In electrical engineering, electrical safety testing is essential to make sure electrical products and installations are safe. To meet this goal, governments and various technical bodies have developed electrical safety standards. All countries have their own electrical safety standards that must be complied with. To meet to these standards, electrical products and installations must pass electrical safety tests.
Some types of electrical safety tests include: dielectric withstand test (also called a hipot test) insulation resistance test (IR test) earth continuity test leakage current test
Electrical safety tests are described in IEC 60335, IEC 61010, AS/NZS 3000, NFPA 70, BS 7671, and other national and international standards.
Electrical Safety tests
Dielectric voltage withstand test
A dielectric voltage withstand test (also known as a hipot test) is done by applying a voltage higher than operating voltage to the device or installation under test. In this test, the electric insulation of a product or installation is put under a voltage stress much higher than its normal operating voltage. If the hipot test is done for type testing purposes, a much larger voltage may be applied.
Insulation resistance test (IR test)
An insulation resistance test (IR test) measures the electrical resistance of insulation by applying a voltage between two locations, and measuring the resultant current flow. Proper safety precautions must be taken when doing this test, such as exclusion zones, making sure no wires are exposed, and personal protective equipment is worn. To do this test, you need to have an insulation resistance tester, which may be a small hand held battery powered device, up to a larger luggage sized tool able to achieve higher test voltages. Variables to choose before starting an electrical resistance test is the test voltage, test duration, and test points. Acceptable values of insulation resistance vary depending on circuit purpose, industry, and country. Typically, standards will dictate acceptable values. An insulation resistance test can be used for simple go/no-go testing, or for periodic condition assessment, where routine insulation resistance tests are performed, with the results tracked over time. By tracking the insulation resistance of a circuit over time, preventative maintenance may be able to be planned before equipment failure. Insulation resistance is dependent on temperature and humidity variations, therefore the temperature and humidity should be recorded when testing and compensation applied to the measured value given. Many standards and safety agencies have specified the insulation resistance test as a required test for electrical installations and electrical products. This test may be referred to as "meggering', after the company Megger was one of the first companies to commercialize an insulation resistance test meter. These days, many other brands are widely available.
Earth Continuity Test
An earth continuity test checks if a metal part is connected to earth. The resistance of the connection to earth can also be measured.
Leakage Current Test
A leakage current test detects current that does not flow back through the circuit. This test may be used as part of testing GFCI or RCD operation.
Electrical Safety test categories
Visual inspection:
A survey without touching anything, and looking at the electrical installation or product before starting any electrical testing. A visual inspection seeks to identify damaged insulation, disconnected wires, incorrect installation, and any other visual issues.
Non-live testing
Continuity test: a test to check the wiring is correct
Earth continuity test: this test is to make sure the earthing system is properly connected
Live testing
Earth fault loop impedance testing: this test is to check that if a fault did occur, that the system meets requirements to cause a disconnection of the supply within the time limit specified by standards
Insulation resistance testing
Polarity test: a test to check that the connections are connected in the right sequence
RCD testing: on modern electrical systems RCD's and RCBO's are regularly fitted, these devices react to electricity leaking from the circuit. Leakage may happen when a person touches live parts, which can cause electricity to passes through their body instead of the normal circuit return path.
SPD Test: SPD (Surge Protective Device) is tested as part of the electrical safety test. Surge protection devices safeguard the electrical setup, including the consumer unit, wiring and accessories from dangerous power surges known as transient over voltages.