Fully automated tester for electric safety compliance testing

for the lighting industry

Overview
Intensive quality assurance is indispensable for explosion-proof products. This testing system delivers secure, automated and fully documented safety and functional tests tailored to Ex linear fluorescent luminaires.

Industry
Luminaires

Challenge
Replace obsolete manual test stations with modern PC-controlled systems offering high flexibility and rapid reconfiguration for mains- and battery-operated linear fluorescent luminaires. Process safety and documented traceability were mandatory; the design must meet stringent Ex requirements.

Solution
PC-controlled testing system with an ergonomically designed workstation and an approved safety light curtain to optimise handling and cycle times. Function tests use original luminaires stored in a drawer for quick replacement. The standard DAT (Windows) software guides the operator through the entire test sequence and manages programs. Safety tests comply with international standards (IEC, EN, UL, VDE). Functional verification is performed by power consumption measurement after safety checks. Test results are automatically archived in XML or Access on a specified network location. The system supports multiple customer-editable test programs. An automated daily dummy test verifies system functionality and prevents further testing until passed.

Benefits

• Turnkey solution including DUT support, adaptation and workstation design
• Intuitive operation for semi-skilled personnel via DAT software
• Device under test needs connection only once; the full test sequence runs automatically
• Automatic network storage of all test data (XML or Access)
• Long service life and service-friendly construction
• Short cycle times through efficient workstation design with safety light curtain
• All parameters and settings configurable via software
• Automatic daily dummy test for start-up verification
• Workplace safety compliant with EN 50191
• Use of original luminaires for realistic functional testing

Technical specifications

• Ground bond test: 10 A to 30 A, max. 0.4 Ω
• Hipot test: 250 V DC to 4,000 V DC / 4 mA
• Function test: 0–300 V AC / up to 1 kVA, 10 Hz to 80 Hz
• Standards: IEC, EN, UL, VDE
• PC-controlled with DAT (Windows) software (user guidance and full quality-system functionality)
• Results storage: XML or Access (network)
• Support for multiple, customer-editable test programs
• Automated daily dummy test; system blocks further tests if dummy fails
• Approved safety light curtain; workplace meets EN 50191
• Original luminaires stored in drawer for quick replacement