Electrical testing:

Electrical safety testing is essential to ensure safe operating standards for any product that
uses electricity. Various governments and agencies have developed stringent requirements for
electrical products that are sold world-wide. In most markets it is mandatory for a product to conform
to safety standards promulgated by safety and standard agencies such as UL, CE, VDE, CSA, BSI, and
so on. To conform to such standards, the product must pass safety tests such as the high voltage
test (also called as Dielectric voltage-withstand test or high potential test), Insulation Resistance Test,
Ground (Earth) Bond & Ground Continuity Test & Leakage Current Test (also called as Line Leakage
Test, Earth Leakage Current Test, Enclosure Leakage Current Test or Patient Leakage Current
Test). These tests are described in IEC 60335, IEC 61010 and many other national and international
standards.

In general, IEC 60335 is the most widely applied standard for electrical safety testing, especially for
domestic appliances. Many safety testing standards in the world have been based on it. To
safeguard workplace health and safety, many sections of the Occupational Health and Safety
Regulation provide guidelines on electrical safety and the appropriate equipment required to work on
low and high voltage electrical appliances.

Visual Inspection

Visual inspection is a common method of quality control, data acquisition, and data analysis. Visual
Inspection, used in maintenance of facilities, mean inspection of equipment and structures using
either or all of raw human senses such as vision, hearing, touch and smell and/or any non-specialized
inspection equipment.

High Voltage Test (Dielectric Voltage-withstand Test)

This test is carried out by applying a significantly higher than operating voltage to the device under
test. In this test, the insulation of a product, stressed to a greater extent than under normal operating
conditions, should not be breached for the product to pass. In most cases, the device is stressed to
twice its normal operating voltage. During type testing, i.e. testing during designing a product or for
a double insulated product, however, much larger voltage may be applied. For all electrical products,
the high voltage test is a universal test, meaning that every unit should pass before it can be used.

Insulation Resistance Test

This test is to measure the total resistance of a product’s insulation by applying a voltage of 500V –
1000V. The minimum acceptable value of resistance for a product to pass an insulation resistance test
is normally 1 Mega Ohms or 100 Mega Ohms. The insulation resistance test is not a substitute for the
high voltage test. Many standards and safety agencies have specified this is a universal test for all
products. This test may also be carried out after every maintenance procedure or repair.
Earth Bond Test

This test is performed by measuring the resistance between the third pin (ground) and outside metal
body of the product under test. The maximum acceptable value is generally 0.5 ohms although
certain standards may specify 0.1 ohms. This test is generally carried out at a slightly higher current
(e.g. 25-60A) so that the ground bond circuit maintains safe voltages on the chassis of the product,
even at a high current, before the circuit breaker trips. This test is essential so that the product does
not cause an electric shock resulting from insulation failure.

Leakage Current Test (Line Leakage Test)

This test is to measure the undesirable leakage current that flows through or across the surface of the
insulation or the dielectric of a capacitor. This test is generally carried out at 100%-110% of the rated
input voltage of the product under test. The maximum acceptable limit of a leakage current is
generally 210 micro amperes. At first, this test was mandatory for medical devices only.

Resource list

For more information regarding electrical testing please refer the book below:

I. Jeffry Hampson, Steven Hanssen. Electrotechnology, Practice. 3rd ed. Pearson, 2014. Pages
487 - 534
II. Christopher Kitcher. Practical Guide to inspection, testing and certification of electrical
installation. 3rd ed. 2013.
Standard Electrical Test Result Template:
DB reference no Details of circuits and/or installed equipment vulnerable to damage Detail of instrument used (state serial and/or asset number)
Location when testing Continuity tester:_____________________________________________
Correct supply polarity confirmed Insulation resistance:___________________________________________
Phase sequence confirmed Earth fault loop impedance:_____________________________________
RCD:________________________________________________________
Earth electrode resistance:______________________________________
Tested by (Name with Capitals): Test results
Remarks (continue
Continuity Insulation RCD on a separate
Ring final circuit continuity Ω Resistance Zs sheet if necessary)
Signature: Date: Polarity
Ω (R1+R2) Insulation Ω
Circuit Details or R2 (MΩ) (ms)
Overcurrent device Conductor details
R1 Live
Breaking Live Test
Circuit Circuit BS Rating Reference Live Cpc R1 Rn R2 + -
Type capacity R2 - @I∆n @5I∆n Button
Number description (EN) (A) method (mm2) (mm2) (line) (neutral) (cpc) R2 Eart
(kA) Live operation
* h