Installation and operation of electrical test facilities

The requirements of DIN EN 50191 VDE 0104 clear and understandable.

DIN EN 50191 VDE 0104 specifies how electrical test stations must be designed.

In the BG brochure, DGUV Information 203-034 (formerly BGI 891), the requirements for setting up and operating electrical test systems are described in clear and comprehensible terms. It is a helpful supplement to the normative requirements of DIN EN 50191 VDE 0104.

We particularly recommend that you read and apply chapter 3 setting up test systems and chapter 4 operation.

We have prepared a short summary of the most important aspects for you below:

The complete description includes a 60-page DIN-A5 brochure, which you can download directly from the ETEM website. You will find the link below our short summary, at the bottom of this page.

You as the operator of the test facility are responsible for safety yourself.

Companies/employers/operators of inspection stations are therefore obliged to equip inspection stations with technical protective measures and to operate them safely. Ideally, test stations should primarily be equipped with mandatory protection against accidental contact.
However, use without mandatory protection against accidental contact is also conceivable if the relevant regulations are observed.

SCHLEICH testing technology is trimmed to “Performance Level e”. This means the highest possible safety for the operator according to the standard. However, the prerequisite for this is – no question – correct operation.

Operation with protection against accidential contact

This is always the best and preferable protective measure. However, it requires a protective cover or test cabin. As a result, a certain amount of time is required for the operator to close or open the protective device.
Even if a little more time is required for individual tests, the motto is always: “Safety first!”

Operation without protection against accidential contact

In test systems with barriers and additional safety precautions, operation is possible without the need for contact protection. The additional protection against unauthorized or automatic restart is important here. The danger of residual voltage in the test object must also be taken into account.
Ultimately, however, it should be clear that there is less safety than that provided by testing with protection against accidential contact.

Operation with safety current limitation

A test device with safety current limitation is also a possible solution. Specifically, the prerequisite for this is that the possible short-circuit current of the test device must not exceed 3 mA AC_eff, 12 mA DC or the energy must not exceed 350 mJ. It should be noted that a considerable amount of residual energy may be stored in the test unit! It should also be noted that when testing test units with a capacitive component, the resulting capacitive leakage current often exceeds the upper limit of 3 mA AC_eff. Many DUTs have integrated filter capacitors or, as is the case with winding materials, have high capacitances due to their construction. For this type of DUT, testing with safety current limitation is therefore ruled out per se. The safety current limitation is therefore not a “magic cure-all” and one reaches its limits very quickly.

Download the DGUV brochure free of charge

Further information on the requirements of DIN EN 50191 VDE 0104 (available in German):
Download the brochure from the DGUV (German Social Accident Insurance) website.

Do you need assistance?
We would be pleased to advise you and help you with the construction of your test system.

SCHLEICH delivers everything from one source.

test covers · test cabins · test facilities · safety light curtains · components for operation without protections against accidential contact · two-hand-start · warning lights · test devices · safety current limitation · automatic testing machines …

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