Catch here
usually based on the increased time and added cost involved. This view needs rectifying. On the time factor, concerns normally arise from misconceptions between type testing requirements and the established practices for 100 per cent routine production line testing. A typical regime of electrical safety testing to meet these routine test requirements can be completed quickly, often within a few seconds.
Advantageous testing
In terms of cost, equipment can be expensive if the type test requirement is to be employed. However, for routine production line testing, there are a number of highly efficient, advanced systems that are readily available and can be used cost effectively to raise quality standards. With simple-to-use set-up, flexibility and advanced control features, these testers can be readily incorporated into the manufacturing environment without the need for highly skilled labour.
For type testing, a flash test can require high current levels (sometimes in excess of 100mA) and extended test times (several minutes for some standards) and consequently this type of test can require application under closely controlled conditions, involving the use of highly skilled and experienced test personnel. However, for routine production line testing, electrical safety standards define not only a lower, safer trip level, but also the setting up of the test area is well defined to
keep the operator safe. Experience has shown that routine test parameters provide a realistic evaluation of electrical safety and does not harm equipment that is designed to comply with the relevant standards for creepage, clearance and insulation properties. Where delicate electronic components are involved, far from omitting the flash test, various techniques can be incorporated to soft start (ramp) the test voltage, applying DC voltages with discharge circuits. This removes any likelihood of damage occurring - a procedure recognised by many international safety standards. Far from costing time and money, 100 per cent electrical safety testing on LED luminaire production lines makes sound economic and business sense, creating a competitive advantage and peace of mind. After all, only 100 per cent testing can categorically show 100 per cent conformance. This is a priority for commercial and industrial LED lighting manufacturers.
Case study
Cambridge-based NET LED, one of the UK’s leading companies has improved the electrical safety testing of its products by using multi-function HAL LED testers from Seaward.
NET LED, which is quality assured by the Lighting Industry Association, has been designing, manufacturing and supplying LED luminaires and systems for installation in commercial and industrial
areas across the UK for over a decade. This includes a range of advanced LED panels lights, downlights, surface linears, tube, battens, emergency lighting, bulkheads, flood lights, streetlights, high/low bays, controls and accessories.
It invested in two HAL LEDs, which are used to verify the safety of tens of thousands of units manufactured at its factory before they are distributed to electrical wholesalers across the UK. It also uses the equipment to batch-test any products sourced from other manufacturers as part of quality control procedures. Each tester provides power measurement readings with a resolution of 0.2VA below 1000VA and performs continuity and ground/ earth bond tests alongside AC/DC Hipot (FLASH/Dielectric Strength). This ensures NET LED’s products guarantee the quality, performance and reliability required and are safety compliant with EN 60598. Function testing is also undertaken to check each unit effectively switches on/off and performs correctly at the required power consumption levels and that any ancillary equipment operates in accordance with technical specifications.
Test results are stored automatically by the HAL units, giving full traceability. This ensures all products are proven to be quality assured before leaving the premises. NET LED use this data to produce a test record for all manufactured units in the event of any damage during distribution, or to track and trace any product returns - in line with the company’s customer service policies. NET LED managing director Oliver Bubb
www.cieonline.co.uk
said investing in improved testing with the HALs, which offer rigorous capabilities and have significantly reduced the time taken to complete a test, provide the reassurance and peace-of-mind that units leaving the factory are 100 per cent safe-to-use and work as required.
The HAL LED delivers better resolution when testing low power products compared to the other safety testers, ensuring improved accuracy of measurement and quality control standards during manufacturing. Manufacturers like NET LED can complete end-of-line tests with the additional benefit of functionality testing of the operation of the equipment, ensuring not only a safe product, but consistent quality control throughout the production process.
The HAL LED combines the performance of a multi-function production line safety tester with power measurement for product energy consumption. The tester can be integrated into automated manufacturing systems with selectable sensors and can be controlled using a PC, either using Seaward’s own software solution or by means of a command protocol. A large graphic display presents information either in a numerical or analogue format while a powerful internal memory allows the storage of up to 6,000 test results and up to 50 configurable test routines. The instrument can also be interfaced with a variety of accessories, to improve both safe working and efficiency, including bar code scanners and safety warning beacons.
www.seaward.com Components in Electronics February 2022 35
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