How to Test Wire Insulation

Wiring is designed to withstand a certain voltage based on the thickness and quality of the wire material, but the ability of a wire to withstand certain voltages also depends on the insulation. Most wire is rated up to a certain voltage and this maximum voltage is generally printed on the side of the wire. If you wish to test a wire to see how much voltage it can withstand before the insulation breaks down, you can do this with a hi-pot tester.

Hi-pot tester
Wires

Instructions

- 1
  Wrap one end of the test wire around the positive terminal on the hi-pot tester. If the tester includes alligator clamps or some other type of connecter, clamp it around the exposed end of the wire, making sure the wire and clamp are not making contact with any other metal.
- 2
  Wrap the other end of the test wire around the negative terminal on the hi-pot tester. If the tester uses a different type of connector, attach it to the wire, making sure it does not come in contact with the other connector or any metal objects.
- 3
  Plug the hi-pot tester into a grounded wall outlet and turn the voltage down to the lowest setting, then press the power switch to turn on the device. Set the switch to "DC."
- 4
  Turn up the voltage knob slowly to the level you would like to test while comparing the meters or reading the digital display for continuity. If the meters or display do not reflect smooth continuity, the insulation has likely failed. You may need a stronger type of wire for your application.
- 5
  Turn the voltage knob to the lowest setting and press the power switch to turn off the tester. Unplug the unit and disconnect the wire from the connectors.

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