Test Equipments for Contactors and Compliance Verification Benches for conformity assessment as per IEC 60947 & others.

We design and manufacture test equipments and automation solutions for testing and production of electrical contactors.
Some of our recent solutions are listed here. These facilitate testing of contactors as per IEC 60947 and others. Please write to us for more details.

• PC based Routine (production) test bench for Contactors
• AC / DC Voltage Source
• Micro-ohm meter

PC based Routine (production) test bench for Contactors

This is a complete routine (production) test system for Electrical Contactors. It covers the tests recommended by IEC 60947 - Flashing, Continuity, Coil Wattage measurement, Pick-up/Drop-Off & High Voltage Test. The entire test sequence is programmed and is controlled by customisable Testware running on PC. The operator has to select the type of contactor (model or SAP code) to be tested once on starting the bench, and then just load the contactors (generally 6 in a single test cycle) in the jigs (electro-pneumatic fixtures).
The accompanying PC based Testware is intuitive, has secured database and exports reports easily for statistical analysis such as pareto analysis, bell-curve etc.

MAIN FEATURES AT A GLANCE:

• Tests six contactors in less than 3 minutes.
• Specially designed jigs for ease and operator safety (can be integrated on an automated assembly).
• Does not require skilled operator.
• Reporting for Data Analysis.

The tests performed are:

1. Flashing & Continuity Test.
2. Coil current & Wattage measurement Test.
3. Pick-up / Drop-off Test.
4. High Voltage Test.

The Test Panel will be suitable for testing contactors (three/four pole contactor with or without an auxiliary contact) with coil voltage 24V, 42V, 48V, 110V, 220V, 240V, 360V, 380V, 415V, 440V & 525V AC. The software supports calibration of measuring instruments. Hardware interlock is provided for H.V. & L.V. Supplies through contactor.

AC / DC Voltage Source

This is another option for testing electrical contactors manually.
The tests that can be performed are:

1. Flashing & Continuity Test.
2. Coil current & Wattage measurement Test.
3. Pick-up / Drop-off Test.
4. High Voltage Test.

Specifications:

1. Variable output:
   1. 0 – 750V AC / 50 Hz. regulated with 4 point selector switch. Tapping Ranges 0 – 75 V/15A, 0–150 V/8A, 0–300 V/4A & 0-750V/2A; with current 2A (AC) max.
   2. 0 – 600 V DC regulated with 4 Point Selector Switch. Tapping Ranges 0 – 75 V/12A, 0 – 150 V/6A, 0 – 300 V/4A & 0 – 600 V/2A; with current 2A (DC) max.
   3. Additional tapping for ½ wave rectified AC Upto 75V.
2. Provision of contact continuity with 12V (AC), Step down transformer for 5 points with pilot bulbs.
3. Main transformer rating – 5 KV A with tolerable regulation.
4. Control Switch for current reading / inching operation.
5. DC Digital Voltmeter 0 – 750V, 3 ½ Digit with accuracy + / - 1 %.
6. AC Digital Voltmeter 0 – 750V, 3 ½ Digit with accuracy + / - 1 %.
7. DC Digital Ampere Meter 0 – 1.9999A, 4 ½ Digit with accuracy + / - 1 %.
8. AC Digital Ampere Meter 0 – 1.9999A, 4 ½ Digit with accuracy + / - 1 %.
9. Milivolt Drop measurement at 10A DC Constant Current.
10. Resistance meter with 3 Ranges:
    • 0-200Ω
    • 0-2000Ω
    • 0-20000Ω

Micro-ohm meter

Micro Ohm Meter (MVDT) primarily consists of a DC Constant Current Source and a Micro-Controller based Control & Display Module

DC Constant Current Source: This is a constant current source with line & load regulation better than 0.2%. Its output (test) current can be adjusted remotely from an external device. This accepts input signal (say, 0-5V) from the control module (discussed ahead). The current gets adjusted to the required value. Millivolt signal proportional to actual current is made available for display. The output is made available on heavy-duty terminals or bus bars. This unit is light in weight and portable with great degree of reliability.

Micro-Controller based Control & Display Module: This is a compact and feature rich CU containing:

1. DAC Output for setting the required current in power source
2. ADC Module to monitor the actual current value and display the same on Digital Display
3. LED Display to display the different parameters like actual current, millivolt drop & contact resistance and also to prompt the parameters to be entered.
4. Keypad for programming i.e. setting the parameters and selecting the display of measured parameters like actual current, millivolt drop & microohm value.

The microohm data can be downloaded on PC. The PC based Software that is (optionally) shipped along, enables the user to view the data and export it as a spreadsheet so as to generate reports.