Low-Voltage Switch Comprehensive Testing Device

Low-Voltage Switch Comprehensive Testing Device

• The low-voltage switch comprehensive testing system complies with relevant national standards such as GB/T 11022-2020, GB 1984-2014, GB 1985-2014, GB/T 3804-2017, GB/T 7251 series, GB/T 15576-2020, and GB 14048 series.
• This testing system is mainly used for routine and type tests of low-voltage switchgear.
• The control operation of the testing system is based on a PLC programmable logic controller and a computer software interface, realizing automatic control of the control circuit and real-time sampling of electrical parameters. Through optimized software design, the test items can be completed automatically, and a data management system is introduced to automatically save the test results of each test item and automatically generate test reports, eliminating tedious operations such as recording and input by test personnel and improving test efficiency.
• This system adopts a highly integrated design, internally integrating intelligent instrumentation modules, multi-branch temperature rise modules, intelligent AC/DC power supply modules, and compensation circuit measurement and control modules. The core control unit uses a PLC control module, enabling automatic control integration with safety fences and logistics systems.

1. Grounding continuity tester

• Test range: 80μΩ~600mΩ (30A), 100μΩ~1Ω (20A), 500μΩ~2Ω (10A), 1mΩ~4Ω (5A), 2mΩ~8Ω (2.5A)
• Minimum resolution: 0.1μΩ
• Accuracy: ± (0.5% ± 2 characters)

2. AC withstand voltage insulation tester

• Voltage range: 0.2V~5.00kV AC
• Output resolution: 10V
• Output accuracy: ±(2.5% × set value + 10V)
• Maximum output current: 200mA
• Current resolution: 0.001mA/0.01mA/0.1mA (segmented)

3. Impulse Voltage Tester

• Maximum charging voltage: 20kV
• Output waveform: 1.2±30%/50±20%μs, standard lightning impulse voltage full wave, efficiency >90%, overshoot <5%.
• Operating conditions: -10~+50℃, <90% RH (non-condensing)
• Operating power supply: AC220V/50Hz, 400W

4. Insulation resistance tester

• Test voltages: 250V, 0.5kV, 1kV, 2.5kV, 5kV, 10kV
• Short-circuit current: ≥5mA
• Measurement time: 1~10 minutes
• Note: Independent manual testing is required; the system does not support automatic testing.

5. Temperature monitoring instrument

• Sensor: Standard K-type thermocouple (-270~1370℃)
• Measurement accuracy: ±0.2℃ (high precision range)
• Number of channels: 20
• Standard environment: Temperature 23±2℃, Humidity 55±10% RH

II. System Hardware Core Parameters

• Control core: Siemens PLC + industrial control computer
• Communication methods: RS485, Industrial Ethernet, Modbus
• Power supply module: 0~60V/0~270V DC adjustable power supply, maximum output 40A
• Current boosting capability: Maximum 800A per branch , multi-branch parallel output
• Protection types: overload, short circuit, over-temperature, IGBT fault, range over-limit, hardware/software interlock.
• Emergency stop device: dual emergency stop buttons on the main cabinet and operating terminal.
• Warning: Three-color warning light (green/yellow/red)

III. Software System Parameters

• Development platform: Microsoft Visual Studio
• Control modes: Manual/Automatic dual mode
• Data management: Local database + backend information management system, automatically saving and generating reports.
• Interface: PC/touchscreen operation, parameters displayed in separate areas, customizable.
• Mistake-proofing mechanisms: operation interlocking, input verification, and intelligent parameter calculation.
• Report format: Word/Excel, templates can be customized.

IV. Applicable Standards and Test Items

Follow the standards

GB/T 11022-2020, GB 1984-2014, GB 1985-2014, GB/T 7251.1-2023, GB 14048 series, etc.

Experimental Project

1. Electric shock protection and protection circuit integrity

2. Dielectric properties (power frequency withstand + shock withstand)

3. Mechanical operation

4. Power-on operation test

5. Power frequency overvoltage protection test

6. Insulation resistance test

7. Temperature rise test (power distribution/capacitor compensation circuit)

V. Usage Environment and Installation Requirements

• Power supply: Three-phase four-wire AC220V (A/B/CN)
• Grounding: Protective grounding resistance **≤0.5Ω**
• Operating environment: No water accumulation, no electrical discharge or burning, reliable wiring.

• This system is fully computer-operated and can be used to complete experiments via mouse or touchscreen. After the experiment, the data is automatically uploaded to the local database and the background information management system. When querying raw data, you only need to enter the data number to automatically retrieve the data.
• By entering the sample number and retrieving the sample's basic parameters, the system can automatically select and switch the primary measurement circuit and automatically schedule the corresponding test function modules.
• The fully automatic power supply for testing rises and falls, and automatically adjusts its speed, stopping automatically when the rated current or voltage is reached. It also locks the test data and automatically uploads it to the local database and the backend information management system.
• It automatically performs abnormal current and voltage protection and issues alarm instructions;
• It automatically collects and saves data, and automatically restores the machine to its initial state.
• High-precision current transformers are used for measurement, and data monitoring adopts full data monitoring (displaying all parameters on the same screen) in accordance with industry standards to ensure data integrity.
• The system protection employs multiple layers of protection, including software, hardware, and system interlocks. The cabinet adopts an integrated design, and the control section uses separate designs for primary and secondary control circuits, which greatly improves the safety of test personnel and test products.
• This system supports expansion and integration with information management and control platforms.

I. Core Application Areas

√ Low-voltage switchgear/complete equipment manufacturers : routine factory testing, type testing, full inspection of mass production lines, R&D verification and new product finalization.

√ State Grid/China Southern Power Grid and power supply companies : random inspection of distribution network equipment upon arrival, on-site handover testing, operation and maintenance cycle verification, fault diagnosis and retesting.

√ Power engineering/installation/commissioning unit : On-site power-on and safety verification for new/renovated power distribution rooms, transformer substations, JP cabinets, and cable branch boxes.

√ Third-party testing/measuring/certification organizations : conduct type testing, CQC/CCC certification testing, and quality arbitration testing in accordance with national standards such as GB 7251 and GB 14048.

√ For large users such as industrial and mining enterprises, construction enterprises, and data centers : conduct regular preventive tests and hazard investigations on the switchgear of their own power distribution rooms and important load circuits.

√ Research institutes/university laboratories : Low-voltage electrical appliance performance research, protection characteristic testing, temperature rise and insulation aging tests, and standard verification.

II. Applicable Products to be Tested

• 0.4kV and below low-voltage switchgear, drawer cabinets, MNS/GCK/GCS and other complete sets of equipment
• JP cabinet, cable branch box, distribution box, lighting/power distribution cabinet
• Circuit breakers, disconnect switches, load switches, contactors, thermal relays and other components
• Capacitor compensation cabinet, active/passive filter device, reactive power compensation circuit
• Low-voltage switch circuit for mining/explosion-proof/new energy charging piles/energy storage systems

III. Typical Application Scenarios (by Operation Stage)

1. The production and factory testing can be completed in one stop, including dielectric, grounding, temperature rise, power-on operation, power frequency overvoltage, insulation resistance and other items, and reports can be automatically generated, which is suitable for batch production lines.

2. On-site handover/acceptance of newly commissioned power distribution rooms, ring main units, and JP cabinets involves full-item verification to ensure qualified installation and wiring, and reliable protection.

3. Preventive maintenance tests are conducted periodically to retest operating switches for temperature rise, insulation, withstand voltage, and grounding continuity, in order to detect potential problems such as aging, poor contact, and decreased insulation in advance.

4. Type testing and certification meet the full set of type testing requirements such as GB 14048 and GB 7251, and support verification of temperature rise, dielectric, mechanical life, protection characteristics, etc., and issue compliance reports.

5. Fault diagnosis and repair verification locate faults such as tripping, overheating, poor insulation, and grounding failure; after repair, retesting confirms that it is qualified before putting it back into operation.

6. Research and development and quality control include new product design verification, extreme working condition testing, material and process comparison, and quality consistency spot checks.

IV. Highlights of Scenario Value

• Integrated system : One device covers multiple projects, reducing the wiring of multiple instruments and improving efficiency by more than 30%.
• Fully automated process : one-click start, automatic voltage/current regulation, data saving, and report generation, reducing human error.
• Safe and reliable : Multiple interlocks in software and hardware, emergency stop, overcurrent and overvoltage protection, and overtemperature protection, suitable for production lines and high-pressure testing environments.
• Data traceability : Dual storage (local + backend) supports querying, exporting, and printing, meeting quality inspection and certification requirements.

• This equipment is for professional use only, operated by qualified electrical engineers.
• Before testing, ensure reliable grounding (grounding resistance ≤ 0.5Ω).
• Do not perform wiring when the system is powered on.
• Emergency stop button is available at the main cabinet and operation terminal; press immediately in case of danger.
• Keep the workspace dry, clean and free of flammables during testing.
• High voltage and large current may cause electric shock or burn; keep safety distance.

• Main test cabinet 1 set
• Operation terminal (touch screen + computer) 1 set
• Standard test cables and connectors 1 set
• Grounding wire and temperature sensors 1 set
• Operation manual and certificate 1 set
• Test software and USB drive 1 set
• Power cord 1 set
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√ Warranty period: 12 months

√ Free lifetime software upgrade

√ Free remote technical support and debugging

√ On-site service (negotiable)

√ Regular calibration and maintenance service

√ Quick response: within 24 hours