STROMA GUIDE TO INSULATION RESISTANCE TESTING.

1.0 The importance of Insulation Resistance Testing

Insulation resistance testing is an important test to verify the safety of an electrical

installation. This test should be performed as the third test after confirming the continuity
of protective conductors and the continuity of ring final conductors, if they are present,
when carrying out the initial verification of new installations see Chapter 61 of BS7671
(Ref. 1). It is important that the continuity of protective conductors is confirmed before
insulation resistance testing as an insulation resistance fault to earth may not be revealed
if there is not a continuous earth path throughout the installation.

For larger installations the construction work may be completed in sections with circuits
being tested before they are connected to distribution boards. In addition the new
installation may not be connected to a supply or a means of earthing during the early
stages of construction. It is sensible and advisable to carry out insulation resistance
testing as the construction progresses. However it is critical that further insulation
resistance tests are carried out when the installation is connected to a means of earthing
as this may reveal insulation resistance faults to earth that may not have been detected
when the installation is unearthed.

2.0 Test Instruments.

Electrical inspectors should always use good quality test equipment made by a reputable
manufacturer. Insulation resistance testers are usually combined with a continuity tester
or may be one function of a multi-function tester. In any case the instrument should
comply with BS EN 61557-2 (Ref. 2). Before using any instrument inspectors should
check that the instrument is undamaged and in good condition, the instrument has a
current calibration certificate and the batteries are in a charged condition.

All test instruments should be tested on a regular basis for ongoing accuracy at least on a
monthly basis and ideally before periods of use on a propriety test box or in the case of an
insulation resistance tester a selection of known resistors. On site connecting the leads
together and pressing the test button on any range should indicate a short circuit and with
the leads apart an open circuit. For a useful field test a small piece of paper dampened
with water will and tested between the leads will indicate a low insulation resistance.

Inspectors should select good quality test leads, probes and crocodile clips for use with
the instrument. As insulation resistance testing is carried out at a voltage exceeding 50V
leads and probes should comply with the guidance contained in the Health and Safety
Executive Guidance GS38 (Ref. 3). Leads, probes and crocodile clips should be inspected
to ensure they are undamaged and in good condition before they are used.
3.0 Test Voltages

Insulation resistance test instrument are capable at operating at a range of voltages. The
output of the instrument is a DC voltage and it should be capable of 1mA in to a short
circuit. The required test voltage will need to be set on the instrument and the appropriate
test voltages are set out in the table below. The table also indicates the minimum
insulation resistance to comply with BS7671.

Circuit nominal voltage Test Voltage (DC) Minimum Insulation

Resistance (MΩ)
SELV and PELV 250 0.5
Up to and including 500V 500 1.0
but excluding above
systems.
Above 500V 1000 1.0

Where electronic devices and surge protection devices are fitted on a 230/400V
installation and they cannot easily be removed BS7671allows a test voltage of 250V to be
used but the minimum insulation resistance must be 1MΩ (see Regulation 612.3.2).

4.0 Safety

Insulation resistance testers deliver voltages (250-1000V) that will give an electric shock
to persons and animals. Whilst this may not cause direct injury due to the low test current
(mA) a resultant shock may cause an indirect injury by a person’s reaction to the shock
such as fall. As previously stated good quality leads and probes should be used
complying with GS38 and inspectors should be careful to avoid direct or indirect contact
with the test voltage.

An installation with good insulation resistance will act as a capacitor and in addition the
installation may contain capacitors for such things as power factor correction. Applying
the test voltage to the installation may cause it to charge up and retain that charge which
in turn could deliver a fatal shock. Insulation resistance tester to BS EN 61557-2 is
designed to discharge any charge voltage on the installation after test. It is important that
the test leads remain connected to the installation when the test button is released so that
any charge will be discharged through the instrument.

Insulation resistance test voltages may damage connected electronic equipment. It is

important that all electronic equipment is disconnected prior to commencing insulation
resistance testing. If this cannot be done the test voltage should be reduced to 250V or the
test should be applied between all the live conductors connected together (neutral is a live
conductor) and earth.

If the premises being tested contains animals such as horses, cattle or sheep these should
be removed to another area before testing commences.
5.0 Preparation

The following steps should be taken prior to commencing testing.

1. Seek permission to isolate the installation from the building occupier, owner or
duty holder.
2. Isolate the installation from all sources of supply and lock off all supplies.
3. Test the installation to ensure it is dead with an approved voltage tester.
4. Remove all connected loads, lamps, electronic devices, neons and indicator
lamps, disconnect functional earths from RCBOs etc.
5. If the installation is 3 phase the supply neutral will need to be disconnected. If the
main switch is not a 4 pole switch then the neutral link or neutral will need to be
disconnected. WARNING when removing neutral links or a neutral connection
use insulated tools. This is necessary as if there is a borrowed neutral on the
installation, for example from another distribution board, the moment the neutral
is disconnected the installation may become live although it is isolated.
6. Select an insulation resistance tester and check to see it is undamaged, in god
condition, the batteries are in a charged state and the instrument is in calibration.
7. Select a set of leads, probes and clips hat comply with HSE GS38 and are
undamaged and in good condition.
8. Select the appropriate test voltage.
9. Connect the leads to the tester and check for correct function.

6.0 Procedure

1. Connect with a temporary link to short all the live conductors (including neutral)
together.
2. Apply the IR test between the live conductors and earth and record the test result.
3. Remove the temporary link from the neutral leaving all 3 lines connected
together. For single phase remove the link altogether.
4. Apply an IR test between the 3 lines and neutral and record the result. For single
phase test Line to Neutral.
5. Remove the temporary link and test between the line conductors i.e. L1 to L2, L1
to Line 3 and L2 to L3. And record the result.
6. Record the lowest test results on the schedule of test results.
7. Remove all temporary links. Reconnect the neutral or neutral link. DANGER
if the neutral is not connected and the installation is energised extensive
damage due to over voltage will be caused or a fire may be started.
 7.0 Evaluating Test Results

For a 230/400V installation BS7671 requires a minimum insulation resistance of 1 MΩ

for a distribution circuit or complete switchboard (distribution board). IET Guidance
Note 3 (Ref. 4) states that if any reading of less that 2MΩ is obtained then further
investigation is needed. In practice individual new circuits will have values in excess of
200MΩ.

A new domestic installation with a consumer unit of up to 15 circuits should exhibit an

insulation resistance of >200MΩ when all circuits are tested as a complete installation.
Low insulation resistance values may indicate a breakdown of insulation, missed
electronic devices, presence of moisture, touching conductors, damage to conductors. etc.
When testing a new installation and finding low insulation resistance no further testing
should be carried out. The defect should be found and rectified. Previous continuity tests
should be repeated before carrying out a further insulation resistance test. The installation
should not be energized until all the required dead tests are completed in the correct order
and satisfactory test results are achieved.

NOTES ON GLOBAL IR TESTING OF DISTRIBUTION BOARDS.

The table below lists some of the possible outcomes for insulation resistance testing
carried distribution boards. The outcomes are based on a whole board (global) test
between all live conductors connected together and earth at a test voltage of 500V. It
should be noted that 3 phase distribution boards with large numbers of final circuits will
have lower insulation resistance readings than smaller, say 15 way, single phase
consumer units. Whilst BS7671:2008 provides a minimum acceptable value of 1MΩ for a
switchboard (distribution board) for Initial Verification there is no given minimum value
for periodic testing . The inspector will need to measure the values of insulation
resistance for a given distribution board and then take a view based on his/her
engineering judgement whether this is acceptable. For example a large 72 way
distribution board supplying an office floor with over 100 fluorescent light fittings,
numerous emergency light fittings controlled by one or more electronic control panels
may exhibit a global insulation resistance of less than 1MΩ but the installation may
actually be satisfactory.
 TEST RESULT MΩ POSSIBLE CAUSE SUGGESTED ACTION
O Neutral Earth Fault 1. Check neutral is
disconnected or neutral link
has been removed on 3
phase DB.
2. Carry out continuity test
live/earth. If low ohms
neutral earth fault. Possible
crushed or damaged
conductors behind
accessories or in
containment.
<1 Surge Protection Device(s) fitted. 1. Repeated slow rising IR
values followed by a sharp
drop in IR value.
2. Re-test at 250V for steady
reading.
<1 Function earth flying leads of 1. Disconnect flying leads and retest.
RCDs/RCBOs connected to earth
<1 Large numbers of final circuits on 1. Verify numbers of light
large 3 phase distribution board. fittings and other
equipment with electronic
devices are connected to
the neutral bar.
2. Check for computers,
servers, comms. cabinets
and other IT equipment is
still connected.
Take an engineering view of IR
value
<20 Domestic installation or similar 1. Check for appliances
single phase installation with up to 15 plugged in.
circuits may have connected 2. Check boilers, immersion
equipment. heaters, alarm panels and
similar equipment is
switched off at a double
pole switch.
Low IR for the size of the 1. Damage to conductor or 1. May be identified by visual
installation. accessory insulation. inspection.
2. Water penetration of 2. May be identified by
enclosures. dividing the installation in
3. Failure of MICC cable to smaller parts or testing
insulation. individual circuits.
4. Thermal damage,
burning/charring of
conductor or accessory
insulation.
5. Plaster or other dust
particle deposits on or near
conductor terminations.
6. Mould growth on or near
conductor terminations.
7. RCD sockets or RCD
fused connection units.
8. Conductor/cable insulation
degrading with age e.g. old
rubber (VIR) cables.
9. Deposits of hygroscopic
salts in accessories after
flooding of premises.