CE marking and electrical safety tests: what you need to know

The CE mark falls under European harmonisation legislation. For electrical products, the two most important directives are:

Low Voltage Directive (2014/35/EU): applies to electrical equipment with a nominal voltage between 50 and 1000 V AC (or 75 and 1500 V DC).

Machinery Directive (2006/42/EC): applies to machines and installations with moving parts and/or electrical drive.

In addition, the EMC Directive (2014/30/EU) may apply, and for specific product groups additional directives such as the RoHS Directive or the ATEX Directive apply.

The manufacturer is responsible for compiling a technical file, carrying out a conformity assessment, and affixing the CE mark. Part of that file is the proof that the product complies with the relevant harmonised standards. And those standards prescribe in concrete terms which tests you must carry out.

Which safety tests belong to CE marking?

The specific tests depend on the standard that applies to your product. But for virtually all electrical products, the same basic tests come back:

Protective conductor measurement (PE): checks whether the earthing works and can safely discharge a fault current. Prescribed by EN 60204, EN 60335, EN 60598 and IEC 62368.

Insulation resistance measurement: checks whether the insulation between live parts and enclosure is intact. Prescribed by all the above standards.

High-voltage test (HV): proves that the insulation holds up under extreme conditions. Prescribed by EN 60204, EN 60335 and IEC 62368.

Leakage current measurement: measures whether any dangerous current flows to the user. Prescribed by EN 60335 and IEC 62368.

Functional test: verifies that the product works properly. Prescribed by EN 60335 and EN 60598.

This is not about sampling. Most standards prescribe that you test every unit that leaves production. These are routine tests, also known as end-of-line tests. Without these test results you cannot build a valid technical file and your CE marking is effectively worthless.

Common mistakes in CE marking and testing

1. Only a type test, no routine test

Many manufacturers have a type test carried out at a test laboratory and then think they are done. But a type test proves that the design complies. The routine test proves that each individual product complies. Both are necessary.

2. Not documenting test results

Your CE file must be verifiable. That means: test results per serial number, with date, test parameters and outcome. A safety tester with data storage and barcode coupling does this automatically.

3. Testing with wrong parameters

The test voltage, test current and limit values differ per standard. A high-voltage test at 1500 V AC is not the same as a test at 3000 V AC. Your tester must be programmed with the correct parameters for your standard and product.

4. No safety measures with high voltage

When testing above a certain voltage and current, you are required to take measures in accordance with EN 50191. In automated production this means a test cage. In manual testing, the safety functions in the tester (emergency stop, test cage, or two-hand start) must be present.

Which tester do you need for CE-compliant testing?

You need a safety tester that combines the right test methods and documents the results. The choice depends on your product type, volumes and degree of automation.

The GLP2-Basic is a solid choice for most manufacturers. The tester combines PE, ISO, HV-AC/DC, leakage current and functional test in one device. With barcode scanners and label printing you record traceability without extra administration.

For higher volumes or when you test multiple product variants on the same line, the GLP2-Modular offers more flexibility. With programmable I/O and the free scripting language you can fully automate the testing process and integrate it with your PLC or MES.

Do you want to be sure that your test process is CE-proof? Schedule a consultation – we assess your current situation and advise what you need.