

1996

1997

1998 Year

1999

2000

Figure 6. Insulation resistance over a period of time

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Step voltage test The step voltage test involves resistance testing at various voltage settings. In this test, you apply each test voltage for the same period of time (usually 60 seconds), graphing the recorded insulation resistance. By applying increasing voltages in steps, the insulation is exposed to increased electrical stress that can reveal information about flaws in the insulation such as pinholes, physical damage, or brittleness. Good insulation should withstand an increase in over-voltage stress and its resistance should remain approximately the same during testing with different voltage levels. On the other hand, especially at higher voltage levels, deteriorated, cracked or contaminated insulation will experience an increased current flow, resulting in a decrease in insulation resistance. This test is independent of insulation material, equipment capacitance, and temperature effect. Because it takes a longer time to run, it should be performed only after an insulation spot test has been inconclusive. A spot test deals with absolute resistance change (single reading) with respect to time, while the step voltage test looks for trends in resistance, with respect to varying test voltages. Dielectric-absorption/ time-resistance test The time resistance test is independent of equipment size and temperature. It compares the absorption characteristics of contaminated insulation with the absorption characteristics of good insulation. The test voltage is applied over a 10 minute period, with the data recorded every 10 seconds for the first minute and then every minute thereafter. The interpretation of the slope of the plotted graph will determine the condition of the insulation. A continuous increase in graphed resistance indicates good insulation. A flat or downward curve indicates cracked or contaminated insulation.

Test Made with 250V Test Made with 500V

Resistance (in Megohms)

Test Made with 1000V

Direction of Insulation Failure

Time (in seconds)

60 sec

Figure 7. Step voltage test

1000 500 Good Insulation Condition Poor Insulation Condition

100 Resistance (in Megohms) 50

10 5

Voltage (in kV)

Figure 8. Good and poor test curves

Good Insulation

Resistance (in Megohms)

Cracked Insulation

Time (in minutes)

10 min

Figure 9. Dielectric absorption test for good and contaminated curves

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Another method for deterInsulation Resistance 60/30 Second Ratio 10/1 Minute Ratio mining the quality of insulation Condition (Polarization Index) is to use the polarization index Dangerous 0 -1.0 0-1 (PI) test. It is particularly valuPoor 1.0 1.3 12 able for uncovering moisture Good 1.3 1.6 24 and oil ingress that have a flatExcellent 1.6 and above 4 and above tening effect on the PI curve, Table 4. Approximate dielectric absorption ratios causing leakage current and eventually shorted windings. Proof Test Spot- Test Step Test DielectricPolarization The polarization index is the Reading Voltage Absorption Index Test ratio of two time-resistance Test readings: one is taken after 1 Single reading minute and the other is taken High test voltage after 10 minutes. With good Performed insulation, the insulation resisperiodically tance will start low and get higher as the capacitive leakage Various test voltages current and absorption current Timed test get smaller. Results are obtained intervals by dividing the 10 minute test Diagnostic information value by the one-minute test value. A low polarization index Table 5. Various insulation tests usually indicates problems with the insulation. When test time is Rm - Minimum insulation resis- For a three phase system tested constrained, a shortcut to the tance corrected to 40C with the other two phases polarization index test is the (104F) in M grounded, the resistance redielectric absorption ratio corded for each phase should Kt - Insulation resistance (60/30) second test. temperature coefficient at be divided by two. Then, the resulting value can be comwinding temperature, Testing connections pared with the recommended obtained from Figure 10 in generators, minimum insulation resistance kV - Rated machine terminal transformers, (Rm). to terminal voltage in motors, and wiring kilovolts To test the insulation resistance 100 in generators, transformers, motors, and wiring installations, 50 we can employ any of the previously mentioned predictive maintenance tests. Whether we choose the spot-reading, step voltage, or time-resistance tests depends on the reason for test10 ing and the validity of the data obtained. When testing genera5 tors, motors, or transformers each winding/phase should be tested in sequence and separately while all the other windings are grounded. In this way, 1.0 the insulation between phases is also tested. 0.5 Temperature correction for testing rotating machines For testing armature and field winding insulation resistance at various temperatures, the IEEE 0.1 recommends the following insulation resistance formula.
Insulation Resistance Temperature Coefficient, K t

0.05

Rm = Kt x (kV + 1) Table 6. Insulation resistance equation for ac and dc rotating machinery

-10 0 10 20 30 40 50 60 70 80 90 100

Winding Temperature, Degrees Celsius

Figure 10. Approximate temperature coefficient for rotating machines

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Testing generators and motors When testing the resistance of the stator coils make sure the stator winding and phases are disconnected. Measure the insulation resistance between windings and windings to ground. Also, when dc generators or motors are being tested the brushes should be raised so the coils can be tested separately from the armature. The following table lists recommended minimum resistance readings for various motor voltage ratings.
Motor Nameplate Voltage Rating 0-208 208-240 240-600 600-1000 1000-2400 2400-5000 Minimum Acceptable Resistance 100,000 200,000 300,000 1 M 2 M 3 M

Transformer Type Tanked oil-filled type Untanked oil-filled type Dry or compound-filled type

60-Hertz 1.5 30.0 30.0

To Different Windings

Table 9. Constant C values at 20C (68)

Testing wiring and cable installations When testing wires or cables, they should be disconnected from panels and machinery to keep them isolated. The wires and cables should be tested against each other and against ground (see Figure 4 on page 4). The Insulated Power Cable Engineers Association (IPCEA) provides the following formula that suggests minimum insulation resistance values.
R = K x Log10 (D/d) Table 10. Cable insulation resistance

To Ground

Fluke 1520 MegOhmMeter

Figure 11. Testing the insulation resistance of a motor

R - Ms per 1000 feet (305 meters) of cable. Based on dc test potential of 500 Testing transformers volts, applied for one When testing single-phase minute at 15.6C (60F) transformers, test winding to temperature) winding, winding to ground, or test one winding at a time with K - Insulation material constant. (For example: Impregnated all others grounded. For threePaper-2640, Varnished phase transformers, substitute E Cambric-2460, Thermoplaswith EP-P (for delta transformers) tic Polyethlene-50000, or Ep-n (for wye transformers) Composite Polyethyleneand kVA with kVA3 rating of the 30000) winding under test. D - Outside diameter of conducFor determining minimum tor insulation for single insulation resistance use the conductor wire and cable following formula. D = d + 2c + 2b diameter Transformer Type Formula Used of single conductor cable Single phase R = C x E kVA d - Diameter of conductor Three phase wye R = C x Ep-n kVA c - Thickness of conductor Three phase delta R = C x Ep-p kVA insulation Table 8. Transformers insulation resistance b - Thickness of jacket equations insulation ROne minute 500 volt dc For example, one thousand minimum insulation feet of number 6 A.W.G. Heat resistance in megohms Resistant Natural Rubber insulation type stranded conductor CConstant for 20C (68) with 0.125 insulation thickness measurements will have K = 10,560 and Log10 (see below) (D/d) = 0.373 inches. According EWinding voltage rating. to the formula (R = K x Log10 KVA - Rated capacity of wind(D/d), R = 10,560 x 0.373 = ing under test. For three 3,939 M per 1000 feet) the phase units kVA3 = expected minimum insulation 3 x kVA1 resistance for single conductor per thousand feet at temperature of 60F will be 3,939 M.

Table 7. Recommended minimum resistance at 40C (104F)

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