Insulation Resistance Testing
Cheat Sheet
What test voltage should I apply?
A 500 Volt test is the Gold Standard for routine testing
of building wiring and equipment running from building
wiring. In troubleshooting, a 1 kV test may be helpful in
exploiting and identifying a weak spot in insulation.
Telecom/datacom applications on more sensitive wiring
generally call for 50 & 100V tests. Plus there are many
specialty applications covered by Standards from IEEE and
NETA, as well as industry SOPs.
What is a good reading?
This is considerably variable but the most general would
be anything in the Megohm (MΩ) range; at least it should
turn on and operate for a while. At the other extreme, the
Gigohm (GΩ) range is good by any standard. In between,
the best evaluation is a previous test result; is the value
holding? Also, Standards committees like IEEE and NETA
provide reliable recommendations by type of equipment.
What does the range limit tell me?
Insulation testers vary enormously in how high they can
measure…Mega-Ohms (MΩ), Giga-Ohms (GΩ), Tera-Ohms
(TΩ). Often, price is commensurate. For pass/fail, ”good/
bad” testing, MΩ will do. Nothing is “bad” if it reads at a
GΩ or more. But for long-range maintenance, the higher,
the better. That way, an actual measurement, not just an
over-range, can be recorded upon commissioning and
compared ever after.
How are test leads connected?
Generally, by appropriately sized alligator clips. But that’s
not the real issue. Where on the test item? Consider this;
you’re testing the quality of insulation, between two
conductors or potential conductors (e.g., ground). Leads
go accordingly, at operator’s discretion; hot-to-neutral,
hot-to-ground, phase-to-phase, etc. Just be careful about
unanticipated continuity, such as phases that are
connected at the other end.
What is a PI test?
Polarization Index; a standard procedure, where a 1-min-
ute reading is divided into the 10-minute reading. The
significance is that it yields a figure of merit which can be
evaluated free of the actual test measurements. “Good”
insulation has little leakage current, charges up over
10 minutes, and yields a high PI. Poor insulation is held
relatively steady by high leakage current and so yields a PI
around 1.
Is an insulation test dangerous?
To the equipment? No. But, possibly yes to the operator.
Despite the voltages applied, the testers themselves are
not inherently dangerous. Why? Because insulation can
pass no more than a couple milli-amps before it isn’t
insulating anymore (5 mA is a “shock”). Therefore, POWER
is extremely limited on an insulation tester. But then what
IS dangerous? Possibly the test item. Large capacitive items
(big windings, long cable runs) can store lethal capacitive
charges. A quality tester will safely Discharge
automatically. Be sure you know your tester!
How long should the test continue?
This is a confusing aspect of insulation testing compared to
many common electrical tests that post a reading in
seconds. This is due to capacitive and absorptive charging
of the insulation, which can proceed, on large equipment,
for hours. If just a “good/bad” test, you need only wait
until you reach that number. The same for conformance
tests. Otherwise, wait until readings are stable and round
off to a convenient time, then record that. Finally, you can
wait for full charge if you have the time.
What are the safety considerations?
Of course, all Safe Working Practices pertaining to
general safety must be followed. In addition, isolate the
test item/area from onlookers and passersby. Contacting
the test item and leads can be dangerous. Upon conclu-
sion, DISCHARGE THE TEST ITEM. In past, this was an
active part of the operation. But with modern testers, just
stand back and watch the display. A modern quality tester
will AUTOMATICALLY discharge and monitor.
Do I need to store test results in a permanent file?
Not necessarily, but it can be critical. Testers without
storage functions are by no means obsolete. But if you
deal with any kind of 3rd-party involvement, it is a good
idea to electronically store results. This could be an
inspector, insurance agent, Standards conformance, client,
or other authority. Automatic storage rids you of tiresome
argument. And it provides a reliable evaluation of all future
tests in a maintenance program.
What should I know about indoor and outdoor testing?
Most is the same but there are some important
considerations. Primary are temperature and humidity.
Temperature has a profound effect on insulation measure-
ments, approximately cutting in half with a 10°C rise. All
recorded results should be corrected to a common base to
prevent later confusion. Humidity, unfortunately, cannot
be so corrected as every type of insulating material reacts
differently to moisture. But it can at least be included as a
test condition.