Lighting test system

on siteautomatic

Overview
Especially for explosion-proof products, intensive quality assurance is essential. Explosion-proof luminaires therefore need safety and functional testing. For a new product of our customer, a fully automatic test system was developed to be integrated directly into the production line.

Industry
Luminaires

Task
A fully automatic test system had to be developed for a new product. Key requirements were high flexibility and rapid conversion for line-powered and battery-operated linear luminaires. In addition to process reliability, documentation of each test was essential. The entire concept had to meet the stringent requirements for explosion-protected products. As the test system is intended for direct use on the production line, ergonomic workplace design was also a priority.

Solution
In cooperation with the customer, a PC-controlled test system was developed. Workplace design played a major role. Using an approved safety curtain improved handling and reduced cycle times. The standard DAT software not only controls the test sequence but also guides the operator through the entire process. DAT is a complete Windows-based quality system; anyone able to operate a PC can run the tester.

After safety tests according to internationally applicable standards (IEC, EN, UL, VDE etc.), the functional test is performed by measuring current consumption. Additional subjective inspections can be connected afterwards.

Benefits

• Turnkey solution including DUT holding fixture, adaptations and workplace design
• Simple, intuitive operation for semi-skilled personnel
• DUT connected once; entire test sequence runs automatically
• In network mode all test data are automatically stored at the desired location / database
• Long service life and service-friendly design
• Short cycle times through efficient workplace layout
• All values and settings configurable via the software
• Automatic dummy test
• Workplace protection according to EN 50191
• Original lamps used for the function test

Characteristics / technical specifications

• Ground bond conductor test: 10 A to 30 A / max. 0.4 Ω
• Hipot test AC: 250 V AC to 5,000 V AC / 3 mA
• Hipot test DC: 250 V DC to 4,000 V DC / 4 mA
• Function test: 0 – 300 V AC / 1 kVA, 10 Hz to 80 Hz
• PC-controlled with DAT software (Windows-based quality system)
• Test programmes: any number can be stored; results saved in XML or Access
• Approved safety curtain for optimized handling and cycle time
• Automatic daily dummy test for self-check of test system functionality