Guide to

Portable Appliance Testing

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Table of Contents
Introduction........................................ 2 Visual Examination and
Electrical Testing................................. 9
What is Portable Appliance
Frequency of Visual Examination
Testing?................................................ 2
and Electrical Testing..................... 9
Why Should Electrical Equipment and Operator Checks (Procedure)...... 10
Appliances be Tested? ....................... 4 Formal Visual Inspection
What Inspection and Testing (Procedure)................................... 12
Needs to be Done?............................. 6 Combined Visual Examination
and Electrical Testing
What Types of Electrical Equipment Procedure..................................... 15
Need Visual Examination and
Electrical Testing?............................... 6 Electrical Tests................................... 16
Multiway adapters and GFCI Earth Bond/Continuity Test......... 17
Adapters......................................... 7 Insulation Test.............................. 19
Extension Cords and GFCI- Protective Conductor/Touch
protected Extension Cords............ 7 Current Measurement................. 20
Hand-held Equipment................... 7 Differential Leakage Test............ 21
Portable Appliances....................... 7 Substitute/Alternative
Information Technology (IT) Leakage Test................................. 21
Equipment...................................... 7 Load Test....................................... 22
Portable Equipment....................... 7 Flash Testing................................. 23
Static Equipment............................ 8 Faulty or Damaged Equipment....... 23
Fixed Appliances............................ 8
Missing Equipment........................... 23
Built-in Equipment......................... 8
Labelling............................................ 24
Construction of Electrical
Equipment .......................................... 8 Documentation................................. 24
Class I Equipment ......................... 8
Portable Appliance Testers
Class II Equipment ........................ 8 Available from Megger.................... 25
Class III Equipment......................... 9 Megger PAT320............................ 25
Megger PAT450............................ 26

www.megger.com A Guide to PAT Testing 1

Introduction
We live and operate in a world filled with electrical equipment and
appliances. Electrical “things” fill our homes, our offices, our manufacturing
facilities and the places we go for leisure activity. Electricity poses dangers.
Personnel can be injured, sometimes fatally, by malfunctioning electrical
equipment. Fires caused by defective electrical equipment and appliances
damage property and cause large financial losses for companies. In addition,
ours is a litigious society and lawyers are waiting for opportunities to file
lawsuits.

How does an equipment rental company ensure that a piece of electrical

equipment is electrically sound/safe every time it goes out to a customer?
How do in-house tool cribs ensure that their electrical equipment is safe for
the next person to use it? How do manufacturing companies ensure that the
appliances and equipment they make have no dangerous electrical faults?

Beyond the challenges of protecting personnel and property, many of

our manufacturing plants produce electrical equipment for sale into
the European Union that must meet European standards. While it is the
responsibility of the European importer to ensure that imported items
are safe to European standards, any testing done at the destination can
prove quite costly for the manufacturer when faults are found. Identifying
problems at the manufacturing plant allows for faults to be fixed prior to
shipping and export.

A number of European countries, including the UK, make extensive use of

portable appliance testing to ensure the safety of electrical equipment and
appliances. This booklet will provide a guide to understanding portable
appliance testing and how/where it fits as part of an overall electrical safety
program. While we use the term “portable appliance testing”, a better
description might be portable electrical equipment testing.

What is Portable Appliance Testing?

Portable appliance testing is the visual examination and electrical testing of
portable electrical equipment used in industrial, commercial or public access
areas and locations (including rented property) to ensure they are safe to
use, and cannot present an electrical hazard to the operator or anyone in
their vicinity. Among the issues that can arise are:

2 A Guide to PAT Testing

n Exposure to live, conductive parts due to damage to the outer casing of
the equipment.

n Worn and/or frayed power cord.

n Defective, loose or missing earth/ground connections.

n Failure to identify and correct problems such as those listed above can
result in the electrical equipment becoming a shock hazard or a fire risk.

Many of these problems can be identified visually, but still often go

unreported. Internal faults often go undetected. Portable appliance testing
involves performing a series of tests that, taken together, are designed to
identify any faults or product defects that would otherwise not be detected.
In addition to protecting personnel, regular safety checks of electrical
equipment tend to increase the operational life of that equipment. A
portable appliance tester (PAT) allows the operator to make a number of
safety tests with a single instrument, including:

Earth Bond and Continuity Tests

To verify the integrity of exposed metalwork on grounded appliances.

Insulation Test
To check that equipment conductors are isolated from earth.

Touch Current Test

To check that the equipment case and all exposed metal parts are isolated
from earth/ground.

Differential Leakage Test

To measure the difference in current between live and neutral conductor
during operation.

Substitute/Alternative Leakage Test

To check that the equipment case and all exposed metal parts are isolated
from earth/ground, by use of a safe test voltages as an added protection
against seriously faulted test items.

Functional Load Test

An operational test to ensure the asset works as it should without drawing
excessive current from the supply.

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Extension Cord and IEC Power Cord Tests
To check extension cords and line cords for safe operation.

In addition to these standard tests, some instruments will perform a flash test
(hipot or dielectric strength test) to test breakdown voltage levels. This test is
normally done on new equipment, articles that have had a major overhaul,
or equipment in the rental industry.

Why Should Electrical Equipment and Appliances be Tested?

The key word is liability. An employer or manufacturer should show as
much concern about safety as does the legal system. The liability is with the
employer or owner of a place of business, or public place, to ensure that all
electrical equipment accessible by employees or the public is maintained in a
safe condition. The liability is with the manufacturer of electrical equipment
to ensure that the equipment is safe for those who operate it. The best way
to ensure electrical safety is by routine visual examination, electrical testing
and documentation.

In the UK, the Health and Safety at Work Act and the Electricity at Work
Regulations, while not specifically dictating that portable appliance testing
must be carried out, do state that all electrical systems (which include
appliances) must be maintained to prevent injury and danger. The Provision
and Use of Work Equipment Regulations 1998 (PUWER 98), made under
the HSW 1974 act, states: “the provision and maintenance of a working
environment for his employees that is, so far as reasonably practicable, safe,
without risks to health, and adequate as regards facilities and arrangements
for their welfare at work”. Regulation 4(1) of PUWER 98 has a more direct
meaning to portable appliances, it states: “Every employer shall ensure
that work equipment is so constructed or adapted as to be suitable for the
purpose for which it is used or provided.” In the USA, the Department of
Labor governs the Occupational Safety and Health Administration (OSHA).
Electrical safety is addressed in rule 72:7135-7221 and the NFPA 70E Electrical
Safety Requirements for Employee Workplaces. The purpose of the OSH
(Occupational Safety & Health) Act, 29 U.S.C. 651 et seq., is “…To assure
so far as possible every working man and woman in the Nation safe and
healthful working conditions and to preserve our human resources.” The
requirements are regularly revised in accordance with the most current

4 A Guide to PAT Testing

practices and technologies, and in response to a request by those concerned
to reflect the most recent editions of NFPA 70E and the NEC. The stated
goal is to “…provide nationally recognized safe electrical installation
requirements,” and to assure that “…the requirements contained in that
standard are current and at the forefront of electrical safety technology.”

The standard states that “…electricity is widely recognized as a serious

workplace hazard, exposing employees to electric shock, burns, fires, and
explosions.” Underlying causes are listed as “...work involving unsafe
equipment and installations, workplaces made unsafe by the environment,
and unsafe work performance.” Hazards stemming from faulty equipment
are further identified as “…faulty insulation, improper grounding, loose
connections, defective parts, ground faults in equipment, unguarded live
parts, and underrated equipment.”

Detailed information on all the definitions and full requirements of portable

appliance testing can be found in the Code of Practice for In-Service
Inspection and Testing of Electrical Equipment (3rd Edition) (ISBN 978-0-
86341-833-4) available from the Institution of Engineering and Technology
(www.theiet.org). Those environments where these regulations are
applicable include any place where someone is employed, areas of public
access, and rented accommodation of all kinds. The Code of Practice for In-
Service Inspection and Testing of Electrical Equipment identifies that regular
visual examination and electrical testing of equipment is an essential part
of any preventive maintenance program. Records of maintenance, including
test results, should be kept throughout the working life of the equipment to
enable the condition of the electrical equipment to be regularly monitored.

While the USA does not have the level of regulation found in the UK, we
are far more litigious. Implementing a regular inspection program that
includes PAT testing of electrical equipment and appliances will help protect
personnel from shock hazards, facilities from electrically induced fires
and businesses from litigation. For businesses that manufacture and ship
electrical products to the European Union, PAT testing at the factory will
ensure that products shipped will pass import testing and not become a
costly problem.

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What Inspection and Testing Needs to be Done?
The dangers of contact with live electrical parts need no explanation to an
electrician. However, the environments in which the majority of portable
appliances are used are not necessarily where operators would be aware
of the dangers or the implications of damage to equipment. The point of
routine visual inspection and electrical testing is to identify potential hazards
and actual dangers before they turn into an accident.

The hazards that must be identified include:

n Personal exposure to live conductors­— electrocution.

n High current faults causing excessive heat­— fire.

n Intermittent connection­— arcing causing heat and potential ignition.

These hazards can be identified by performing in-service:

n Regular electrical tests.

n Visual examination.

n Combined visual examination and electrical tests.

Various people have responsibility for electrical equipment, including:

n Property owners, equipment owners, company owners, directors, and line

managers etc.

n The person undertaking the formal visual examination and electrical

testing.

n Maintenance managers.

n Operators of the equipment.

What Types of Electrical Equipment Need Visual Examination

and Electrical Testing?
Everything portable or transportable, whether fitted with a plug for
connection to a socket-outlet or connected directly to a fused spur, requires
visual inspection and testing. Such items include:

6 A Guide to PAT Testing

Multiway adapters and GFCI Adapters
Multiway adapters are used to increase the number of connection points
at any location within a property. The use of these adapters should be
avoided wherever possible, and a suitable judgement made during the visual
examination as to how appropriate their use is in any specific application.

Extension Cords and GFCI-protected Extension Cords

An extension cord is used where an item of equipment needs to be supplied
but a convenient socket/outlet is not nearby. Preferably, the use of extension
cords should also be avoided whenever possible. They can present physical
hazards such as tripping that could be avoided if an installation has sockets
in the appropriate place. A GFCI extension cord is one that includes GFCI
protection either at the plug or near the sockets, for powering equipment
used outdoors.

Hand-held Equipment
These appliances require the operator to hold them in their hand(s) during
normal operation (i.e. steam irons, hair dryers, soldering irons and drills).

Portable Appliances
These appliances are ones that can be easily moved while they are energized
and have a mass of less than 40 lbs. Equipment included in this category are
items such as coffee makers and electric space heaters.

Information Technology (IT) Equipment

This category covers IT business equipment that is found in most commercial
offices (i.e. mains-powered computers, telephones, printers, photocopiers,
fax machines, laminators, shredders etc.).

Portable Equipment
This category covers equipment that is:

n Not fixed to the location and weighs less than 40 lbs, (i.e. a small
television).

n Furnished with wheels or casters which is intended to be moved on an

occasional basis. (i.e. commercial kitchen or laundry equipment).

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Static Equipment
This equipment weighs over 40 lbs and is not provided with a carrying
handle (i.e. large televisions, washing machines, refrigerators).

Fixed Appliances
This equipment is securely installed in one location. Typical appliances in this
category are hot water boilers and hand dryers.

Built-in Equipment
This equipment is intended to be built into a cupboard or similar where
some electrical protection is provided by the location. Typically this
equipment does not have an enclosure on all sides because that side is
inaccessible when the equipment is in use (i.e. a built-in oven).

Construction of Electrical Equipment

The type of asset can be classified depending on the way it is designed
and made, these being Class I, Class II or Class III. The class of construction
determines what electrical tests need to be carried out.

There are also Class 0 and Class 01 assets, which are not within the scope of
this guide.

Class I Equipment
Class I equipment does not rely solely on insulating materials to protect
against electric shock, but includes the connection of exposed metal parts to
the supply earth/ground via the earth/ground conductor in the supply cable,
(sometimes referred to as CPC) in the fixed wiring of the installation. Class I
items can be identified by the presence of an earth/ground conductor in the
supply cable. Some exposed metalwork may be bonded to earth/ground, and
some may be only in casual contact with earth/ground. This casual contact
may give an unexpectedly high bond resistance when tested, and should not
be confused with a poor connection/fail.

Class II Equipment
Class II equipment has extra layers of insulation to provide additional
barriers between the operator and any hazardous voltages, and does not
rely on just one layer of insulating material to protect against electric shock.
There is no provision for connecting any exposed or internal conductive
parts to the system earth.

8 A Guide to PAT Testing

Class III Equipment
Class III equipment provides protection by supplying the equipment from
a separated extra-low voltage source (SELV), such as a safety isolating
transformer. This would include 12 V or 24 V lighting, electric razors etc.

Class II equipment can be identified by the Class II construction mark located in

a prominent position on the asset. There is no earth/ground conductor in the
supply cable for Class II equipment.

The Class III equipment can be identified by the Class III construction mark.

The safety-isolating transformer should have the identification mark shown.

Visual Examination and Electrical Testing

Visual examination is vital and always precedes electrical testing. It
often reveals major defects that would not be revealed by testing alone.
Categories of in-service visual examination and electrical testing are divided
into three types:

n Operator checks (no records if equipment is OK).

n Formal visual examination (recorded).

n Combined visual examination and electrical testing (recorded).

Frequency of Visual Examination and Electrical Testing

The frequency that the visual examinations and electrical tests are carried
out depends on a number of factors. No strict test schedules exist, but
criteria that may influence the decision include the following:

Intended use: some equipment is just more likely to sustain damage than
others. Handheld types are handled and moved more than other types and
this can lead to rough handling, which often results in damage and early life
failure. For example the continual flexing of a steam-iron cable will subject it
to more risk of early failure than that of a microwave oven.

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Surroundings: equipment installed on a construction site is more likely to
suffer physical damage (and will degrade more quickly) than if installed in
an office, and will require frequent testing.

Design: The safety of Class II equipment does not rely on the supply earth,
but on its own construction. Therefore, if Class II equipment is situated
in a low-risk environment such as an office, electrical testing (not visual
examination for cable or casing damage) may be reduced in frequency. Class
I equipment, however, relies on a low resistance path to the supply earthing/
grounding system for safety protection. If the earth conductor within
the power cable is damaged, the hazard rises and will, therefore, require
electrical testing on a more regular basis.

Operators: If the equipment is likely to receive constant unreported abuse,

more frequent testing will be required. If the equipment users are observant,
aware and responsibly report faults/damage as it occurs, hazards are more
likely to be avoided and test frequency reduced.

Table 1 provides guidance on initial frequencies of visual examination and

electrical testing. However, this is only a guide; experience will lead the
tester to determine correct frequencies.

The frequency of visual examinations and electrical tests must be regularly

reviewed. Particular attention must be paid to these initial inspections and
electrical tests to determine whether the frequency or equipment type needs
to be changed.

Operator Checks (Procedure)

All users of equipment must understand how important operator checks are.
Some equipment and environments may demand special needs but generally
the following list is a typical checklist that operators should be using.

1. Check the overall condition of the equipment for cracks/damage.

2. Check the supply cable, checking for cuts, abrasions, cracks, etc.

3. Look for signs of overheating.

4. Check it has a valid label indicating it has been formally inspected and
tested.

5. Check the item is suitable for the environment.

10 A Guide to PAT Testing

Table 1: Guide to Initial Frequency of Visual Inspection and Electrical Test

Asset Type
IT & Stationary Moveable Portable Hand-Held
Equipment
Class I Class II Class I Class II Class I Class II Class I Class II
V 24 mo. 24 mo. 12 mo. 24 mo. 12 mo. 24 mo. 12 mo. 12 mo.
Offices

C 60 mo. N/A 24 mo. N/A 24 mo. N/A 24 mo. N/A

V N/A N/A 6 mo. 6 mo. 6 mo. 6 mo. 6 mo. 6 mo.

Industrial

C 24 mo. 24 mo. 12 mo. 24 mo. 12 mo. 12 mo. 12 mo. 12 mo.

V N/A N/A 1 mo. 1 mo. 1 mo. 1 mo. 1 mo. 1 mo.

Construction

C N/A N/A 3 mo. 3 mo. 3 mo. 3 mo. 3 mo. 3 mo.

Location

V 24 mo. 24 mo. 12 mo. 24 mo. 12 mo. 24 mo. 12 mo. 12 mo.

Hotels

C 60 mo. N/A 24 mo. N/A 24 mo. N/A 24 mo. N/A

V N/A 12 mo. 6 mo. 12 mo. 6 mo. 12 mo. 6 mo. 12 mo.

Schools

C 12 mo. 48 mo. 12 mo. 48 mo. 12 mo. 48 mo. 12 mo. 48 mo.

V 1 mo. 12 mo. weekly 6 mo. weekly 6 mo. weekly 6 mo.

Public Access

C 12 mo. 24 mo. 6 mo. 12 mo. 6 mo. 12 mo. 6 mo. 12 mo.

Key:
V: Formal visual inspection
C: Combined visual inspection and electrical test
N/A: Not Applicable

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6. Check the plug and make sure the cable is securely gripped and there is no
mechanical damage.

7. Check that the ground pin has not been removed.

8. Check the socket outlet to make sure there are no signs of damage or
overheating.

9. Check that the appliance is working correctly and as expected.

If the operator is not happy with any of the above then the following
actions must be taken:

1. Switch off and disconnect from the supply.

2. Clearly label to identify that it must not be used.

3. Report to the appropriate responsible person.

Note: Once equipment has been reported faulty, the responsible person will
have to make a judgment as to whether the equipment is suitable for both
its use and the environment it is in. More frequent inspection and testing is
not the solution to unsuitable equipment.

Formal Visual Inspection (Procedure)

This type of inspection should only be carried out by a competent person
as defined in OSHA regulation 1926 Subpart K. The results of the formal
visual examination should be documented. There are a number of things
to consider when carrying out formal recorded visual examination of
equipment.

1. The surroundings: the working environment plays a major part in the

selection of appropriate equipment. Selecting the wrong equipment for
its surroundings can have a detrimental effect on its life. For example,
special consideration should be given to equipment for use where it will
be exposed to the weather and natural hazards, extreme temperatures,
high or low pressure, wet, dirty or corrosive conditions, solvents,
mechanical or physical damage and flammable substances.

2. Good housekeeping: this covers several areas, but most of it is logical

common sense. The following is a guide to what should be checked:

12 A Guide to PAT Testing

 n Adequate space around the equipment for ventilation/cooling.

n Easily accessible means of disconnection/isolation from the supply.

nThe equipment is operated with all protective covers located correctly

and any interlocks operational.

n There are no unprotected cable runs under carpets.

n Minimum use of extension cords and multiway adapters.

n Cables are not located where they are likely to be damaged or create
trip hazards.

n Drinks, plants and work materials are not placed where they could spill
into equipment.

3. Equipment suitability: if the equipment that is being tested/inspected is

unsuitable for either the environment or the purpose it is being used for,
this fact should be recorded on the documentation and brought to the
attention of the client.

4. Disconnection/isolation of equipment: in normal circumstances, operators

must be able to reach the plug/socket without difficulty and disconnect/
isolate. Isolation is simplest when the equipment is connected via a plug
and socket. Not all equipment will be connected in this way and isolation
may be achieved via a main switch or removal of a fuse. Caution must
be exercised when inspecting equipment without the usual plug/socket
arrangement. When inspecting business, IT and telecommunications
equipment, permission from the equipment operator should be gained
before disconnecting from the supply. Failure to do this could result
in serious loss of business data. It should also be noted that business
equipment might need to be powered down in the correct manner before
isolation. Equipment supplied by an uninterruptible power supply (UPS)
must be isolated from its standby source before any electrical testing
begins. This is best performed by the system owner if there is any doubt as
to the correct procedure.

5. Equipment condition: before beginning any equipment inspection,

operators should be asked if they are aware of any faults and whether the
equipment is functioning as expected.

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The formal visual examination should involve similar checks to those
undertaken by the operator. The following items need to be inspected:

The power cable

n Is it in good condition?

n Is it free from physical damage, wear and tear?

n Is it in a position where it could be damaged (by chair casters, desk legs

etc.)?

n Is it a suitable length?

n Does it have adequate strain-relief and is the insulation sheath clamped

sufficiently at the terminations?

The cable-outlet or wall-socket

n Is it free from cracks or damage?

n Is there any sign of overheating?

The asset
n Does it work?

n Does it switch on/off correctly?

n Is it free from cracks and damage that could cause a hazard?

n Can it be used safely?

The standard plug

The diagram shows the wiring of a standard NEMA 5-15 plug.

Some of the following checks may not be possible if a

non-rewirable (molded-on) plug is used:

n Does the Class I power cable incorporate a continuous

protective conductor (earth/ground)?

n Are there signs of overheating? (This could be caused by a faulty or loose

connection in the plug or the socket outlet.)

n Is the cable firmly fixed in its clamp? (On a non-rewirable type, the cable
grip can be tested by firmly pulling and twisting the cable. No movement
should be apparent.)

14 A Guide to PAT Testing

n Are the cable core terminations tight and the plug correctly wired?

n If a fuse is fitting, is it secure with no signs of overheating? Is it of the

correct type and correct rating?

The fuse should be BS 1362 approved. Also check the rating; it is usual that
an appliance up to 700 W should have a 3 A fuse (colored red). Appliances
larger than 700 W should have a 13 A fuse (colored brown). Some IT
equipment may have a 5 A fuse fitted; however, this is less common.

Environment/use
n Is the equipment suitable for the environment in which it is being used?

n Is the equipment being used for the correct purpose?

n Is the user satisfied with the equipment?

Combined Visual Examination and Electrical Testing Procedure

If carried out correctly, formal visual examinations will reveal most (but
not all) potentially dangerous faults. However, some internal deterioration
of the cable, its terminals, and the equipment itself can be expected after
significant use. Additionally, equipment may be misused or abused to the
extent that it may give rise to danger. Electrical testing, together with
a thorough visual examination, can detect faults such as loss of ground
integrity, i.e. broken earth/ground (CPC - circuit protective conductor) within
a flexible cable, or deterioration of insulation integrity or contamination of
internal and external surfaces. Lack of insulation could result in the operator
receiving an electric shock with potentially fatal results.

Initial examination
This activity is a vital part of the testing process, and many faults are found
at this stage. The nature of these faults is such that they will not always be
found with electrical testing alone. The procedure for initial examination is
as follows:

1. Obtain permission from the responsible person and disconnect any

business equipment communications cords. Do not test business
equipment that is still connected to communications links as it may
damage other remote equipment. Care should be taken when handling
fiber optic links as they may be ‘live’ from remote equipment and cause
retina damage. Fit dust caps to disconnected fiber links.

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2. Identify if the equipment can be powered down and isolated from the
supply. If permission cannot be obtained then electrical tests cannot
be performed. If it cannot be disconnected, perform as much visual
examination as is possible without compromising your safety or the
operation of the equipment. Record any defects and the fact that the
equipment has not been electrically tested, and label it as such.

3. Thoroughly examine the asset for any signs of damage during a visual
examination, including the power cable, plug and wall connection (socket
or flex outlet).

4. Judge the suitability of the appliance for the application and

surroundings.

Note: Standard new NEMA 15-5 plugs (molded-on or re-wirable) must

conform to the latest NEMA standards. This legislation only applies to new
plugs, not old plugs already in use. However, it would be worth noting on
the visual examination notes that the plug is not to the latest regulation.

Test procedures
Megger portable appliance testers are designed to test standard equipment
that is supplied by plug and socket connection. This is done simply by
unplugging the equipment and plugging it into a Megger portable
appliance tester.

An insulation/continuity tester can test equipment that is permanently

connected to a flex outlet with the test leads connected directly to
the accessory terminals. However, to carry out this method the person
performing the test would need additional relevant competencies. An
alternative method is to temporarily connect the asset to a NEMA 15-5 and
test conventionally using the portable appliance tester.

Electrical Tests
Before any in-service electrical testing can be carried out, a preliminary
inspection should have been performed. The electrical testing then consists
of the following in this specific order:
1. Earth continuity or bond tests
2. Insulation resistance testing (if a 500 V insulation test is not appropriate,
this can be replaced by a touch current or alternative leakage current test)
3. Functional Checks

16 A Guide to PAT Testing

Some test equipment is capable of performing tests that in certain
circumstances could damage the appliance they are used on. Flash testing
(also known as hi-pot or dielectric strength testing) is one such test and is
only normally carried out by manufacturers or when an appliance has had a
deep overhaul.

Earth Bond/Continuity Test

Earth bond/continuity tests only apply to Class I equipment and are used
to confirm the existence of a safety return path. The purpose of the test is
to ensure that the ground terminal has a low resistance connection to the
conductive metal casing of the appliance. An effective connection to the
system ground within the fixed installation of the premises ensures safety.

There are two methods available and different circumstances will require
each method:

1. Low current continuity test: A continuity measurement should be made

using a short circuit test current between 20-200 mA between exposed
conductive parts of the equipment and the earth pin of the plug (or
earth/ground-terminal of the supply). This test is performed using the
earth bond lead. The maximum value of resistance should be noted while
flexing the asset supply cable and a visual examination of the power cable
terminations at both ends should be made. Any fluctuation in the reading
should be investigated to identify the cause. The test current is so low
that there is no risk of damaging earth connections that may exist for
functional, rather than safety, reasons. This low-current test is sometimes
referred to as a “soft test.”

2. High current bond test: a continuity measurement using a test current of

max 26 A for between 5 to 20 seconds. This test is used where the user has
concerns that a ground may be maintained by a few strands of wire or
where poor surface contact by the probes or clips could give a misleading
reading. The bond test should be connected between exposed earthed/
grounded conductive parts of the equipment and the ground pin of the
plug (or ground-terminal of the supply). This is done by connecting the
earth bond lead to the exposed metalwork. The maximum value of
resistance should be noted while flexing the asset supply cable and a
visual examination of the power cable terminations at both ends should
be made. Any fluctuation in the reading should be investigated to identify
the cause.

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Care should be taken when measuring ground bond on appliances
where the design of construction includes exposed metalwork having a
casual contact to earth. This metalwork is primarily protected by double
or reinforced insulation, and the ground connection is only classed as
‘fortuitous’. Under these circumstances, the resistance value is unlikely to be
as low as truly bonded metalwork. A bond test performed on this unbonded
metalwork may give unexpected or misleading results. Examples of this
construction may include the sole plate of a steam iron or the metal chassis
of a coffee maker. Additionally, a high-current bond test using up to 26 A
may, in some circumstances, damage casual contact components and a low-
current test should be performed first to identify potential issues. Table 2
indicates the limits of the earth bond test.
Table 2: Earth Bond Limits

For appliances For appliances with a power cable (3 core);

with a supply cord extension cords, multiway and GFCI adapters
(0.1 + R) Ω where R is the resistance of the
0.1 Ω
protective conductor of the supply cable

For manual verification, or if the resistance R of the protective conductor

of the power cable cannot easily be measured, the information in Table 3
provides nominal cable resistances per meter length for various types of
flexible cable. The supply cable should first be identified and the length
measured. The resistance of the protective conductor can then be calculated
by multiplying the nominal resistance by the length.

The bond test may fail due to the excessive length of the equipment supply
cord. Extension cords may also fail due to increased resistance induced by
long cable lengths.

18 A Guide to PAT Testing

Table 3: Nominal Conductor Resistance

Nominal Typical no. Maximum current Nominal conductor

conductor of strands in carrying capacity (A) resistance (Ω/m)
CSA (mm2) conductor
0.5 16 3 0.039
0.75 24 6 0.026
1.0 32 10 0.0195
1.25 40 13 0.0156
1.5 30 15 0.0133
2.5 50 20 0.008
4.0 53 25 0.005

Insulation Test
The insulation test is used to confirm that there is separation between
the live conductors (live and neutral) and any accessible conductive parts.
Generally, insulation testing is carried out by applying a known test voltage
(500 V DC) and measuring the resistance. On sensitive equipment (IT for
example) 500 V may cause damage, and so be unsuitable. Therefore, it may
be substituted with a low-voltage (250 V) insulation test, a touch current test
or an alternative leakage current test.

Appliances must not be touched during an insulation test because, if a fault

exists, the exposed metalwork may rise to the test voltage, although this
voltage in itself is not dangerous. The test method varies, depending on
whether the appliance is Class I or Class II. For a grounded (Class I) appliance,
the insulation test is carried out between the earth pin and the combined
live and neutral pins of the plug. Megger PAT testers make these connections
for you. A Class II appliance is slightly different as there is no connection to
the plug earth pin. This time a connection is made between the combined
live and neutral pins and any metal parts or dirty/conductive areas of the
casing which may involve several tests. The connection method is the same as
that used for the earth bond/continuity return, using the same lead.

Note: For both test methods it is essential that the appliance is switched
on at its own power switch. If it is not then the electrical test is only being
carried out as far as the switch. The minimum insulation readings that should
be obtained are shown in Table 4.

www.megger.com A Guide to PAT Testing 19

Table 4: Insulation/Touch Current Limits

Pass Value Insulation (min) Touch Current (max)

Portable or Handheld Class I 1.0 MW 0.75 mA
Class I Heating Equipment 0.3 MW 0.75 mA or 0.75 mA per
with a Rating ≥3 KW kW, whichever is the
greater, with a max of
5 mA
All other Class I Equipment 1.0 MW 3.5 mA

Class II Equipment 2.0 MW 0.25 mA

Class III Equipment 250 kW 0.5 mA

Protective Conductor/Touch Current Measurement

This test is an alternative to an insulation test and can be used where
either an insulation test could damage the equipment it is applied to or
the results of the test are suspect. For this test, the asset is energized at its
normal operating voltage, and any current flowing to earth is measured.
For Class I, this measurement is to the earth pin of the plug. For Class II, it is
to any accessible conductive surfaces using a remote probe. A low-voltage
insulation test should be performed prior to any energized test such as the
touch-current test to identify any potential danger from low insulation and
shorted connections.

During this test, the appliance is powered from its normal mains supply
and the test lead and probe is connected to the PAT terminal. The probe is
applied to any conductive parts on the appliance and performs a current
measurement with respect to earth. This test can also be performed on
three-phase appliances.

This test is only available on the more sophisticated portable appliance

testers, such as the Megger PAT400 Series.

The asset should be turned on for the time the test is made so it will be
powered-up and operational during this period. It is essential, therefore, to
ensure that the asset is safe to run during the test. For example, if testing
a coffee maker, it should be part-filled with water so as not to damage the

20 A Guide to PAT Testing

element during this test. It should also be noted that if testing a drill, or
other appliance with moving parts, a potential hazard may exist while the
drill is energized and machinery rotating.

The current is measured within five seconds after the application of the test
voltage (usually the supply voltage); the values must not exceed those given
as shown in Table 4.

Differential Leakage Test

The differential leakage current (also called protective conductor current)
test measures the difference in current between the live and neutral
conductors and determines if any current is flowing to earth. Normally,
appliances should have no, or very little, earth leakage current. Class II
(double insulated) appliances could exhibit earth leakage through their
mountings or by operator contact.

During the test, the actual mains voltage is measured at the appliance
socket. To ensure that the equipment is safe even when the mains supply
rises to its maximum permitted value, the PAT calculates and displays the
leakage current that would flow at this value.

Substitute/Alternative Leakage Test

The substitute leakage test measures the leakage current in the earth
conductor using a low ac voltage (typically 40 Vac). This approach reduces
the risk of electric shock and prevents the equipment from running during
the test. The test socket is optional, as this test is independent of the supply
voltage. The measured value is adjusted to reflect the worst leakage current
at the upper operating voltage limit.

For Class I equipment, the appliance has its phase conductors joined together
within the PAT and a 40 V supply is applied between both phase conductors
and the protective conductor connection of the equipment under test. In the
case of Class II equipment, the test lead and probe are connected to the item
under test.

The probe is applied to any conductive parts on the appliance under

test. The actual voltage is measured at the appliance socket. From these
readings, the earth leakage current of the appliance is calculated and scaled
depending on the appliance supply voltage.

www.megger.com A Guide to PAT Testing 21

Load Test
The load test (also called the operational or VA test) measures the power
consumption of the equipment when running. Measuring the load (VA) of
an appliance is a good indication of its operating condition. By setting a
load VA limit in the instrument’s test groups, an appliance can be assessed
automatically for excessive load. The load VA limit is usually set based on the
rating plate on the appliance.

When using the Megger portable appliance testers, which power up the
equipment for you, a functional test is carried out during the “load” test.
This test will determine:

n If the asset functions correctly

n The VA rating of the appliance

The results of this test can be a good indicator of future problems and
potential failures in an appliance. Problems like worn bearings on a drill
would probably result in increased current drawn from the supply and
therefore an increase in the VA reading.

Care should be exercised when electrical testing equipment with suspected

high leakage currents as substantial electric shocks can be received from
exposed conductive parts and/or the ground terminal if the appliance is
not adequately grounded. Whenever high leakage currents are present
a warning label like the one below should be displayed adjacent to the
primary power connections.

WARNING HIGH PROTECTIVE CONDUCTOR CURRENT

Earth connection essential before connecting the supply

The reason that the cord set should be inspected and tested separately is
that the cord set could be used to supply a different appliance. A 2-core cord
set should not be fitted with a 3-pole appliance coupler.

Power Cables and Leads

Appliances with detachable power supply flexes (such as electric lawn
mowers) should be electrically tested with the cable plugged into the
appliance as a complete assembly. The cable should then be labelled and
tested again, separately from the appliance. A 3-core cable should be tested
as a Class I appliance, with a visual examination and earth bond, polarity

22 A Guide to PAT Testing

and insulation tests. A 2-core cable should be tested as a Class II appliance,
with a visual examination and polarity and insulation tests.

The reason the cable is examined and tested again separately from the asset
is that the cable could potentially be used to supply a different appliance.

A 2-core cable should not be fitted with a 3-pole connector.

Extension cords
If extension cords have a normal 3-pin socket outlet, it is essential that a
protective conductor exist in the cable. Class II extension cords are dangerous
and should not be used. The code of practice recommends maximum
extension cord lengths, which should not exceed the lengths as indicated in
Table 5.

Table 5: Extension Cord Lengths

Conductor CSA 1.25 mm2 1.5 mm2 2.5 mm2
Max Length 39 ft (12 m) 49 ft (15 m) 82 ft (25 m)

Flash Testing
Flash testing measures the leakage current when high test voltages are
applied to an asset. The flash test provides a high ac test voltage (2500 V or
3000 V) and measures the leakage current. This test can be destructive and
is usually only used on equipment that has been repaired. It is not generally
used for “in-service testing” of electrical equipment.

Faulty or Damaged Equipment

If you find damaged or faulty equipment then this should be labelled, and
if unsafe removed from service, and brought to the attention of the client.
They need to make a judgment on whether the equipment is suitable for
both the environment in which it is being used and the application to which
it is being put. If the person assesses that it is unsuitable for either of these
reasons it has to be replaced with more suitable equipment.

Missing Equipment
Items of equipment on the test register that are not where they are
expected to be should be brought to the attention of the client.

www.megger.com A Guide to PAT Testing 23

Labelling
Any equipment that requires visual examination and electrical testing must
be clearly labelled. The label must consist of a unique identifier for the
equipment, the date it was tested, the re-test date and an indication of its
state. A failed asset does not need the dates on, just clear identification that
it has failed.

Labels may either be filled in by hand or printed. Printed labels often consist
of a bar code for the identifier making them easy to read with a suitable
barcode scanner. This is a great time saver with an instrument that supports
it such as the PAT400 Series by Megger.

Labels should be manufactured so they can be applied to a variety of

surfaces. They should be tough and capable of lasting until the next
retest date. In harsh environments it may be necessary to apply additional
protection in the form of clear vinyl covers.

Documentation
As best practice, the following records should be established and maintained:

n A register of all equipment

n A record of formal and combined visual examinations and electrical tests

n A register of all faulty equipment

n A repair register

All of these records can be stored on paper or electronically, as long as

reasonable precautions are taken with regard to the safeguarding of the
data. Whichever method is chosen, previous test results must be available to
the test operative.

The company carrying out the testing should maintain the following paper
or electronic records:

n Copy of the formal visual examination and combined visual examination

and electrical test results

n Register of all equipment repaired

24 A Guide to PAT Testing

Portable Appliance Testers Available from Megger

Megger PAT320
The PAT320 is a portable bench-top
appliance tester for testing the safety
of electrical equipment by performing a
ground bond test, an insulation test, specific
ground leakage tests and operational VA
tests to international standards. It is a fully
featured tester designed for customers
who do not need the complexity of a fully
configurable database of clients and results
within the tester but require a complete
range of functions to allow automatic or
manual testing of the widest range of
electrical equipment.

Simple push-button operation makes the PAT320 fast and intuitive to

use. All regulatory test requirements are supported: Class I (grounded)
and Class II (non-grounded) equipment, IEC power cords and extension
leads. An automatic mode is available for Class I and Class II testing. In
automatic mode, the tests proceed sequentially through bond, insulation
and operation (VA), indicating a pass or fail at each test. If a fail occurs,
testing is stopped. When manual testing, each test is preceded by a selection
screen where the test parameters are chosen, such as bond test current,
insulation test voltage or leakage test type. These diagnostic buttons provide
direct access to any test individually, allowing single tests to be performed
following repair or a suspect result.

www.megger.com A Guide to PAT Testing 25

Megger PAT450
Operators of electric tools and other
electrical equipment must be protected
from potentially dangerous flaws in
workmanship or wear and tear. The
PAT450 is designed to test portable
electrical equipment for safe operation.
The tests conform to the latest editions
of European regulations and standards
including VDE0701/0702 and the Code of
Practice for the In-Service Inspection and
Testing of Electrical Equipment in the UK.

All standard PAT tests are available which include the following:

n Earth bond at 200 mA, 10A and 25A (suitable for all equipment
including IT)

n Insulation at 250 V and 500 V

n Polarity for extension lead testing,

n Full load (VA)

n Alternative leakage tests (substitute, differential and touch current)

n 1.5 kV and 3 kV flash, or dielectric strength tests

The PAT450 is the ideal instrument for companies who engage in portable
appliance testing and have a requirement to customize and adapt testing
routines to their own requirements, and where the level is such that on-
board storage and asset management is seen as a requirement beyond
simple manual testing. The PAT450 has fully customizable and configurable
test groups with selectable PASS/FAIL limits, and on-board storage for 10,000
asset records.

26 A Guide to PAT Testing

 Megger makes high quality instruments for
the following electrical testing applications:

n Insulation Testing n Battery Testing

n Relay Testing n Watthour Meter Testing

n Oil Testing n Transformer Testing

n Circuit Breaker Testing n Cable Fault Locating

n Power Quality Analysis n Power Factor Testing

n Low Resistance Testing n Hi Pot Testing

Megger manufactures electrical test and maintenance

instruments for electrical power, process manufacturing,
building wiring, engineering services and communications.

Visit our website for local assistance worldwide at

www.megger.com.

UNITED STATES
Megger Valley Forge
2621 Van Buren Avenue
Norristown, PA 19403
866-254-0962
PATGuide_en_V01