Photovoltaic module insulation resistance tester

The Photovoltaic Module Insulation Resistance Tester is a precision instrument designed for simultaneous measurement of insulation resistance and leakage current in PV modules. It ensures compliance with IEC 61215 and UL 61730 standards, providing reliable and non-destructive testing for residential, commercial, and utility-scale photovoltaic modules. The tester integrates advanced AI-powered diagnostics and auto-ranging functionality for efficient and accurate evaluation of module insulation integrity.

Application

The tester is suitable for:

Quality control in photovoltaic module production lines.

Research and development of module insulation materials.

Periodic inspection of installed PV modules for insulation degradation.

Testing for potential PID (Potential Induced Degradation) risks.

Standards

IEC 61215: Terrestrial Photovoltaic (PV) Modules – Design Qualification and Type Approval

UL 61730: Safety Standard for Photovoltaic Modules

ISO 17025: General Requirements for the Competence of Testing and Calibration Laboratories

CE Certification (Conformité Européenne)

Features

Dual-Parameter Testing: Simultaneously measures insulation resistance and leakage current, eliminating the need for separate instruments.

High Reliability: AI-assisted diagnostics automatically flag insulation breakdown patterns and predict PID risks.

User-Friendly Operation: Laser-guided probe placement ensures precise contact on textured module surfaces.

Non-Destructive Testing: Preserves sample integrity during measurement.

Environmental Compensation: Dynamic calibration corrects for temperature and humidity drift.

Safety Assurance: Dual redundant emergency circuits and E-stop ensure safe operation.

Integration Capability: Can interface with MES/ERP systems and cloud-based analytics for smart data management.

Parameters

Parameter	Specification
Insulation Resistance	100 kΩ – 10 TΩ (10⁵ Ω – 10¹³ Ω)
Leakage Current	10 nA – 20 mA (auto-ranging)
Test Voltage	1.0 – 1,000 VDC (0.1 V steps <100 V, 1 V steps ≥100 V)
Voltage Accuracy	±1% (at 1,000 VDC)
Measurement Speed	55 / 25 / 3 readings/second (high / medium / full)
Max Charging Current	30 mA ±5 mA
Power Supply	100–240V AC, 50/60Hz (universal adapter)
Dimensions (W×D×H)	300mm × 250mm × 150mm
Weight (Net/Gross)	5 kg / 7 kg

Accessories

Testing Kit: 4x insulated test probes (10 kV rated), 10x alligator clip leads (red/black)

Software Suite: License key for InsulationAI Pro (Windows/macOS), 1-year free cloud-based analytics

Calibration & Safety: NIST-traceable resistance standards (1 GΩ, 10 GΩ), explosion-proof gloves (Class 00, 3 pairs)

Maintenance Kit: Spare fuses, probe tips, cleaning solution for optical components

Documentation: Multilingual quick-start guide (printed + digital), IEC/UL/ISO compliance certificates

Test Procedures

Install the PV module on the test fixture and connect the insulated probes.

Set the desired test voltage or allow auto-ranging to select optimal voltage.

Initiate the measurement sequence via the touchscreen HMI.

Monitor real-time readings of insulation resistance and leakage current.

Review AI-powered diagnostics for potential insulation defects or PID risks.

Record and export test results to local or cloud storage.

Maintenance Information

Inspect and clean probes and leads after each testing session.

Calibrate resistance standards periodically following NIST guidelines.

Check and replace fuses and probe tips as needed.

Ensure environmental conditions (temperature/humidity) are stable during long-term operation.

Store the tester in a dry, dust-free environment when not in use.

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