How to choose the right wire and cable tester

Together with MK Test Systems, we offer a comprehensive range of specification models for Automeg test systems, giving the system the modular flexibility to meet your exact requirements.

When choosing an electrical test system – whether for wire harnesses or other applications – the range of options can be overwhelming. This article has been written to help you understand which specification is right for your business.

Which test system specification is right for you?

IONIO can work with you to create the perfect specification for your test system. Initially, however, this concise guide to the range of Automeg models is a useful starting point.

An overview: all Automeg models have the following features:

• • Continuous resistance measurement, low-voltage insulation test (short circuit) and high-voltage DC insulation resistance test standard.

• • Optional high-voltage AC HiPot tests, capacitance measurement LCR modules.

• • Optional function test stimulating switching modules and power supplies to enable activation and function testing. Note: This option is suitable for testing a small number of active components in the assembly under test. For testing larger numbers of active components, we recommend a full function test system from our E or M series.

• • Integration with a range of third-party sources, scopes and measurement modules.

• • All systems can be configured to suit your business and application. From static rack cabinets to heavy-duty mobile cabinets suitable for shop floor and hangar use; from distributed switching where the system is spread across large assemblies such as aircraft or vehicles; to portable systems built into a rugged case or rack format for use in the field.

• • MKAT, our powerful test management software. MKAT, our own third-generation software, combines ease of use with powerful capabilities for creating and managing test programmes.

Our Automeg test system specifications:

Our range of basic models consists of the following groups:

Automeg Wire and cable tester T series: This Automeg model series is called T for ‘two’ wires, because our T series applies continuous resistance measurements with 2 wires.

If your testing requirements require a high number of test points and you only need continuous resistance measurement down to 0.1Ω, the T series is your entry-level, low-cost, automatic testing option.

Automeg Wire and cable tester F series: The F series is our special 4-wire Kelvin measurement solution. As with the T series, F stands for four-wire.

When your continuity and resistance measurements need to be milliohm-accurate, the special 4-wire F-system guarantees you the best possible accuracy. Thanks to its high accuracy, this Automeg series is ideal for testing critical cables, components, shield connections and low resistance joints.

Automeg Wire and cable tester D series: The D series is our most popular model for testing standard electrical wire harnesses, where D stands for ‘dual’. It offers both 2-wire and 4-wire resistance measurements, and the ability to mix these modes in a single test programme.

The D series Automeg models can handle a mix of resistance measurements up to 2mΩ. The result is a highly flexible system that allows fast automatic testing of complex assemblies.

Automeg Wire and cable tester E series: The E series is our entry-level multibus function test solution.

If your product has active components, or if you may need to function test active assemblies in the future, the E-series offers options for both measurement and function testing. Any E-series relay card can be used as a measurement card or as a switch card for function testing. The only limitation with the E-series is that the card can be used for measurement or stimulus switching during a subtest. So you need to plan your test interface to allow a full function test.

The E-series Automeg is the ideal solution if the density of active components is low or if your designs are stable.

Automeg Wire and cable tester M series: The M series offers the highest degree of flexibility. These systems can be used for both 2-wire and 4-wire kelvin measurements and they can also provide functional stimulus from any test at any time. As with the E-series, the card can be used for measurement or stimulus switching during a subtest.

The M series simplifies your interface design. Each interface channel can both measure and stimulate, eliminating the need for a complex Y-cable interface. For example, when testing a contactor, the system measures the resistance of a coil and then stimulates the coil using the same test points and the same interface cable. The system then simultaneously measures the change in contact resistance.

If the density of the active components is high or the size of the active product is flexible, the Automeg M series is the ideal system.

Summary

This article describes the differences between our Automeg test systems.

The key to understanding which testing system is right for you is knowing what your testing requirements are. Ideally, you can tell us the following details:

Number of test points (to test a single wire 2 if required, or 4 if using a Kelvin measurement). Maximum voltage required for AC and DC insulation testing. Whether you need a static, mobile or distributed system. Your interface requirements – standard or customised. Is excitation required? If so, what is the maximum current and voltage? Is high current switching required (more than 2 amps)? Do you need capacity testing? If, in addition to the above, you can send us the test specification you want to achieve, it will be a great help.

Next steps

Once you have provided the above details, IONIO can advise you on the best Automeg test system specification for you and recommend any additional modules.

For more production information, visit our dedicated Automeg and portable Automeg product pages. Our latest wiring harness testing system is RTS, which uses fewer interface cables and offers real-time testing during connection.