How to Test & Tag
Testing and tagging electrical equipment involves more than connecting an appliance to a portable appliance tester. You must first inspect the equipment, identify its class, choose the appropriate electrical tests, interpret the results, attach the correct tag and maintain an accurate record.
The basic test and tag procedure involves:
- identifying the equipment and where it is used
- completing a thorough visual inspection
- determining whether it is Class I, Class II or a cord assembly
- performing the appropriate electrical tests
- interpreting and recording the results
- removing failed equipment from service
- tagging equipment that passes
Important: Inspection and testing must be performed by a competent person with the knowledge and practical skills required to complete the work safely and correctly. This guide provides an overview of the process but does not replace practical training, assessment or the instructions supplied with your testing equipment.
What Do You Need to Start Testing and Tagging?
Before beginning, make sure you have:
- a suitable portable appliance tester
- the required test leads, probes and adaptors
- compliant passed and failed test tags
- a paper or digital system for recording results
- access to the equipment instructions or rating information where required
- a safe area in which to inspect and test the equipment
Your PAT tester must be suitable for the equipment and tests you need to perform. You should also understand how to operate it and confirm that it is working correctly before relying on its results.
The Test and Tag Procedure
1. Identify the Equipment and Its Testing Requirements
Start by identifying the item and checking its rating plate, plug, flexible cord and any manufacturer markings.
Consider:
- what type of equipment it is
- where and how it is used
- whether it has a detachable lead or separate power supply
- its previous testing history
- the applicable testing interval
- any workplace, industry or state requirements
The operating environment matters. Equipment that is frequently moved or exposed to moisture, dust, heat, chemicals, vibration or physical damage may require more frequent inspection and testing.
2. Complete a Visual Inspection
Disconnect the equipment from the power supply and examine the entire item before conducting any electrical tests.
Check for:
- cracks, dents or damaged enclosures
- cuts, abrasion or exposed conductors
- damaged plugs, pins and sockets
- loose cord entries or strain relief
- signs of overheating or discolouration
- damaged switches, controls, covers or guards
- blocked ventilation openings
- missing or unreadable safety markings
- unauthorised modifications or makeshift repairs
If visible damage indicates that the equipment may be unsafe, it fails the visual inspection and must be removed from service.
See our complete Test & Tag Visual Inspection Checklist.
3. Determine the Equipment Class
Correctly identifying the equipment class is essential because it determines which electrical tests must be performed.
- Class I Equipment
Class I equipment relies on protective earthing to reduce the risk of electric shock. It generally has an earth connection, but you should not classify equipment based on the number of plug pins alone.
Class I equipment normally requires an earth-continuity test together with the other applicable electrical tests.
- Class II Equipment
Class II equipment uses double or reinforced insulation and does not rely on protective earthing. It is generally identified by the square-within-a-square symbol.
Class II equipment does not require an earth-continuity test, but insulation-resistance or leakage-current testing may apply.
- Cord Assemblies
Extension leads, IEC leads and power boards must be treated according to their construction. Applicable tests can include earth continuity, insulation resistance and polarity.
A detachable lead should normally be inspected, tested and identified separately from the equipment it powers.
If the equipment class or construction is unclear, check the rating plate, manufacturer information or operating instructions. Do not guess.
Class I vs Class II: Quick Comparison
| Class I | Class II | |
|---|---|---|
| Main protection | Protective earthing | Double or reinforced insulation |
| Common identification | Usually an earth connection | Square-within-a-square symbol |
| Earth-continuity test | Generally required | Not required |
| Other tests | Insulation resistance or leakage as applicable | |
| Important caution | Do not rely only on the plug pins | Do not rely only on a plastic enclosure |
4. Select and Perform the Appropriate Electrical Tests
Once the equipment has passed its visual inspection and been correctly classified, select the tests that apply to that item.
Common test and tag procedures include:
- Earth-Continuity Testing
This checks whether Class I equipment has a sufficiently reliable path between the earth pin and accessible earthed parts.
- Insulation-Resistance Testing
This assesses the condition of the insulation separating live electrical parts from accessible surfaces or protective earth.
- Leakage-Current Testing
This measures current that may flow outside its intended path while the equipment is operating. It may be required for equipment that cannot be adequately assessed using an insulation-resistance test or contains electronic controls.
- Polarity Testing
This confirms that the active, neutral and earth conductors in leads, power boards and similar equipment are connected to the correct terminals.
The required tests depend on the equipment, its construction, and the applicable requirements. Follow your training, the current Standard and the instructions supplied with your PAT tester. Do not apply a test simply because it is the easiest option on the tester.
5. Interpret the Results
Compare each result with the applicable pass/fail requirements. Do not rely on assumptions based only on the equipment appearing to operate normally.
A result may require further investigation if:
- the reading is close to the applicable limit
- results differ considerably from the equipment's previous history
- the PAT displays an unexpected result
- the equipment cannot be confidently classified
- you cannot establish an appropriate test connection
If you are uncertain about a result, do not pass the equipment until you have obtained appropriate technical guidance.
6. Deal With Failed Equipment
Equipment that fails its visual inspection or an electrical test must not be returned to normal use.
The item should be:
- disconnected and removed or isolated from service
- clearly marked with a "Do Not Use" or "Out of Service" warning
- recorded as having failed
- reported to the person responsible for the equipment
- referred for appropriate repair, replacement or disposal
Electrical repairs must be completed by an appropriately licensed person. The equipment must pass the required inspection and testing before returning to service.
7. Attach the Correct Test Tag
Equipment that passes must be fitted with a durable, legible, non-metallic and non-reusable test tag.
The tag must include the required information, such as:
- who completed the inspection and testing
- the test date
- when the next inspection and test are due
- the applicable Standard reference
The tag shows that the equipment passed on the recorded date. It does not guarantee that the item will remain safe until its next scheduled test.
See our Electrical Test Tags Guide for passed, failed, new-to-service and second-hand equipment tags.
8. Record the Results
Record-keeping provides a history of the equipment and helps demonstrate that you have completed inspection and testing.
The record should identify:
- the equipment tested
- who completed the test
- the test date
- the inspection and testing outcome
- any faults found or action taken
- the next scheduled test date
Records may be maintained using a paper register, spreadsheet, PAT tester memory or dedicated asset-management software.
How Often Should Equipment Be Tested?
No single interval applies to every appliance. The appropriate frequency depends on the equipment, how it is used, its operating environment and any applicable workplace, industry or state requirements.
See the recommended Test and Tag Intervals and the requirements for your state or territory.
Learn How to Test and Tag Correctly
Knowing the basic steps is helpful, but you need proper training and practical skills to test and tag equipment safely and correctly.
Our nationally recognised Test & Tag Courses combine essential theory with guided hands-on practice and assessment.
Face-to-Face Test & Tag Course
How to Test Specific Electrical Equipment
How to Test and Tag an Extension Lead »
Learn how to inspect an extension lead and complete the applicable earth-continuity, insulation-resistance and polarity tests.
How to Test and Tag a Surge-Protected Device »
See how surge protection affects the test sequence and what to consider when using your PAT tester.
How to Test and Tag a Computer »
Learn an efficient approach to inspecting and testing a desktop computer and its detachable power lead.
How to Test and Tag a Laptop »
See how to approach the detachable IEC lead, power supply and laptop as separate components.
How to Test and Tag a USB Charger »
Find out whether USB chargers require testing and how to approach their mains-powered side.
How to Test and Tag a Battery Charger »
Understand which mains-powered components require testing and why the connected battery itself is outside the usual scope.
How to Test and Tag a Kettle »
See how a kettle's construction and detachable base can affect the testing method.
How to Test and Tag a Toaster »
Learn how to classify a toaster and perform the tests appropriate to its construction.
How to Test and Tag an Iron »
See how to identify whether an iron is Class I or Class II before choosing the appropriate tests.
How to Test and Tag a Vacuum Cleaner »
Learn what to consider when inspecting and testing an appliance containing a motor.
How to Test and Tag a Coffee Machine »
See how testing can differ between standard coffee machines and pod-style models.
How to Test and Tag a Microwave »
Learn how to approach the electrical safety tests and common testing difficulties presented by microwave ovens.
How to Test for Microwave Leakage »
Learn when microwave leakage testing is appropriate and how to use a dedicated leakage detector.
How to Test and Tag a Fridge »
Understand the considerations for leakage-current testing and how to safely prepare a refrigerator for testing.
How to Test and Tag a TV »
See how different TV designs and power supplies can affect equipment classification and test selection.
How to Test and Tag a UPS »
Learn how to identify an appropriate earth point and test sequence for an uninterruptible power supply.
How to Test and Tag a Welder »
Review the earth-continuity and insulation considerations that may apply when testing a plug-connected welder.
How to Test and Tag a 3-Phase Appliance »
Understand the additional equipment, competency and procedures involved in testing three-phase appliances.
How to Interpret Insulation Resistance Readings »
Learn what insulation-resistance readings can reveal beyond a simple pass-or-fail result.
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