EN
PL Analysis and LVD Tests
LVD electrical safety tests for machinery: insulation, high voltage, leakage voltage and earth continuity trials, reported by engineers.
PL analysis and LVD tests verify the electrical safety of machinery and equipment used at work within the Low Voltage Directive (LVD) scope through measurement. The tests consist of insulation resistance, high voltage (dielectric strength), leakage voltage and protective earth continuity items, each targeting a different touch-arc scenario. The aim is to prove numerically that the protective device really operates when insulation fails or earthing breaks, and that touch voltage stays within the safe band.
Test Set and Purposes
- Insulation test: Measuring insulation resistance in a de-energised circuit; diagnosis of insulation failure and moisture-absorbed surfaces.
- High voltage test: Applying the foreseen overvoltage to the insulation and watching for puncture-flashover; the type and routine dielectric trial approach.
- Leakage voltage test: Measuring the touch currents flowing from a live equipment to earth and non-conductive metal surfaces; the direct counterpart of the human contact scenario.
- Earth continuity test: Low-current measurement of the resistance between the protective conductor and the body; the guarantee that fault current takes the protection path.
Why Run Together?
The four tests complement one another: a high insulation resistance gives no confidence alone if earth continuity is broken; a low leakage current masks a fatal scenario if the protection relay is defective. Therefore the LVD set is interpreted as a whole and the measurement conditions (mains voltage, frequency, ambient humidity) enter the record. On equipment with PLCs, drives and power electronics, the correct measurement order and voltage level protect sensitive cards before testing; otherwise the dielectric test may damage the equipment. Results are compared with the acceptance values of TS EN 60204-1 and the relevant machine safety standards.
Legislation and Scope
LVD tests are part of the periodic electrical inspection-test programme under Law No. 6331, the Work Equipment Regulation, the Internal Electrical Installations Regulation and CE conformity duties. The product side follows 2014/35/EU (LVD) and 2006/42/EC; measurement methods follow TS EN 60204-1 and relevant IEC approaches. On machines with PLC-power electronics, the manufacturer test guide specifies where dielectric test voltage must be reduced.
Outcome
At the end of the test programme, equipment-based measurement tables, pass/fail assessment, finding photos and rectification proposals are presented in a signed report with retest dates planned. LVD measurements are a heading in our Tests and Analyses group; for an integrated programme with thermography and panel control, contact us. The readings are entered into a per-equipment insulation file; the insulation, leakage and continuity values graphed year to year catch degradation before it becomes a fault.
FAQ on PL Analysis and LVD Tests
LVD (Low Voltage Directive 2014/35/EU) tests are the electrical safety measurements of equipment and machines in scope: insulation resistance, high voltage (dielectric) withstand, leakage current, protective earth continuity and touch current. PL (Performance Level) analysis verifies, per TS EN ISO 13849, the target reliability class of safety functions (emergency stop, door lock, light curtain, two-hand); it is the engineering bridge between risk assessment and test.
Electrical machines in the 50-1000 V AC / 75-1500 V DC range, control panels (TS EN 61439), circuit devices, hand-held appliances (periodic electrical tests with the IEC 62353 approach), automation-safety circuits and machines with safety functions. Export-CE file, workplace periodic inspection record and post-accident verification are three separate application fields.
Measurements follow the voltage-stress hierarchy: first continuity-earth (low voltage injection), then insulation resistance (megger), then high voltage withstand (kick test) and, live, leakage-touch current. Insulation is not applied before continuity, HV not before insulation; otherwise a faulty insulation is misread or the equipment is damaged. Each measurement is recorded with reference-limit-protocol; PL verification is completed with injection-sensor-time measurement.
The report carries measurement values with standard limits (TS EN 60204-1, TS EN 61439, IEC 62353, TS EN ISO 13849), circuit-schematic matching, PL d (or target class) verification results, calibrated device certificates and finding-removal suggestion. It addresses three stakeholders: the CE conformity file, the occupational health periodic record and insurance-expertise evidence. A failed function is not safe before the repair-retest loop closes; results enter the serial-based inventory.