Automated Test Equipment for Data Center Air Conditioners

A Custom-built fully automated, LabVIEW-powered PC-based test system for Data Center Air Conditioner testing.

High-Current-Injector-10KA
Custom- Built High Current Source System (AC/DC – 3 phase) for Schnieder Electrical Pvt. Ltd., Bangalore

The SCR Make PC-Based Test Panel for Data Center Air Conditioner Testing is an integrated, software-driven solution engineered to perform comprehensive validation of air conditioning units. 

This testing equipment is designed to automate and streamline the complete performance and safety validation of datacenter AC units with precision and adaptability in mind, this test bench employs LabVIEW-based software and a Siemens PLC module to automate sequential testing workflows.  

Our Journey

Since 1975, SCR Elektroniks has been designing and manufacturing specialized electrical test equipment for industries that demand precision and reliability. When Vertiv Energy’ approached us with their challenge of testing precision air conditioning units for data centres, we knew this project would push the boundaries of what’s possible in automated testing.

The result!!!! a fully automated, LabVIEW-powered PC-based test system that revolutionized their quality assurance process

The Challenge We Solved

Data center air conditioners aren’t your typical HVAC units. They operate 24/7 in mission-critical environments where even a few minutes of downtime can cost thousands of dollars. Vertiv needed a way to thoroughly test these units without the inconsistencies and time delays of manual testing.

Their requirements were demanding:

  • Complete electrical safety verification to international standards
  • Functional testing under real-world conditions
  • Consistent, repeatable results with full documentation
  • Faster testing without compromising thoroughness
  • Detailed certification for every unit tested

Manual testing was taking over 2 hours per unit, with significant variations between operators. They needed something better.

This SCR Make high-performance test panel is designed considering three core principles: Modularity , Safety without comprimise & Real World Reliability. 

   The Heart of the System: Our LabVIEW Software

After decades of building test equipment, we’ve learned that great hardware means nothing without equally great software. Our LabVIEW-based control system is the result of years of refinement and real-world feedback. The operator sees everything at a glance – system status, test progress, and real-time measurements. We designed the interface based on feedback from actual production operators, not what looks good in a dem

Key Features

Technical Specification

Control System

Testing Modules

Test Name

Parameters & Description

Earth Bond Test

6–10A AC current; resistance limit ≤ 0.1Ω; test result shown on PC

HV Test

GPT-9803 source; 0–6kV AC/DC with ramp-up/down; trip current (AC: 1–40mA / DC: 1–10mA)

Insulation Resistance

500V DC in OFF condition; insulation resistance measured and displayed

Earth Leakage Test

Conducted during Run test; current range: 1–15mA; result accumulation and display

Performance Test

Sequential testing with RPM sensing, dual pressure transducers, valve actuation, skip logic

Custom-Built High Current Source System (AC/DC - 3Phase)
2D Diagram

Current- Source- 12.5V/10000A- AC/DC- with DC Output

High Current Source System 12.5V /10000A AC 1 & 3 Phase with DC option - Source 3 Front View with DC Output

Safety & Protection Features

The PC, Interface module and software will be common for all the Sources

PC Controller Features

All Sources can be programmed simultaneously or independentlyfrom one interface

High-Current-Injector-10KA

High Current Injector 10kA -AC/DC

The High Current Injector (HCI) is designed to deliver controlled high-current outputs up to 10,000 A for both AC and DC applications across three phases. It is engineered for testing, calibration, and validation of power components, busbars, switchgear, and protective devices under high-load conditions.

                                                           

Current- Source- 12.5V/10000A- AC/DC- with DC Output

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