Tester for electric safety compliance testing

Overview
Manual testing system for determining the triggering of circuit-breakers. Designed to test 1-4-pin RCCBs with currents up to 250 A AC. The system combines manual operator control (manual current adjustment and manual intervention during tests) with PC control and real-time data processing. Different test adapters and an extensive switching matrix allow testing of products that differ in number of pins, breaking current, size and add-on devices. A separate test dummy is used for a fully automatic system self-check at startup.

Industry
electrical industry

Task
The customer required a test system to verify functionality of one- to four-pin circuit-breakers at high currents up to 250 A while permitting safe manual operator intervention. The system had to accommodate products with varying pin counts, breaking currents, sizes and accessories.

Solution
A standing workstation with a protective test cage was developed. The DUT can be manually actuated during tests using a special tool while the operator remains protected. Tests are performed with currents up to 250 A AC and trip time is determined for each contact path. Multiple contact paths and pilot contacts can be connected and detected. Current is set manually via a control knob and shown on a digital display; the remainder of the system is PC-controlled with real-time data processing. Different test adapters and a comprehensive switching matrix enable testing of varied DUT types. Any number of test programs can be stored on the test-PC and assigned via a product list. Test results are saved automatically in XML or Access format to a specified network location. A mandatory dummy test at daily start-up prevents further testing unless passed.

Benefits

• Turnkey solution including DUT support, adaptation and workplace design
• Simple, intuitive operation for semi-skilled personnel
• DUT connected once only; complete test sequence runs automatically
• Network operation: automatic storage of all test data to specified location/database
• Long service life and service-friendly design
• All values and settings adjustable via software
• Automatic mandatory dummy test
• Workplace safety compliant with EN 50191
• Operator can manually intervene during function tests without compromising safety
• Testing of different products with currents up to 250 A AC
• PC-controlled system with real-time data processing despite manual setting options
• Different test adapters and extensive switching matrix for varied contact paths

Technical data (summary)

• Manually adjustable power source
• Function test range: 0 to 250 A AC
• Determination of trip time for each contact path
• Detection of pilot contacts
• Multiple contact paths connectable to the power supply
• Manual current adjustment via control knob; digital display for set current
• PC-controlled system with real-time data processing
• Storage of test results in XML or Access format on network locations
• Arbitrary number of test programs storable on the test-PC
• Automatic mandatory dummy test at system start-up
• Workplace safety compliant with EN 50191
• Different test adapters and switching matrix for varied DUTs
• Operator manual operation possible using a special tool within a protective test cage

Characteristics / technical specifications

• Application: testing 1-4 pin RCCBs up to 250 A AC
• Operation: combined manual (knob, tool) and PC-controlled automated testing
• Data output / storage: XML and Access formats; network storage capability
• Safety features: protective test cage, compliance with EN 50191, automatic dummy test
• Flexibility: multiple test adapters, switching matrix, configurable test programs