INSULATION RESISTANCE TEST

INTRODUCTION
Insulation problems on motors and drives usually are caused by improper
installation, environmental contamination, mechanical stress, or age. To
calculate and display insulation resistance, testers can apply a direct-current
(DC) voltage across an insulation system and measure the resulting current.
Typically, the test verifies high insulation resistance between a conductor
and ground.

Insulation-resistance testing can check coil or winding resistances, heating-

element resistances, thermistor resistance values, and so on. All of these
measurements can occur through circuits within the insulators, except when
checking for a short to ground. Once a short to ground is detected, a
catastrophic failure of the device has occurred, and it is too late for
preventive maintenance or proactive remedies. A catastrophic motor failure
within a hermetic or semihermetic compressor containing oil and refrigerant
at best involves extensive cleanup and at worst requires equipment, rather
than component, replacement and results in lost production time and
revenues. It is better to check insulation values regularly and record them for
comparison during the next visit so that changes are readily apparent

INSULATION RESISTANCE TEST

The Insulation Resistance Test consists in measuring the Insulation

resistance of a device under test, while phase and neutral are short
circuited together. The measured resistance has to be higher than the
indicated limit from the international standards.
A megohmmeter (also called insulation resistance tester, teraohmmeter)
is then used to measure the ohmic value of an insulator under a direct
voltage of great stability.
To measure a high value resistance, techniques for measuring a low value
current are used. A constant voltage source is applied to the resistance to be
measured and the resulting current is read on a highly sensitive ammeter
circuit that can display the resistance value.
Two types of ammeter circuits are used on our range of insulation resistance
tester, each circuit being chosen depending on the resistance values to be
measured.

INSULATION TEST
Its objective is to measure the ohmmic value of the insulation under a direct
voltage of great stability, generally 50, 100, 250, 500, or 1000 VDC. The
ohmmic value of the insulation resistance is expressed in megohms (MΩ). To
conform to specific standards, the insulation resistance test can be
performed under voltages up to 1500VDC. Due to the stability of the voltage
source, it is possible to adjust the test voltage by steps of 1 volt.
The stability of the voltage is critical; a non regulated voltage will drop
sharply in presence of a bad insulation which will cause an erroneous
measurement.

SHUNT AMMETER CIRCUIT

The voltmeter input, associated to a resistance, forms

the shunt ammeter circuit. This setting allows
measuring any value of I, many combinations of
sensitivity and values of RI.

This circuit is used for current measurement of high

values which correspond to resistance measurement
of low values (l x l04 Ω to 2.106 Ω).

FEEDBACK AMMETER CIRCUIT

This circuit is the one mostly used on our instruments.

It covers the resistance measurement of high values
higher than 2.106 Ω. The principle is indicated in the
hereunder diagram.

The input current flows through the feedback Rc.

The low level of offset current of the amplifier
negligeably affects
the current l.
HIGH VALUE RESISTANCE MEASUREMENT
Using a constant voltage source offers the advantage of defining with
accuracy the value of voltage used for the measurement.The choice of this
voltage is an important parameter

Indeed the value of a high resistance depends of the

voltage applied to it. Other factors intervene in the
high value resistance measurement. Temperature and
relative humidity are two important parameters which
influence the resistance value of an insulator. We offer
on the latest Sefelec model the measurement of these
two physical parameters (M1501P). 0n the following
table one can find the approximative resistance value
of insulating materials.

GUARD CIRCUIT
In order to minimize leakage currents, guard connection is given. The guard
circuit allows to reduce interferences on the test sample. A terminal
accessible on the front panel of our instruments allows the measurement of
one of the resistance of a Delta configuration (i.e. a cable with two
conductors and its external shielding), so that the result is not affected by
the presence of the other two shunt resistances.

* To this effect the guard terminal is close to the potential of the measuring
input of the instrument.
* The value of Rx, will be defined with great accuracy if the current lx,
measured by the megohmmeter's input, is really the current flowing through
Rx.
* Rp1 : symbolizes the leakage between the high voltage (HV) connections
and ground.
* Rp3 - Rp4 : represent the parallel leakage of Rx. If the middle point Rp2-
Rp4 is connected to the guard, these leakages will not influence the
measurement of Rx.
* Rp2 : has not influence if the guard is connected to earth.

Electrical and insulation resistance tests on motors

1. Visual inspection
First, look for a reason NOT to energize. Remove power from the motor and
starter (or drive), following lockout/tagout procedures, and disengage the
motor from the load.

2. Control contacts check

Next, check the control contacts for quality of contact:

1. Lockout and tagout the disconnect to the starter.

2. Manually engage the starter, so the contacts close.
3. Set the insulation tester to the low ohms range.
4. Measure the resistance across each set of contacts.
5. The reading should be nearly zero.

3. Resistance of line and load circuits to ground

Then, measure the insulation resistance of the line and load circuits to
ground. However, before doing ANY insulation resistance testing, you
MUST isolate any electronic controls and other devices from the
circuit under test. Then:

1. Lockout and tagout the disconnect to the starter.

2. Set the insulation tester to the appropriate test voltage (250, 500 or
1000 V).
3. Identify the resistance between these points:
o Line side of starter to ground
o Load side of starter to ground
4. Winding resistance phase to phase and phase to ground
Take insulation resistance measurements phase to phase and phase to
ground.

Good results:

• Balanced comparative low resistance values on all three stator phases

• High resistance values on the phase to ground insulation test.

Problems:

• Gross resistance deficiencies, such as a phase on phase short.

• Any winding to winding resistance...