How to Test

Routine winding field tests are valuable for identifying signs of

deteriorating insulation, since timely repair or replacement of a
troublesome motor helps avoid costly disruptions in productivity,
regular field testing is invaluable. This is especially true for plants
running applications within harsh operating environments or with
a history of winding failures.

When maintenance records reveal a tendency toward periodic

winding failures, the condition of system insulation can be
efficiently probed by way of a resistance test. Such testing is
especially important when a motor's surroundings are wet,
potentially corrosive, or hot.

The most simply executed field test, the ground-insulation or

megger test, helps prevent a large proportion of common winding
failures. Applying 500 to 1,000 Volts of DC power to the motor
windings, the megger calculates the resistance of the insulation.
NEMA standards require minimum resistance to ground at 40
degrees C ambient of 1 Megaohm per rated kV, plus 1 Megaohm.
Medium size motors in good condition generally have megohmmeter readings in excess of 50
Megaohms. Low readings may indicate seriously impaired insulation. This is most often due to
moisture, oil or conductive dirt contamination, or deterioration due to age or excessive heat.
The megger test indicates the condition of ground insulation. It does not, however, measure the
turn-to-turn state of the insulation, and may not register localized weaknesses. Moreover, voltage
peaks may stress the insulation more severely than megger voltage. For example, the DC output
of a 500 Volt megger is below the normal 625 Volt peak each half cycle of an AC motor
operating on a 440 Volt system. Experience and conditions may indicate the need for more
intensive routine testing.
The AC high potential ground test functions to verify the existence of a safety margin above
operating voltage. The test involves application of a high
AC voltage, typically 65%, times twice the operating
voltage, plus 1,000 Volts, to the windings and motor frame.

Although this test effectively detects the symptoms of poor insulation, the high voltage may arc
to ground, actually burning the insulation and frame, causing failure during the test. DC high
potential tests are becoming more popular than AC tests, because the equipment involved is
smaller and the test current is less dangerous.

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