Keys to Long-term Motor Performance: Exploring the Benefits of Hipot and Insulation Resistance Measurements

by Adam Braverman, Technical Sales Engineer, The Slaughter Company

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With all the rigorous demands in critical applications that we place on rotating machines, it is extremely important to ensure they are functioning properly and safely.
Ths is the full-length version of the abbreviated paper that appeared in Supplier Solutions: Motors and Air-Moving Devices in the April 2006 issue of APPLIANCE magazine.

Introduction

In a world that is constantly on the move, proper motor maintenance and repair can be the difference between heading forward and remaining stagnant. Motors help to simplify our manufacturing processes and improve our quality of life. Omnipresent in mechanical and electrical systems world-wide, they are a fundamental bone in the structure of the technological advancement movement taking place across the globe. According to the SMMA (Small Motor and Motion Association), Over 15 million fractional horsepower electric motors are manufactured in the world every day. That number will no doubt increase as time goes on, as will the number of higher horsepower electric motors. With all the rigorous demands in critical applications that we place on rotating machines, it is extremely important to ensure they are functioning properly and safely.
Safety Testing Theory

In order for a motor to function properly all of its main current-carrying components, namely the stator windings, need to be properly balanced and properly insulated. Since the mains-input power to a motor is applied to the stator windings, it is extremely important to verify their resistance on a regular basis. Resistively balanced phase windings ensure that the motor runs smoothly and within proper thermal specifications. Meanwhile, properly insulated conductors will prevent excessive leakage current between phase windings and line current from reaching ground. The most effective way of sustaining motor life and preventing problems is to implement a sound safety testing routine. Arguably the most important time to test is before a motor leaves the factory. Not only do these initial measurements verify the functionality and safety of the motor, but they can also be used as a benchmark for all future test measurements. Future measurements are often made when motors undergo routine repair and maintenance in a wide variety of applications including aerospace, manufacturing, and aviation. This process of regular testing over time, known as trending, is used to monitor the state of a motors insulation by comparing the results of successive tests.

Figure 1. Typical IR Graph of a Motor

Trending is such an important process because it helps to provide the test operator with insight about how a motor has operated in the past and when to perform repairs so it will continue to operate in the future. The trending process can be applied to several different types of safety test measurements taken on a single motor, but is most commonly associated with the Insulation Resistance (IR) test. Some tests, such as the Hipot test, the Surge test, and the IR test, are designed to check the integrity of a motors insulation. Others, such as the Coil Resistance test, check to make sure that the various phases are balanced and that the resistance of the windings can sufficiently handle the necessary start-up current draw. All of these tests yield valuable information about the state of a motor, but it is only with repeated measurements that we are able to accurately monitor and predict when repair or replacement should be performed before a critical failure occurs.
Two Important Safety Tests

For the purposes of this document, we will discuss two of the more commonly performed safety tests, the Hipot test and the Insulation Resistance test: 1.) Hipot (Dielectric Withstand) test a high voltage test used to stress the integrity of a motors insulation between the current carrying windings and the motors chassis. 2.) Insulation Resistance test a high voltage test used to measure the resistance of a motors insulation between the current carrying windings and the chassis.
Why is Testing Important?

It isnt hard to believe that many motor manufacturers and operators are still unfamiliar with the benefits of electrical safety testing. For the most part, the safety testing industry flies under the radar, that is, until some critical electrical system fails. The Slaughter Company has been in the electrical safety testing industry for over 40 years, and weve found that being proactive with safety testing is always the best policy. In the long run, preventative testing and maintenance will save time, money, and even possible litigation from liability lawsuits.

Electrical safety testing starts in the engineering lab during the research and development phase of any new product. Called design or type tests, they are usually specified by safety organizations, and provide useful information about a new motor design. For instance, the Hipot test can be used to check for manufacturing defects: shorts between stator coil phases, shorts to ground, and a host of other possible problems as well. The Insulation Resistance test is used to provide a benchmark for all future resistance measurements, helping a manufacturer or a technician corroborate future readings with the original to determine the strength of a motors insulation. Production line testing is performed before products leave the factory. Safety agencies usually state that 100 percent of manufactured electrical products need to be Hipot tested before they are shipped. Hipot testing ensures that a motor is safe for use by checking the integrity of its insulation before it leaves the factory. Without the Hipot test, motors with faulty insulation can find their way into finished products creating a potential shock or fire hazard. Further, Hipot testing on the production line can detect poorly assembled products before they are shipped, allowing manufacturers to avoid costly recalls and replacement requests. Safety testing is also performed during repair and routine maintenance. Once the repair and reassembly of a product is complete, it is always sound practice to Hipot the motor to make sure that it was assembled correctly. IR testing is can be performed as part of a regular maintenance program, as well as after a Hipot test to verify the resistance of the motors insulation. Liability is another reason that electrical safety testing is so important. By actively pursuing and implementing a standard set of safety tests on all products that leave the warehouse, motor manufacturers can have the piece of mind that they are doing all they can to ensure a quality product. With records traceable back to safety agencies and other organizations, a manufacturer can provide clients with documentation that their products have been tested and comply with all relevant standardized tests.
Common Safety Organizations and Standards

In the United States, safety organizations usually require both Hipot and Insulation Resistance tests along with other tests to be performed after the initial product design is completed, on the production line, and during repair and service. As long as a product uses electricity, routine electrical safety testing is always a good idea no matter what the industry. Independent affiliations and organizations like the Electrical Apparatus Service Association (EASA), National Electrical Manufacturers Association (NEMA), and the Institute of Electronics and Electrical Engineers (IEEE) set the standards for electrical safety. Depending on your product, you may be required to perform a specific set of tests in order to comply with these agency specifications. In addition, it might also be a good idea to contact Underwriters Laboratories (UL), one of the more popular electrical safety compliance agencies in the United States. Examples of some common standards are as follows:
y y y y
IEEE Std. 43-2000, Recommended Practice for Testing Insulation Resistance of Rotating Machines IEEE Std. 95-1977, Guide for Insulation Maintenance of Large AC Rotating Machinery NEMA MG-1, Motors and Generators UL 1004, Electric Motors

Other countries, including the countries of the European Union have their own standards and safety organizations that products must comply with in order to be sold within their borders. The CE Mark is a commonly used seal of approval given to products that comply with European Union safety standards. It is important to know and understand these differences if you are going to be selling products internationally as well as within the borders of the United States. The Hipot Test The Hipot test, sometimes called a Dielectric Withstand test, is used to verify the strength of the insulation between the current carrying stator windings and the grounded chassis of the motor. This is done by applying a high voltage from the stator windings to the chassis and measuring the resulting leakage current through the insulation. The theory is that if a voltage much higher than the motor were normally to see is applied across the insulation without a breakdown (an excessive amount of leakage current flow), the motor will be able to operate safely when run under nominal operating conditions. This test is usually performed during the manufacturing process on 100 percent of all manufactured units, as well as during routine repair and maintenance. The Hipot test is so crucial because it is the best test for uncovering workmanship and assembly defects in a motor. Poor assembly or damages incurred during shipping exist to an extent in any manufacturing environment, and the Hipot test can uncover units that are unfit and dangerous to sell. It does this by monitoring the leakage current that flows through the motors insulation. Under normal conditions, some leakage current will be present in any product, but at minute and safe levels. This leakage current becomes a problem when the insulation breaks down and an excessive amount flows from the stator windings to the chassis of the motor. This can present a substantial shock hazard to anyone that comes into contact with the motor. The Hipot test can help to identify a number of defects, pinched insulation, pinholes, and poorly crimped wiring to name a few. When performing Hipot tests, setting the test voltage is generally a point of confusion. Most of the time safety agencies specify the test voltage that should be applied. Generally speaking, the test voltage is supposed to be two times the operating voltage, plus 1000 volts. This specification is usually given for AC Hipot tests, but DC Hipots are an alternative.

The most important consideration when deciding on a Hipot tester is to make sure that the output current capacity is substantial enough for your application. Generally, AC Hipots need to have higher output current capability due to the reactive nature of a motors coils (excessive capacitance and inductance). DC Hipot tests can be performed at lower current levels but generally take longer since the test voltage needs to ramped up slowly in order to prevent false current trips due to charging current. Products like the Slaughter Companys Model 1340 Hipot, capable of outputting up to 40 mA of current, are ideal for motor testing applications. The Insulation Resistance Test Figure 2. Slaughter Model The Insulation Resistance (IR) test is used to provide a 1340 AC Hipot numerical resistance value of a motors basic insulation which separates the current-carrying stator coils and the metal chassis. Maintaining the integrity of this insulation system is extremely important for the motor to function correctly and safely throughout its life. A weak insulation system can produce dangerous fault currents back to ground and can present a serious shock hazard to anyone who comes into contact with the motors casing. The purpose of the IR measurement is twofold. First, the measurement provides a good indication whether or not a new product is constructed correctly and can be shipped to a customer in good condition. Second, it provides a benchmark for all future measurements taken throughout the life of a motor (the trending process). An IR test is performed by applying a DC voltage across the stator coils and the motor casing. The instrument then uses Ohms Law to calculate the resistance of the motors insulation. V / I = R. Since the test setup inherently creates a capacitive circuit, it is important to ramp up the voltage in order to keep the reactive charging currents low. Once the test voltage has stabilized the charging current falls to zero and a measurement may be taken. Generally, the test measurement is specified to be taken after 60 seconds in order to record an accurate measurement. Accuracy is always an issue with the IR test. The resistivity of a motors insulation is dependent on several factors such as temperature and humidity, and can drastically change due to a build up of condensation, dirt or grime between the conductors and the insulating material. For this reason it is important to try to keep testing conditions constant each time an IR test is performed. If the temperature during the test cannot be controlled, the IR measurement must be corrected for a temperature of around 40C. A general rule of thumb states that for every 10C increase in temperature, divide the IR reading by 2. Likewise, for every 10C decrease in temperature, multiple the IR ready by 2. A motors insulation system will generally degrade over time. The trending process allows the test operator to record and graph this degradation process. By taking repeated measurements and graphing the data, it is easy to see how the insulation is degrading and make a judgment as to when it should be repaired or replaced.

Another useful form of IR test measurement is known as the Polarization Index (PI). Polarization is the ability for a materials dipoles (equal and opposite charges separated by some distance) to line up in the presence of an electric field, in this case the applied DC test voltage. As the dipoles align themselves absorption current is created that decreases over time. Initially the absorption current is high, but as fewer and fewer dipoles are left to align themselves with the applied field the current drops. Thus an IR measurement taken after 1 second would yield a lower resistance than an IR measurement taken at say, 60 seconds. In fact, the most common test times are a 10 minute test divided by a 1 minute test. The resulting ratio of the test measurements helps to give a more accurate representation of a motors ground wall insulation integrity than a single IR measurement. Operator Safety When performing electrical safety testing, proper precautions must be made to help avoid injury to the test operator. Both Hipot and Insulation Resistance tests require the application of high voltage to a motor and should be carefully performed under correct testing conditions. Test operators should be well trained and aware of the inherent risks in working with high voltage, and the proper procedures for dealing with electrical shock. For more information on this subject, please contact OSHA (Occupation Safety and Health Administration), your local safety agency representative, or the Slaughter Company. Summary The electrical safety testing industry is often only vaguely understood by most manufacturers. Yet the benefits of a sound safety testing process more than justify the time spent in getting to know the instruments and tests involved. Safety testing helps to verify product design, assure that only good products are shipped from the factory, protect customers from injury, and prevent unfounded and frivolous law suits. When dealing with motors, safety testing is of particular importance due to the rigorous demands and applications we place on rotating machines. Two common tests worth noting are the Hipot test and the Insulation Resistance test. The Hipot test, usually specified as a 100 percent production line test, is essential for determining the integrity of a motors ground wall insulation. It is, in fact, the only test capable of identify many defects that occur in the manufacturing and shipping processes before products leave the factory. The Insulation Resistance test provides manufacturers and customers alike with crucial information about the inherent degradation of a motors insulation, including when it may be necessary to repair or replace it. In short, electrical safety testing is the key to long term motor performance and reliability. If you require any further information on tests or instruments, feel free to contact the Slaughter Company.