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All of these tests are tools you can use to better understand how a cable will perform and to monitor any changes in the cable's performance.
Dielectric breakdown testing is used in product design and qualification stages. It helps establish the maximum voltage of the design. It can also be used on a random sample basis to verify that the maximum voltage is not changing. Dielectric breakdown testing may be required during the development of assemblies used in critical applications.
Many test specifications require a Dielectric Withstand Test on every cable produced. The test is usually done at about 75% of the typical breakdown voltage. It is done as a safety net. The test is sensitive to arcs or corona so it often finds terminal spacing problems, over-mold problems, tolerance errors in IDC cables, or any problem that might produce arcs. This test doesn't significantly degrade the cable.
The Insulation Resistance test is typically done on every cable tested. It is usually done at 300 to 500 Vdc with 100 to 500 Megahoms resistance. The test is very sensitive to contamination in the assembly process. Solder flux, oils, mold release agents, and skin oil all can cause problems. This test excels at identifying insulation that will conduct in the presence of moisture. Doing this test on every cable allows you to detect contamination changes in the manufacturing process.
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