GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS
(For official use only)

MEGGERING OF SIGNALLING CABLE

CAMTECH/ S /2004/MSC/1.0

AUGUST 2004

Centre
for
Advanced
Maintenance
TECHnology Excellence in Maintenance

Maharajpur, Gwalior – 474020

E-mail –[email protected]
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INTRODUCTION
Meggering of Signalling cable is done to test the continuity and
insulation of the cable conductors. The Meggering should be
carried out at initial stages, before and after cable laying. For
maintenance purposes these tests shall be performed periodically.
Low insulation of cable leads to inadvertent energisation or de-
energisation of circuits. Check for insulation values periodically
enables to ensure integrity of circuits.
If a sudden fall in the value of insulation is observed during the
test, the cause should be investigated and immediate action should
be taken to repair or replace the defective cable.

PREPARATORY STEPS
1. Before commencement of cable Meggering necessary
disconnection from traffic shall be obtained.
2. All working circuits and power supply shall be disconnected
from the cable at both ends.
3. Communication between the ends of cable under test shall be
established by magneto telephones with other cable which is
not under test if possible, otherwise by VHF sets.
4. Competent staff, required instruments and material shall be
available at both the ends.
5. Meggering shall be carried out when conductors and
insulated parts like terminal blocks are clean and dry.
6. Cable conductors shall be shorted/earthed momentarily to
discharge the accumulated charge, if any, before the
commencement and after the end of Meggering.

PROCEDURE OF CABLE MEGGERING

Following tests are performed for Meggering of Signalling cable:
(A) CONTINUITY TEST

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Tools & Equipments required
1. Multimeter
2. Wire nipper
3. Screw driver set
4. Box spanner

Multimeter Armour
Earth

1 1
2 2
E 3 3
4 4
5 5
6 6
LOCATION A LOCATION B

This test is carried out to confirm that the core under test is either
showing break between both ends or continuous. Testing can be
commenced as per the following procedure:
• Set the knob of multimeter to check resistance at 200 ohm
range. (At Location A)
• Connect one probe of multimeter to earth and other probe to
the end of the cable conductor to be tested, as shown in above
figure.
• Instruct staff at the other end (at Location B) to connect earth
to same conductor of the cable.
• If earth is light at both ends, connect earth to armour also at
both the ends.
• Deflection of multimeter needle shows that the conductor
under test is OK; otherwise there is a break in the conductor.
• Then test continuity of all other conductors with respect to
this tested conductor. For example to test conductor 2,

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 connect the one probe of the multimeter to conductor 2 and
other probe to the tested conductor (at Location A). Instruct
the staff at other end (at Location B) to short conductor 2 with
the tested conductor.
• Test continuity of all other conductors as above.
(B) INSULATION TEST
Tools and Instruments required
1. Insulation Tester (Megger) 500V DC
2. 2. Wire nipper
3. Screw Driver set.
4. Box spanner
5. Crocodile clips (equal to maximum No. of cores of cable
to be tested) looped together in series
This test is carried out to measure the insulation resistance of the
cable under test. Insulation resistance measured between (1)
conductor to conductor, called cross insulation, and (2) conductor
to earth. Procedure is as follows:
(1) Conductors to conductor (Cross Insulation)
1 Cable
Meggar Line 2 Conductors
500 V 3
DC Earth 4
5
Location 6

(i) A 500 V Insulation Tester ( Megger ) shall be used for this

test and kept at one end of the cable under test.
(ii) The first conductor for which cross insulation is being
measured shall be connected to Line terminal of the megger.
The remaining conductors looped together (with the help of
crocodile clips) i. e. Conductor 2 and onwards, are connected

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 to Earth terminal of megger as shown in figure. Conductors at
the other end are left free.
(iii) Now rotate the handle of megger or press push button of
megger. The reading of meter will show the cross insulation
between conductor 1 and rest of the conductors. Insulation
reading shall be recorded after applying the test voltage for
about a minute till a steady reading is obtained.
(iv) Now connect next conductor to Line terminal of the megger
& connect the remaining conductors to earth terminal of the
megger and take measurements as per procedure II & III.
(v) Record the measurements in the prescribed format as shown
in Annexure A.
II) Conductor to Earth Insulation

500 V Line
CONDUCTOR
Meggar
Earth
Earth

(i) By this we can measure individual insulation of conductors

w.r.t. earth.
(ii) Connect conductor under test to the Line terminal of the
megger.
(iii) Connect earth terminal of the megger to the earth.
Rotate the handle of megger or press push button of megger.
The reading of meter will show the insulation resistance of the
conductors. Insulation reading shall be recorded after applying
the test voltage for about a minute till a steady reading is
obtained.
(iv) Replace the conductor at Line terminal of the megger by
another conductor under test and repeat as process IV.
(v) Record the measurements in the format:

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ANNEXURE ‘A’
Proforma for cable testing.
____________ Railway
Station ___________________
CABLE INSULATION RESISTANCE TEST SHEET
Main/Tail* Cable
1. Location: From . . . . . . . To . . . . .. . . . . .
2. Cores: .......................
3. Size: . . . . . . . . . . . . . . . . . . . . . . .
4. Grade 250/440/650/1100V
5. Length: ……………………..
6. Type:Unscreened/Screened……………
7. Insulation: PVC/Paper *………….
8. Date of installation/Commissioning . . . .
9. Name of the manufacturer: . . . . . . . . . . .
Core No. Date of Test ……… Temperature…….
or Designation and whether Remarks…………
………………. wet, damp or dry. Signature………..
*Strike out whichever is not applicable.
CABLE MEGGERING CHART
1 2 3 4 5 6 7 8 9 Earth Re-
marks
1 X
2 X X
3 X X X
4 X X X X
5 X X X X X
6 X X X X X X
7 X X X X X X X
8 X X X X X X X X
9 X X X X X X X X X
Signature
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NOTE : These measurements shall be recorded in two
copies. One copy each shall be kept in SE(Sig.) office and
Sr.DSTE’s office.
Insulation Resistance for a new should not be less than 200
Mega ohm per kilometer at 200C For converting measured value
of Insulation resistance at any temperature to that of 20o C, a table
of multiplier constants is to be referred
PERIODICITY OF TESTING: The periodicity of testing of cable
insulation may be different in different railways. But testing
programme shall be followed as per policy guidelines issued by
Railway Board as under: (ref.-8th MSG meeting Sept.2001)
(i) First measurement of insulation of the cable should be carried
out after laying of the cable and after first monsoon for all the
conductors.
(ii) Insulation measurement of the cable need not be carried for
next 3 years.
(iii) Testing of all the conductors should be carried out on 5th year
after 1st monsoon and every alternate year thereafter. Spare
conductors will be tested every year.
(iv) From 10th year after first monsoon, testing of all conductors
should be carried out (a) every alternate year if insulation is
more than 10 mega ohm/km or (b) every year if insulation is
less than 10 mega ohm/km
PREVENTIVE MEASURES:
(i) If during periodical testing, insulation resistance of cable is
found between 5 and 1 mega ohm/km at buried temperature,
the subject cable should be programmed for replacement.

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(ii) If insulation resistance of the cable is found between 1000 and
100 kilo ohm/km, at buried temperature, the subject cable
should be replaced urgently within a year.
(iii) If the insulation resistence of the cable is found less than 100
kilo ohm/km., the subject cable must be replaced immediately
on emergency basis.
PRECAUTIONS:
Before commencement of Meggering:
Make sure that all connections in the test circuit are tight.
Test the megger before use, whether it gives INFINITY value
when not connected , and ZERO when the two terminals are
connected together and the handle is rotated.
During Meggering:
Make sure when testing for earth, that the far end of the conductor
is not touching, otherwise the test will show faulty insulation when
such is not actually the case.
Make sure that the earth used when testing for earth and open
circuits is a good one otherwise the test will give wrong
information
Spare conductors should not be meggered when other working
conductors of the same cable are connected to the respective
circuits.
After completion of cable Meggering:
Ensure that all conductors have been reconnected properly.
Test the functions of Points, Tracks & Signals connected through
the cable for their correct response.
In case of signals, aspect should be verified personally.
In case of points, verify positions at site.
Check whether any polarity of any feed taken through the cable
has got earthed inadvertently.

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