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Electrical Safety Testing

electrical safety testing

Electrical Safety Testing, When a product is produced, these tests allow it to check whether the product is suitable for protection against electrical voltage, as well as to check component quality and safety. The following are the most popular tests for security tests.

EN60065: Security for audio, visual and simple electronic devices:

Example: amplifiers, radio receivers, antenna amplifiers, electronic music circuits

EN60204-1: Safety for machines

Example: Metal, wood, textile machinery

EN60335-1: Safety for Household Appliances and Similar Electrical Devices

Example: coffee machines, dishwashers, washing machines

EN60598-1: Safety of Lighting Devices

Example: Lampholders, lamps, electronic ballasts

EN60601-1 Safety of Medical Electronics Devices

Example: Surgical devices, dental examination devices

EN60950: IT equipment security

Example: typewriter, calculators, modems

EN61010-1. Safety of electrical equipment for measurement, control and laboratory use

Example: Regulation devices, measuring devices, electrical devices for laboratories

EN61131-2 Safety for Vending Machines

Example: Programmable controls

IEC990 TECHNICAL REPORT-Measurement methods for touch current and protection operating current

This report is the reference for illicit procurement and will be the only reference in the future.

Main Electrical Safety Testing

  1. Earthing continuity test
  2. HIPOT test (withstand, dielectric insulation test, high voltage, flash test)
  3. Insulation Test (also called high resistance or megaohm test)
  4. Leakage Current Measurement Test (other name leakage current test)


Purpose: To check whether the touchable accessible surfaces have earth protection.

Principle: voltage is applied between the earth protection connection and accessible metal surfaces and the voltage between these two parts is measured.

It is checked that the resistance calculated according to Ohm is smaller than the specified resistance.

Test conditions (according to main standard):

  • Current 10.25 A AV-C or DC, or 2xIn
  • Voltage between 6-12 V AV or DC
  • Resistance <0.1 Ω, 0.2 Ω or 0.5 Ω
  • Time> 5 sec. 1mn or defined.



To check insulation and material quality

A constant continuous voltage is applied for a specified period of time, the current generated between the two parts tested is measured, and Ohmic’s law checks that the insulation resistance is higher than the minimum required by the standard.

In general, phase and neutral shunt are made and between these 2 shunt points are tested from earthed points. The device is not connected to the mains.

Test conditions (according to main standard):

  • Voltage 500 V DC
  • Duration 1 minute
  • Resistance> 1 M to 10 MΩ

HIGH VOLTAGE TEST (also called hypot, flash or dielectric resistance test)

Purpose: It is checked that insulation distances and gap distances are met.

Principle: DC or AC voltage is applied over a period of time, the resistance between the two parts tested is measured, and Ohmic’s law checks that the current is below the required value by the standard.

Usually phase and neutral shunt is made and between these 2 shunt points are tested at grounded points. The device is not connected to the mains.

Test conditions (according to main standard):

  • Voltage: from 230 V to 15 KV (50 or 60 Hz) or peak level from 330 V to 20 KV in 1.2 / 50 microseconds
  • Current: Equivalent to 200 mA max or 500 VA in short-circuit or unspecified (in this case, the current acceptable to the customer must be defined by itself to avoid NPNFO)
  • Duration: 1 second to 1 min. Yeah, that’s it.
  • Sanction: Neither puncture nor arc

** Half of the nominal voltage must be applied first, then the nominal voltage must be reached.


To check that the leakage current from the power supply to accessible parts is below the permissible value under normal operating conditions (equipment powered).


The device under test is powered by an isolation transformer at nominal voltage and the leakage current between each line (phase or neutral) and protective earth is measured.

This is the only test that requires power to the Device.

Test conditions (according to main standard):

  • Voltage (Power supply): Nominal voltage, 6% of nominal voltage or 9% or 10% of nominal voltage
  • Current limit: between 0.5-7 mA
  • Measured circuit: 1750 Ω or 2000 Ω
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