Tester for electric safety compliance testing

Overview
Power strips must be tested for safety and function after production to ensure compliance and reliable operation.

Industry
Electrical industry

Task
Develop an automated testing system capable of testing power strips with varying numbers and positions of sockets and different functional variants (e.g. master‑slave).

Solution
To handle a large variety of DUTs, a configurable test cover accepts up to twelve interchangeable socket adapters for different connector types and flexible positioning. An actuator for the power strip switch can be integrated. After closing the test cover, between one and twelve sockets are contacted automatically via pneumatic cylinders. During the test, the strip switch can be actuated automatically via two additional cylinders to verify switch function. Ground bond for all sockets, dielectric strength, insulation and functional checks are performed. For master‑slave strips, a load is connected to the first socket to verify switching of the additional sockets. The PC software stores an unlimited number of test programs; programs can be assigned via the product list and settings are validated by DUT contact coding. Test results are saved automatically in XML or Access formats. A separate test dummy verifies system functionality; the system blocks further tests if the dummy test fails.

Benefits

• Turnkey solution including DUT mounting, adaptation and workplace design
• Intuitive operation for semi‑skilled operators
• DUT connected once; full test sequence runs automatically
• Network operation: automatic storage of test data to selected location/database
• Durable, service‑friendly design
• All values and settings configurable via software
• Automatic dummy test before production testing
• Workplace safety compliant with EN 50191
• Easy retooling for many DUT types

Technical data

• Continuity test: 24 V
• Ground bond test: 10 A–30 A on the 12 PE terminals of the sockets and on the housing
• High voltage test: 5.5 kV AC / 2.99 mA and 6.0 kV DC / 3.99 mA (safety‑current‑limited)
• Insulation test: 6 kV DC
• Function test: single‑phase to check all connections and master‑slave function
• Switch actuation via pneumatic cylinders