3 STATION SWITCH ENDURANCE TEST BENCH

The SCR Elektroniks 3 station Switch Endurance Test Bench is designed to verify the endurance testing of household and rocker switches as per IEC 60669, IS 3854 and BS EN 60669. Typical switch ratings covered are for the entire range (typically 6 – 45 A) for both 3 phase and single phase loads. The tests included (that can be customized) are as follows: 1. Normal Operation (Referred to as Cl 19.1 in IEC 60669, IS 3854 and BS EN 60669) 2. Making and Breaking Capacity (Referred to as Cl 18.1 in IEC 60669, IS 3854 and BS EN 60669) 3. Temperature Rise (Referred to as Cl 17 in IEC 60669, IS 3854 and BS EN 60669) 4. Fluorescent Lamp Load (Referred to as Cl 19.2 in IEC 60669, IS 3854 and BS EN 60669) 5. Tungsten Filament Lamp Load (Referred to as Cl 18.2 in IEC 60669, IS 3854 and BS EN 60669)

Stand-alone unit after initial configuration of test parameters: The panel is capable to generate accurate test results even after days of continuous operation with no loss of data.
Single / Three Phase operation possible
Servo controlled mechanism to control current (+/- 1%) against incoming fluctuations
CT range selection for current measurement accuracy
Load selection is selector switch based: Quick and easy
PLC based timer unit (Siemens Logo) for quick and easy user interface and automated operation: Easy setting of parameters such as on time, off time, no. of cycles and threshold consecutive contact weld, contact open cycles
Accurately designed iron core inductors (Optional air core inductors as per customer specifications) for circuit parameter accuracy
Specially designed fixture for safe operation with operator safety in view
Cooling shall be provided by means of optimally placed Exhaust fans distributed all over to remove the hot air generated inside the panel cabinet: This avoids change in circuit parameters as a result of over heating of loads
Ceramic core wire wound resistors with enamel coating: This ensures best quality of resistors that have a favourable resistance v/s temperature rise graph enabling operation for an elongated duration with accuracy
Temperature rise test can be integrated with the main endurance test
PC based option available: Complete PC data logging and control plus online plotting of temperature rise graphs

  • Total Voltage and current range of the source: 200-270 V , 6-57 A AC (Depending upon the switch ratings selected)

  • Load Current options: 6, 10, 13, 15 16, 20, 25, 32, 45 Amp for Normal Operation and 1.25 times 6, 10, 13, 15 16, 20, 25, 32, 45 Amp for Making-Breaking test (Also respective test currents for fluorescent lamp load (Load A and Load B) and tungsten filament lamp load)

  • Rated Voltage Options: 220 V, 230 V, 240 V and 250 V (As per user specifications)

  • Power Factor: 0.3 for Breaking Capacity and 0.6 for Normal Operation

  • User Specified Number of Phases: 3 phase or 1 Phase

  • For temperature rise test: k type Cr / Al thermocouples with upto 12 temperature channels (customizable) per phase

  • 50 / 60 Hz operation as per incoming line frequency

  • Pneumatic Pressure: approximately 8 bar

  • Class 1 Accuracy (for current and voltage display)

The SCR Elektroniks 3 station Switch Endurance Test Bench is designed to verify the endurance testing of household and rocker switches as per IEC 60669, IS 3854 and BS EN 60669. Typical switch ratings covered are for the entire range (typically 6 – 45 A) for both 3 phase and single phase loads.

The tests included (that can be customized) are as follows:

  1. Normal Operation (Referred to as Cl 19.1 in IEC 60669, IS 3854 and BS EN 60669)
  2. Making and Breaking Capacity (Referred to as Cl 18.1 in IEC 60669, IS 3854 and BS EN 60669)
  3. Temperature Rise (Referred to as Cl 17 in IEC 60669, IS 3854 and BS EN 60669)
  4. Fluorescent Lamp Load (Referred to as Cl 19.2 in IEC 60669, IS 3854 and BS EN 60669)
  5. Tungsten Filament Lamp Load (Referred to as Cl 18.2 in IEC 60669, IS 3854 and BS EN 60669)

The above tests can be chosen by the customer in tailor made manner, meaning that the user may choose only those tests which are required for the testing needs. Even the switch current ratings can be chosen from the list of ratings: 6, 10, 13, 15 16, 20, 25, 32, 45 Amp making the bench easy to procure depending upon the testing needs and the budget of the client.

The system essentially consists of a servo controlled constant voltage / current source, a PLC module for controlling the on-off sequence (with user specified on and off time and number of cycles), a measurement module (including current and potential transformers) to measure and display current, voltage and p.f., an adjustable load bank designed as per the IEC specification and a pneumatic based fixture for ON-OFF operation. The PLC module is interfaced with an indigenously designed contact weld-contact open diagnostic circuit which helps in diagnosis of the switch under test: It points to the exact number of cycles the switch under test has withstood after suffering either welding or opening of contacts (switch failure) prematurely before the IEC / IS / BS stipulated number of cycles are completed.

Since most of the switch manufacturers have different mechanical switch designs, our fixture design team realizes the fixture in such a way that the endurance testing is carried out perfectly without subjecting the switch under test to undue mechanical stresses, thus conforming closely to the IEC needs. Plus, say if the 6 A switch has a different mechanical design (w r t loading and on-off operation) than the 32 A switch, the fixture is designed so as to accommodate both switches in their respective testing cycles: Thus the customer is offered an optimized design (without the use of multiple fixtures) to test a variety of switches.

Additionally, the system boasts of integral temperature rise test along with a thermocouple based temperature rise module and digital display of temperature. An optional PC based operation provides customers wanting to carry out test on a SCADA based system with complete data logging of all parameters. The temperature rise module may integrate isolation amplifiers enabling temperature rise of the current carrying (live parts) enabling online monitoring of temperature against rated / other current.

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