Test Gen Evolution

Every control panel built by Design Ready Controls undergoes a structured testing process to ensure that every wire is landed, every component is properly connected, and the panel is operating as intended. To accomplish this, panels are connected to testing systems where functionality, wiring accuracy, and power integrity are verified.

As control panel complexity and capability have grown over time, our testing procedures have also evolved. To maintain high-quality standards and ensure reliability, the Design Ready Controls team developed five distinct generations of testing. Each generation reflects an increased level of verification, automation, and efficiency, allowing us to match the appropriate testing method to the panel being produced.

Gen 1 – Point-to-Point Verification

Gen 1 represents our most basic level of testing and focuses solely on point-to-point verification. During this process, the operator follows detailed reports and electrical schematics to confirm that every wire and connection has been terminated at the correct destination.

The primary objective of this level of testing is to ensure proper wiring and electrical continuity. Each connection is manually checked to confirm that it is both correctly placed and electrically sound. While simple, this step provides a critical foundation to verify the integrity of the panel’s wiring before power is applied.

Gen 2 – Power Verification

Gen 2 builds upon the procedures of Gen 1 by adding system power-up using the appropriate voltage levels. This is Design Ready Controls’ most commonly used testing for control panels.

The panel is energized to ensure that all devices power up correctly. The team of testers also verify transformers, power supplies, and other electrical components produce the proper secondary voltages. This step confirms that the panel not only has correct wiring but also functions properly when connected with power.

Gen 3 – Computer-Assisted Manual Testing

Gen 3 introduces computer-assisted testing and test jigs. At this level, testers use proprietary software, DRCTesterAutomation, to interact with the panel’s circuits and, if applicable, its programmable logic controller (PLC). However, the process is still fully manual in terms of execution, and is subsequently Design Ready Controls’ least commonly used test methods. To supplement the necessary field signals and to read system outputs, a test jig is hooked up to the panel under test that emulates the field conditions.


The tester manually triggers outputs and monitors inputs through DRCTesterAutomation to verify circuit behavior. Unlike later generations, there are no automated scripts guiding the process. Instead, the tester evaluates each circuit’s function individually to determine whether the circuit operates as expected. This level of control allows for deeper functional validation of the panel’s control logic.

Gen 4 – Semi-Automated Scripted Testing

Gen 4 introduces automation into the testing process through predefined test scripts. These scripts guide the testing sequence and allows the PLC in the panel under test to be controlled automatically.

While much of the process is automated, the tester still provides occasional input when prompted (e.g. turn on MMP1). This makes Gen 4 a semi-automated testing method. Automation performs the majority of verification tasks while the operator oversees the process and confirms key steps. The result is a more efficient testing procedure while still managed with the tester’s oversight.

Gen 5 – Fully Automated Testing

Gen 5 represents the most automated stage of our testing evolution. At this level, the entire process is fully automated and requires no intervention from the tester beyond initiating the test.

Using a comprehensive predefined script and test jig, DRCTesterAutomation automatically verifies all circuits’ functionality and system responses. Once the process is started, the system executes all required checks independently and lets the operator know the outcome.

Conclusion

Each generation of testing delivers meaningful value and plays a vital role to ensure every panel is built and tested with excellence. Test levels differ by panel type and customer, taking into account a wide range of factors such as project complexity, scope, and scale. Design Ready Controls is deliberate to select the appropriate generation of testing for each panel and customer, to ensure the method aligns with the project’s purpose: an effective way to confirm performance, reliability, and compliance with customer expectations.