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03/14/05

Safety test system for solar power inverters handed over to customer

 

A computer-controlled test system for the automatic high-voltage, insulation resistance and earth wire resistance testing of solar power inverters connected to a versatile installation system also supplied by Elabo has been delivered to the customer.

 

The power inverters are manually pushed into the test position on workpiece carriers and fastened down. The operator starts the test sequence by actuating the two-hand control unit. The system closes the test room and makes electrical contact with the test item via an interchangeable adapter. Subsequently, the electrical tests begin in accordance with the test plan instructions.


Sicherheitsprüfsystem für Solar-Wechselrichter an Kunden übergeben


The test system is made up of the following components:

 

Test rack for installing 19" test systems with an integral relay matrix and contact monitoring for 8 test points (freely extendible)

 

Earth wire resistance measurement with universal test unit 91-3J

Test current partially stabilised min. 10 A

Voltage drop 0 - 3.5 V

or resistance 0 - 0.35 Ohm

 

Insulation resistance measurement with universal test unit 91-3J

Test voltage: 530 V DC

Test current: < 3 mA

Measuring range: 0 - 3.5 / 0 - 35 MOhm

 

High voltage test with universal test unit 91-3J

Test voltage: 0 - 5 kV AC

Tripping current: 0 - 100 mA DC

 

high voltage test with 90-1V

Test voltage 0 - 6000 V DC

Test current max. 2 mA safety current restricted

Tripping current: 0 - 2mA

 

Standard PC Pentium 4 2.0 GHz

15" TFT monitor

Control panel / main switch

Keyboard with touchpad

Barcode scanner

 

Test item specific interchangeable adapters

 

Pneumatic modules

 

The system is controlled entirely by computer. The test sequence and the limit values for the test in addition to the test points are defined in test plans. Freely definable test sequences, limit values and test points allow the tests to be adapted accordingly and performed in line with the respective tasks. The test system is controlled entirely via the graphic ELABO Windows user interface.


Sicherheitsprüfsystem für Solar-Wechselrichter an Kunden übergeben


The test cell is equipped with an interchangeable adapter system. This allows the system to be equipped with various adapters and, as such, makes it possible to test different types of converters. The interchangeable adapters in turn feature an electrical coding, which enable the system to tell which adapter has been inserted. In order to change adapters, an additional function has been incorporated into the test program.

Sicherheitsprüfsystem für Solar-Wechselrichter an Kunden übergeben

A special feature of the interchangeable adapters is the floating-mounted contacting unit attached to the interchangeable adapter. Thanks to this special mechanical design, it is possible to compensate tolerances in the test item due to the manual installation of the PCB sets inside the test item case automatically when moving the interchangeable adapter unit up to the test item, without having to integrate a complex mechanical aligning facility.

Sicherheitsprüfsystem für Solar-Wechselrichter an Kunden übergeben

The operator-friendly user interface makes the test system intuitive to work with. The automatic test sequence is displayed on the screen in a way that can be easily followed by the operator.

The ELABO software package allows a test sequence to be used that has a variable structure, which is defined on the basis of individual test plans. In addition, powerful wizards permit the simple administration of test plans, measured values and statistics. It is possible to generate and output detailed test reports for each test item. The test program is implemented using LabView. LabView is a modern graphic programming system, which is deployed the world over by thousands of engineers for demanding assignments.

The network connection of the system facilitates the automatic forwarding of all the test results and data to the customer's QA system.


Sicherheitsprüfsystem für Solar-Wechselrichter an Kunden übergeben


Source: Elabo GmbH

Author: Christian H. Bunke / Michael Posovszky

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