How are electrical products tested?

Part of an electrician’s job is to test, test and test again. But who’s testing the stuff you work with? Here’s the inside story on a couple of crucial pieces of kit, from our experts in the field.

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Products are put through their paces before they reach shelves.

Testing can begin virtually.

Conditions the product will be used in need to be replicated.

When you pick up a piece of electrical equipment, you do so safely in the knowledge that it’s been thoroughly put through its paces before it gets into the hands of the end user.

But what exactly does that testing process look like?

Testing cable support systems

If you’re running large quantities of cable, the integrity of the ladders and trays is a critical part of the job. They need to perform optimally for everyday use, and in case of an extreme event.

“Testing of the cable support systems is critical to their development,” says EzyStrut’s Engineering Manager, Brenton Davey.

Testing begins in the virtual world and is verified through physical testing. Fire testing is undertaken in a furnace at over 1000C, and vermin are taken seriously!

“Ducting or cable ladders are supplied with top and bottom covers to achieve a rat-proof structure.”

EzyStrut supplies a range of products tested for different applications.

“Cable installation inside an outback roadhouse may only require a light-duty, zinc-coated cable tray, whereas the tray at Glenelg Beach may need to be 316 stainless to survive the salty environment, and a heavy-duty HDG ladder is needed to survive cyclonic conditions in Port Hedland.”

The good news for sparkies is that cable support systems require little on-site testing.

“For the more demanding applications like fire, cyclonic and seismic, we have a team of engineers that develop, test and document unique solutions. There are some applications where the support systems need to be either isolated or earthed, and on-site testing is undertaken to verify our internal testing results.”

Testing emergency lighting

Emergency lighting, by its very purpose, absolutely cannot go wrong, something that Sid Gaurav, Category Manager – Emergency lighting at Pierlite knows only too well.

“Testing emergency lighting is crucial to ensuring the safety of people in a building during an emergency or power outage, and it undergoes more rigorous testing than regular household lighting,” he says.

“Products are tested under a variety of conditions, including temperature, humidity, duration, optics, battery compliance, endurance and emergency switching.”

Manufacturers of emergency lighting products continue testing and evaluating their products even after they have been released to the market.

“This includes batch testing, component testing, and quality assurance procedures to ensure that their products are safe, reliable, and meet all relevant standards and regulations,” says Sid.

And it’s recommended that electricians further test emergency lighting equipment prior to installing it.

But testing doesn’t stop at installation.

“It is crucial that building owners and managers test their emergency lighting regularly to ensure the safety of their tenants and customers in case of an emergency and power outage,” says Sid.

In Australia, emergency lights and exit signs need to be inspected at least once every six months.

“During the inspection, lamp tests and replacements are conducted, as well as a 90-minute discharge test,” says Sid. “To ensure that the emergency lighting system is up to date and compliant with regulations, regular cleaning and replacement of any damaged components is crucial. As is keeping accurate records of all tests and maintenance.”

Testing your tools

Using hand tools and power tools that are sub-performance or past their best is the express lane to the ER. Here’s how to make sure your tool bag is up to scratch.

Check tools are not damaged or blunt.
Check the handle and casing for cracks.
Inspect cords, switches, trigger locks and plugs for defects.
Test tools for effective grounding with a continuity tester or a ground fault circuit interrupter (GFCI).
Use only the correct battery for the tool you are using.
If a tool is defective, remove it and mark it ‘For repair’.
Don’t be tempted to use defective tools to finish a quick job.
Have tools repaired by an expert – do not attempt your own repairs.

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