Test & Tag Visual Inspection Checklist

Visual inspection is the first step in testing and tagging electrical equipment. It can identify obvious damage, wear or other conditions that may make equipment unsafe before electrical testing begins.

Many common defects, such as damaged cords, cracked plugs, loose connections and missing protective parts, can be detected visually. However, visual inspection does not replace the electrical tests required under AS/NZS 3760:2022, because some faults and deterioration may not be visible.

A thorough inspection involves closely examining the equipment and physically checking components such as the flexible cord, plug, socket, controls, covers, and ventilation openings.

The checklist below explains what to examine and common reasons electrical equipment may fail a visual inspection.

What to Check

Important: Before you begin, disconnect the equipment from the power supply and make sure you can handle it safely. Inspect the entire item, not just the plug or cord.

1. Check the Equipment Body

Look for:

• cracks, dents or other physical damage
• loose, broken or missing parts
• damaged or missing covers and guards
• signs of unauthorised modification
• discolouration, melting or burn marks that may indicate overheating
• moisture, chemical contamination or excessive dirt that could affect safe operation

Protective covers, handles and guards should be secure and suitable for their intended purpose.

2. Inspect the Flexible Cord

Check the full length of the cord for:

• cuts, abrasion, crushing or fraying
• exposed inner insulation or conductors
• heat, chemical or moisture damage
• excessive twisting, stretching or sharp bends
• taped sections or other makeshift repairs
• damage where the cord enters the equipment or plug

The cord grip or strain relief should hold the cord securely. Insulation tape should not be treated as a suitable repair for a damaged electrical lead.

3. Inspect the Plug and Cord Entry

Check that:

• the plug body is not cracked, loose or damaged
• the pins are straight, secure and free from burn marks or corrosion
• insulated pins have no missing or damaged insulation
• the cord is firmly secured where it enters the plug
• no inner insulation or conductors are exposed
• the plug, cord and socket ratings are suitable for the equipment

Any signs of overheating, incorrect assembly or unauthorised modification require further attention.

4. Check Extension Sockets, Connectors and Power Boards

Inspect socket outlets, extension-cord sockets, IEC connectors and electrical portable outlet devices for:

• cracked or damaged housings
• loose, recessed or damaged contacts
• burn marks or discolouration
• damaged switches, safety shutters or protective devices
• missing parts
• signs of overloading or modification

For power boards and other electrical portable outlet devices, check that the maximum-load warning remains present and legible.

5. Check Switches, Controls and Ventilation

Make sure that:

• switches and buttons are secure and operate correctly
• controls are clearly identified
• protective covers and guards are fitted
• cooling vents are clean and unobstructed
• warning labels and operating instructions remain legible

Blocked vents or damaged controls can make otherwise functional equipment unsafe to use.

6. Check the Rating Plate and Safety Markings

Look for a readable rating plate or label showing the information needed to identify the equipment and determine the appropriate tests.

Check for markings that indicate whether the equipment is Class I or Class II. If the markings are missing or unclear, do not guess—refer to the manufacturer's information or seek appropriate technical guidance.

Identifying Class I and Class II Equipment

Correctly identifying the equipment class is important because it determines which electrical safety tests must be performed.

• 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 II equipment uses double or reinforced insulation and does not rely on protective earthing. It is normally identified by the square-within-a-square symbol. A plastic enclosure alone does not automatically mean that an item is Class II.

If you cannot confidently determine the equipment class, check its rating plate, operating instructions or manufacturer information before proceeding.

Detachable Leads and Power Supplies

A removable power lead, such as an IEC lead, should be treated as a separate item and inspected and tested accordingly. The appliance, lead and any separate power supply may require their own inspection, test result and identification.

Follow the applicable testing procedure for each component. Do not damage a coating, enclosure or protective surface while attempting to find a test point.

What Happens If Equipment Fails Visual Inspection?

If visible damage or another condition indicates that the equipment may be unsafe, it fails the visual inspection.

The item should then be:

• disconnected and removed or isolated from use
• clearly identified with a warning such as "Do Not Use" or "Out of Service"
• 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. Do not return equipment to service until the required work is complete and it has passed the appropriate inspection and testing.

Visual Inspection Is Only the First Step

Passing a visual inspection does not confirm that the equipment is electrically safe. Some faults and deterioration are not visible, so you must still complete the appropriate electrical tests where required.

Users should also continue checking equipment for obvious damage before use. A current test tag does not guarantee that damage has not occurred since the previous inspection.

Learn to Inspect and Test Equipment Correctly

Our nationally recognised Test & Tag Courses teach you how to visually inspect electrical equipment, identify its class, perform the appropriate PAT tests, interpret the results and correctly identify failed equipment.

Face-to-Face Test & Tag Course

Online Test & Tag Course

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