Auto Run Test stations are located on the assembly line after the Evacuation and Charge stations.
The operator connects the various test connections to the unit to be tested. The computer uses the scanned serial
number to look up the unit model number and load the Model specific Program from the database. Each test in the program is
executed and evaluated for pass and fail. If a test fails, testing is stopped and an error message displayed. The failed information
for the unit under test along with the test parameters are logged to the database. If all tests pass, the testing parameters, as well
as the results, are stored to the database.
A standard 70 amp Auto Run Test for a package unit with single compressor and gas heat will consist of the following:
1. Control panel containing I/O
2. 70Amp Variable transformer (external or internal)
3. Junction box for unit test connections located at test bay
4. 100 Amp field disconnect for test leads located at test bay with quick change plugs for 1PH, 3PH-3WIRE AND 3PH-4WIRE units
5. Voltage Transducer
6. Watt Meter
7. Current Meters for L1, L2, L3
8. Current Clamps for Compressor Start winding, Outdoor Fan, Indoor Fan, and Inducer Motor
9. Unit Vibration Transducer
10. 2 Sail Switches for fans
11. Gas Flow Meter
12. Suction and Discharge Pressure Transducers
13. Hi-Pot Tester (Optional)
14. 24Vac Compressor Winding Tests
The model specific program is designed by the user using test definitions and by entering parameters appropriate for the unit under test. These test
definitions can be entered in any order to accommodate testing. In general, test definitions are provided for the following:
1. Turn Off/On status of each Digital Output Point
2. Verify Off/On status of each Digital Input Point
3. Verify Analog Inputs within user defined parameters
4. Verify and Log to Database Analog Inputs within user defined parameters
5. Capture peak starting current and minimum starting voltage
6. Perform low voltage start test accommodating TOL with retries
7. Post Purge test for gas heat units
8. Gas safety device tests with relight
9. AC/DC Hi-Pot, Gnd Continuity, Gnd Bond, and Simulated Earth Line Leakage Setup and testing
10. Serial or Ethernet commands to interface to control boards requiring com.
Software for this station includes the following:
1. Test Definition software (Figure 11)
2. Program creation and editing software (Figure 12)
3. Results Lookup and Standard Reporting software
4. Station Configuration Software (Figure 14)
5. Linear Calibration Software for analog devices
6. Ambient Temperature Compensation for Program Parameters
The following data is collected at this station:
1. All Test Parameters for all tests
2. All Test Results
3. Total Test Time
4. Test Status
5. Test Failure Messages
6. Defect Codes
7. Operator Comments
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