Fully automated tester for electric safety compliance testing

Overview
Automated testing system for continuity, ground bond and hipot (high-voltage) tests of multiple 19'' MPH PDUs. Designed to test PDUs with up to 24 outlets and to handle multiple outlet and connector types via adapters.

Industry
electrical industry

Task
Verify a variety of power distribution units at a single test station: contact and test up to 24 outlets per unit, validate different outlet types and connector configurations, and record results linked to each DUT.

Solution
A sophisticated switching matrix addresses each outlet individually. Barcode identification of the DUT selects the correct test program from the system PC. Sensors confirm correct contact to each outlet and adapter. Continuity checks are performed first, followed by ground bond and hipot tests for every terminal/connector. A safety light curtain ensures operator protection. Adapter cables allow testing of multiple connector standards.

Benefits

• Turnkey workstation including DUT support, adaptation and ergonomic layout
• Simple, intuitive operation for semi-skilled personnel
• DUT connected once; full test sequence runs automatically
• Network integration: automatic storage of test data (XML or Access) at specified locations
• Short cycle times through efficient workplace design and safety curtain
• All test parameters configurable via software
• Automatic daily dummy test; system blocks further testing if dummy check fails
• Workplace safety compliant with EN 50191
• Automatic wiring, short-circuit and hipot tests for all DUT terminals

Technical specifications

• Supports several 19'' MPH PDUs; designed for up to 24 outlets
• Continuity test of all connections via I/O signals
• Ground bond test up to 30 A AC
• Hipot test up to 5,500 V AC / 6,000 V DC (test current 2–3 mA)
• Sophisticated switching matrix to address each outlet individually
• Sensors to verify outlet contact and correct adapter connection
• DUT identification via barcode; DUT data used to select test program
• Various adapter cables supported for multiple connector types
• Automatic storage of test results in XML or Access format to network locations
• Automatic daily dummy test; further testing blocked if dummy test not passed
• Workplace safety according to EN 50191