Testing method and system

A method and system for functionally testing units under test, such as electronic controller boards for a spa system.

This application claims the benefit of U.S. Provisional Application No. 60/761,680 filed Jan. 23, 2006, hereby incorporated by reference.

REFERENCE TO A COMPUTER PROGRAM LISTING APPENDIX

An appendix is submitted herewith in the form of a file titled “Test Script Example.txt”, created Jan. 23, 2006, with a file size of 36,861 bytes (36,864 bytes on disc), the entire contents of which are incorporated herein by this reference.

BACKGROUND

Spa installations may have sophisticated control systems for controlling operation of the spa heater, pumps, lighting and ancillary systems and equipment. The control systems may include microprocessor systems which interface to various devices through circuit board circuitry. The control system may include a controller circuit board which has mounted thereon a microprocessor as well as discrete circuit elements and controlled devices such as relays and the like.

The controller board may be a circuit system of considerable complexity. Installation of a defective controller board in a controller system can cause considerable difficulty in testing of spa controllers at a manufacturing distribution facility.

Once a spa has been installed at a customer site, and in the case of spa malfunctions, or customer operating problems, a controller board may be replaced in an effort to resolve the malfunction or operating problem. Due to its complexity, there may be difficulties in determining whether the particular controller board is defective. The field technician may replace the board without isolating the problem. Return of allegedly defective controller boards can represent a considerable expense to a spa controller manufacturer. Moreover, determining whether a part is covered by a manufacturer's warranty may be a time consuming project.

DETAILED DESCRIPTION

In the following detailed description and in the several figures of the drawing, like elements are identified with like reference numerals. The figures are not to scale, and relative feature sizes may be exaggerated for illustrative purposes.

FIG. 1illustrates an overall block diagram of a spa system with typical equipment and plumbing installed. The system includes a spa1for bathers with water, and a control system2to activate and manage the various parameters of the spa. Connected to the spa1through a series of plumbing lines13are pumps4and5for pumping water, a skimmer12for cleaning the surface of the spa, a filter20for removing particulate impurities in the water, an air blower6for delivering therapy bubbles to the spa through air pipe19, and an electric heater3for maintaining the temperature of the spa at a temperature set by the user. The heater3in this embodiment is an electric heater, but a gas heater can be used for this purpose also. Generally, a light7is provided for internal illumination of the water.

Service voltage power is supplied to the spa control system at electrical service wiring15, which can be 120V or 240V single phase 60 cycle, 220V single phase 50 cycle, or any other generally accepted power service suitable for commercial or residential service. An earth ground16is connected to the control system and there through to all electrical components which carry service voltage power and all metal parts. Electrically connected to the control system through respective cables9and11are the control panels8and10. All components powered by the control system are connected by cables14suitable for carrying appropriate levels of voltage and current to properly operate the spa.

Water is drawn to the plumbing system generally through the skimmer12or suction fittings17, and discharged back into the spa through therapy jets18.

A typical spa controller board may include a microcomputer for overall control, as well as various relays, switches, discrete logic, fuses, and connection terminals for connecting to line voltage and to line voltage loads, as well as low voltage connections. Described herein is an exemplary test station and method for testing spa controller board assemblies which are not installed into the spa system. Exemplary applications for the method and system include use by a distributor of portable spa systems, repair depots, and even spa controller board manufacturers.

An exemplary embodiment of a test system50for testing a spa controller board assembly20is illustrated inFIG. 2. In an exemplary embodiment, the system includes a spa controller board excitation and measurement system60including components which may be controlled by instructions received from a controller100, e.g. a personal computer running a board test software program. The controller100may be interfaced to the board excitation and measurement system60by an interface102, which may be, for example, a USB, RS-485, RS-232 or TCPIP (internet) interface. In an exemplary embodiment, a bar code scanner104or other input device may be connected to the controller for inputting data. A display106controlled by the controller100may facilitate the test procedures through display of images associated with a given test setup and test procedure. A printer108may be connected to the controller100to provide printing capability, e.g. of test results, RMAs, and other records. The controller100may be connected to a remote server116, e.g. through an internet connection, a local area network or by a wireless link.

The system60may be electrically connected to a unit under test (UUT)20, which in an exemplary embodiment may be a spa controller board. In one exemplary application, the UUT may be a previously fielded unit, which may be suspected of having a need for repair. The test system100may be utilized, for example, by a spa OEM (original equipment manufacturer), a distributor, or a service center. The controller100controls the system60to subject the UUT20to a test sequence, while measuring parameters such as voltage, current, resistance and capacitance to determine whether the UUT performs to specifications which are stored in a database, e.g. on the controller100or a remote server.

An exemplary embodiment of the test system for testing spa controller boards may support one or more of the following features.Serial number, item number, item description, manufacturing date, date tested, and defect analysis database tracking and reporting on a local test system.Test options for a variety of software revisions and circuit board configurations.Certification certificate generated with a passed circuit board or topside panel.Test initiation by scan of board serial number, which automatically loads proper test script for the unit under test.Test hookup instructions provided in both narrative and visual formats to simplify setup and reduce errors.Test will run continuously from initiation, but may provide option for single stepping, or interactive mode, of troubleshooting.Printout of failure mode for “no-pass” tested units.Script interface may support images of the UUT to assist the operator in finding connectors, switch settings and jumpers by means of a X/Y cross-pointer.Software may set current limit trigger set points to protect the operator from over-current conditions (e.g., heater dry fires). Heater test points may have a circuit breaker for added protection. Heater test scripts may have a pre-power resistance test to verify that heater is disconnected prior to applying power.Software may provide a virtual panel display to assist the operator with panel type error codes, temperature and output status information.Setup server to support remote actions, such as remote updates for test scripts and drawing, test result data file transmission to the manufacturer server for archiving; RMA failure ticket recording.

In an exemplary embodiment, the system60includes a control module62, which converts commands received from the controller100via interface102, a signal measurement module64, e.g. a voltage/current/resistance/capacitance measurement module such as a digital multi-meter (DMM), which may measures parameters resulting from connecting to the UUT or from exercising the controller functions, a load module66which provides a proper electrical load for a given controlled function of the controller, and a multiplexer68for channel selection. The measurement results can be digitized, and provided to the controller100via interface102for processing, storage and comparison against expected signal profiles stored in memory for a given type of unit-under-test (UUT) and for a given test or excitation.

The control module62may in an exemplary embodiment include commercially available modules for performing the functions of module62. For example, the module62may include units marketed by CyMod as the CM4530 for USB to RS485 conversion, the CM 4531 for RS485 to RS232 conversion, the CM4056 for digital input/output (I/O) control of the multiplexer68and other relay or switch components of module80, and the CM4017 for analog-to-digital conversion.

Exemplary devices suitable for the purpose of the measurement module64are commercially available, such as, by way of example, the model GDM 824 DMM.

In an exemplary embodiment, the system60includes a panel and sensor emulator (PSE) module70which is connectable through electrical connectors to a set of master panel and auxiliary panel terminals on the spa controller board. The PSE module70includes a panel emulator module72which may convert instructions received from the controller100through the control module62into signals emulating signals from a spa master panel and spa auxiliary panel. A test mode signal generator module74may generate signals to put the spa into a special test mode for testing heater control functions. A temperature sensor emulator module76may generate signals emulating those received from spa heater temperature sensors, in order to test the response of the controller board to a set of temperatures during a heater test mode.

The system60further includes, in an exemplary embodiment, an AC power module80, which provides a line voltage service to the UUT, with a ground fault interrupter (GFCI) and circuit breakers. In an exemplary embodiment, the module80may provide a 240 VAC, 30 Ampere service capacity through the GFCI and circuit breaker and an on/off relay system. A line service connection82may be established between the module80and the AC input connectors of the controller board20, through a current sensor90. The current sensor signals are provided to the control module62for processing, e.g. analog-to-digital conversion, and provided to the controller. The current sensor90may measure the current drawn by the UUT20during test procedures.

In an exemplary embodiment, the system60may include a voltage level shifting adapter86for converting between signal levels of the computer serial port, e.g. RS-232, and SPI protocol TTL signal levels which are compatible with the microcomputer comprising the spa controller board. In an exemplary embodiment, the adapter module86can include a MAX 232 RS-232 driver receiver device, marketed by Maxim, or an equivalent, for performing the level shifting. For some applications, the adapter86may be omitted, e.g. in a design in which the TTL conversion is performed on the spa controller board, and RS-232 signals are communicated between the test station controller100and an RS-232 port on the spa controller board. A serial data stream can be passed between the controller100and the spa controller board, allowing data and commands to be passed from the test system controller100to the spa controller board20, and for status and other data to be passed from the spa controller board to the controller100.

FIG. 2schematically illustrates features of an exemplary embodiment of a spa controller board20which may include a controller printed circuit board, having a conductor pattern formed thereon and populated by various components, which may include, for example, relays, terminal blocks, dip switch blocks, and a microcomputer. The spa controller board can employ power and signal routing features as described in pending application Ser. No. 10/677,510, entitled Controller System for Bathing Installation, filed Oct. 2, 2003, the entire contents of which are incorporated herein. In an exemplary embodiment, the microcomputer may be a PIC 18F6620 microcomputer, although other microprocessors can alternatively be employed. The spa controller board20may also include a serial data bus or ADCM (advanced diagnostic control and monitoring) port which may be connected to the test station controller100through the level shifting module86. In an exemplary embodiment, the port may provide full duplex serial data bus connections allowing signals to be passed in both directions simultaneously between the controller and the controller20. The terminals of the ADCM port may be coupled to terminals of the microcomputer, e.g. through buffer circuits well known in the art.

The controller2in an exemplary embodiment may include DIP switch assemblies, or virtual DIP switches, which can be set at the factory or by a service technician to setting indicative of settings of the controller or a particular configuration of the spa1. The DIP switch settings can be read by the spa controller board microprocessor, and can be passed to the test station50through ADCM (advanced diagnostic control and monitoring) port during a test of the spa controller board.

Data can therefore be exchanged between the spa controller2and external systems such as the test station controller100. In an exemplary embodiment, the data can be in the form of data packets of a predetermined protocol. Further details concerning an exemplary protocol are described in co-pending application Ser. No. 10/815,556, filed Mar. 31, 2004, entitled Method and System for Testing Spas, the entire contents of which are incorporated herein by this reference.

FIG. 3is a simplified schematic diagram of an exemplary embodiment of a multiplexing and load selection system150which may be employed to implement functions of multiplexer66and load module68ofFIG. 1. An instrument select relay set152may be employed to allow selection of one of multiple measurement instruments for signal measurements. For example, the relay set152may allow selection of a DMM (digital multi-meter)64or another instrument64A, such as for example, an oscilloscope.

The system150includes a relay control module156which controls the various relays or other types of electronically controllable switching devices which perform the switching functions in system150. In this exemplary embodiment, the relay control module may energize relay coils, e.g. relay coil158which actuates relays152, or relay coil160, which actives a set154of crossover relay set154or relay coils164,166,168which activate load select relay set170. In an exemplary embodiment, the relay control module156is controlled by signals received from the control module62, which in turn is controlled by the computer100. The computer100may therefore control all relay functions of the system150. in an exemplary embodiment, the relay control module is a digital control unit connected to an external RS 485 control module62.

The crossover relay set154allows polarity swapping of the signal to be measured. This function may be useful during unpowered active component and DC voltage measurements to increase stability.

A load select relay set170performs a function of allowing control over the load impedance to be connected to the unit under test. In an exemplary embodiment, the relay set170includes relays172,174,176which may be closed selectively under control of the relay control module156through relay coils162,164,166. The exemplary load impedances selected by these relays includes resistors178,180,182, with corresponding resistance values of 25 ohms, 1 K ohms and 25 K ohms. The relays may be actuated to select individual ones of the resistors, or particular combinations in parallel. In an exemplary embodiment, the load select170allows selection of loads to facilitate stable measurements on signals while drawing relatively low load currents. The particular channel and unit under test will determine which impedance value is to be used as a load for a given measurement. This test program running on the pc will typically select the load impedance for a given measurement. Alternatively, the system supports connecting actual load devices, e.g. pumps, as load devices.

The system150also includes a test point input channel select multiplexer190, which may perform functions of the multiplexer66(FIG. 2). In an exemplary embodiment, the multiplexer190includes a high (“Hi”) channel set of 32 relays, for selecting one of the 32 channels, and a “low” (“Lo”) channel set of 32 relays, for allowing selection of 32 independent Hi/Lo inputs for measurement. This allows selection of any one of the 32 Hi channels and any of the 32 Lo channels. The relays192,194allow the controller100to control, through the control module62and the relay control module156, the particular inputs for measurement.

FIG. 4is a simplified schematic block diagram of a PSE system200which may implement functions of the PSE module ofFIG. 2. The system200includes an RS232 communication interface204, which communicates with an RS232-RS485converter in the control module62. A microcomputer202decodes commands received from the computer100, and provides overall control of the system200. The system200includes a panel protocol emulator circuit210which in an exemplary embodiment provides functions of synchronizing in real time with the data stream for panel command and display used on the UUT20′. In an exemplary embodiment, the circuit210may be capable of emulating a plurality of different protocols, so that the system may be used for more than one type or model of UUT. In an exemplary application, the UUT may include a panel port20-1and an auxiliary panel port20-2, for connection via cables210-1,210-2to a spa control panel and an auxiliary control panel. During the test procedure, these ports may be connected to the test system50, and in the exemplary embodiment ofFIG. 4, to the PSE system210.

The system200further includes, in an exemplary embodiment, a temperature sensor emulation circuit214, which is connectable to sensor terminals20-3of the spa controller board20′ under test by cable212-1. The circuit214simulates water temperature signals on the sensor terminals. In an exemplary embodiment, the spa controller board has terminals for receiving temperature information from two temperature sensors, e.g. one located on the water input to the spa water heater, and a second one located on the water output from the spa water heater. In this example, the circuit214simulates temperature signals for the two temperature sensors over a temperature range. In an exemplary embodiment, the circuit214is controllable to simulate temperatures from 30 degrees F. to 120 degrees F. The temperature simulation may be useful, for example, for spa heater turn-on testing and over heat (OH) safety circuit testing.

The PSE system200in an exemplary embodiment may include an accelerator test pulser circuit214, which allows the computer100to accelerate testing of the heater and ozone outputs on some spa controller boards. This can save some time in testing cycles. The circuit214is connectable to the spa controller board heater accelerator terminals20-4by cable214-1. By reception of a special signal, e.g. an 11 Hz low voltage square wave signal, a specially designed spa controller board may be placed into a special test mode, to allow the accelerated heater testing mode to be performed.

The system200may include, in an exemplary embodiment, a flow switch simulation circuit216, which simulates the function of a water flow switch and a freeze detect signal in an exemplary spa system. The circuit216is connectable to the UUT by cable216-1, e.g. to freeze sensor and heater on/off terminals20-5. Some spa controller boards may be designed to accept a water flow switch output signal as an indication of water flow through a circulation path, and to turn off a heater if no flow is detected. Some spa controller boards may be designed to accept a freeze sensor output signal as an indication of a freeze condition which may be addressed by turning pumps and heaters on.

The system200may also include an LED indicator control circuit218which is connectable to operator LEDs located next to the test cable input terminals on the tester housing. These LED indicators may assist the operator to identify the proper cable connections prior to starting a test.

In an exemplary embodiment, the system200may also include a built-in test loop back circuit220, which enables the system controller100to perform a cable connection test to test for proper connection on test points prior to starting a test. This is intended to minimize test failure because of incorrect setup. The circuit220includes a relay set, represented schematically by coil220-1, and relay switches220-2. . .220-6, connected to cables210-2. . .216-2on one side of the respective switches and cable220-7on the other side of the switches. The cable220-7is connected to multiplexer channel32of the multiplexer190(FIG. 2), to allow per-cable signal measurement through the test cable connections to the UUT. For example, the circuit220may activate switch220-2to allow signal measurement on cable210-1through multiplexer channel32. This can determine whether the cable210-1is properly connected to the UUT, by determining whether an expected signal is measured. Examples of typical pre-power connection measurements may include, in an exemplary embodiment, the following:

1.) AC service connection to board: Measure resistance of UUT transformer to verify power cable is connected. Expected: 45 ohms, +−20%.

2.) AC service voltage setting: Measure resistance of UUT service strapping to verify board is setup correct for 120 or 240 VAC. Expected: <20 ohm for 120 VAC; >20 K ohms for 240 VAC.

3.) Panel port connection: Measure resistance of each button signal input to verify panel cable is connected to UUT and input impedance is correct. Expected resistance: 1M ohms, +−25%.

4.) Freeze input connection: Measure resistance of freeze input to verify test cable is connected to UUT correctly. Expected: 10 K ohms, +−25%.

5.) Sensor A&B input connection: Measure resistance of sensor inputs to verify test cables are connected to UUT correctly. Expected: 20 K ohms, +−20%.

6.) Test point connections: Measure capacitance on each test point output (Ex: Pumps, Blower, etc . . . ) to verify test cables are connected to UUT correctly. Expected Capacitance measurement: 30-60 ufd.

FIGS. 4A-4Eare schematic illustrations of exemplary embodiments of the respective circuits212-220. Referring toFIG. 4A, an exemplary panel protocol emulator circuit212is depicted. In an exemplary embodiment, the emulator circuit212may synchronize in real-time with the data stream for panel command and display used for the spa controller board under test. In an exemplary embodiment, the emulator circuit212may be adapted to handle the data stream for a plurality of types of spa controller boards, and the particular data stream for the UUT may be selected from one of a plurality of protocols stored for use by the controller100. In an exemplary embodiment, the circuit212may be adapted to allow for automated testing of the UUT without requiring the operator to install and operate a test panel. Thus, for an exemplary embodiment, the circuit may simulate control panel protocols to perform automated commanding and display functions. The embodiment illustrated inFIG. 4Ais connected to terminals of the microcomputer202of the circuit200through a buffer, e.g. buffer210-9, and is protected by clamp and resettable fuse components, e.g., clamp210-7and fuse210-8. If an over voltage condition occurs on any input or output the resettable fuse will open and protect the circuit. When the over voltage condition is removed, the circuit may automatically reset for normal operation without operator service. Exemplary UUT panel button and port connections are illustrated inFIG. 4A, as buttons1-4, etc. Signals are also connected to the test loop-back multiplexer circuit220, so that proper connection to the UUT panel terminals.

FIG. 4Bdepicts a schematic diagram of an exemplary temperature sensor emulator circuit212. Typically the temperature sensor used in a spa may be a variable resistance device, with the resistance indicating the sensed temperature. This circuit is controller by the microcomputer202, and includes several resistors connected in series ladder arrangements between ports to be connected between the temperature sensor terminals. In this embodiment, there may be two sensors, sensor A and sensor B, connected to the spa controller board. Each resistor may be bypassed (shorted) by a relay, e.g. relay212-5to affect the series resistance connected between the respective sensor terminals by the respective resistor ladder. Thus, series combinations of different ones of the resistors, e.g. resistors R1-R5, may be selected by appropriate control of the respective relays, to simulate different temperature values presented to the UUT. In an exemplary embodiment, the temperature sensor emulator circuit212may simulate water temperatures on the A and B inputs, controllable between 30 degrees and 126 degrees F. The temperature sensor emulator circuit may be used for heater turn-on testing and Over Heat (OH) safety circuit testing. Signals may also be connected to the test loop back multiplexer circuit220for self-test of the signals and pre-power connection testing on the UUT.

FIG. 4Cdepicts a schematic diagram of an exemplary embodiment of an accelerated test pulser circuit214. This circuit may allow the controller100to accelerate testing of heater and ozone outputs on some UUTs, saving test time by eliminating wait time for firmware on the controller board (UUT) to turn the heater on. In an exemplary type of spa controller board, for example, accelerated testing operation may be facilitated through a special test input on the UUT. When the UUT senses an 11 Hz pulse on its ACCEL Input at power up of the UUT, the UUT will automatically toggle the heater/zone outputs on then off. After the heater and ozone circuits are tested through this feature, the accelerated test mode is disabled. In this exemplary embodiment, an LMC555 timer214-3is configured to generate an 11 Hz pulse. This signal then drives an AQV210 solid-state switch214-4used to isolate the timer from the UUT. The switch may further be protected by use of resettable fuses214-5. The signals are also connected to the test loop back multiplexer220for self-test of the signals and pre-power connection testing on the UUT.

FIG. 4Dillustrates a schematic diagram of an exemplary embodiment of a freeze detector/flow switch emulator circuit216. This circuit may simulate the function of the flow switch and freeze detect signals, which may be connected to the spa controller board. This exemplary circuit may simulate up to four independent switch controls during UUT testing, each by control of a relay switch such as216-3by the microcomputer202, which may connected to the flow switch or freeze sensor inputs of the UUT. The signals may also be connected to the test loop back multiplexer circuit220for self-test of the signals and pre-power connection testing on the UUT.

FIG. 4Edepicts schematically an exemplary embodiment of a LED indicator control circuit218, under control of the microcomputer202. Thus, the microcomputer may control LED indicators mounted on an enclosure for the system60, next to test cable connectors. The LED indicators assist the operator to identify the appropriate cable connections prior to starting a test.

The test station controller100may be programmed with a test algorithm designed to functionally test a spa controller board. In one exemplary embodiment, the test algorithm is defined by test scripts which are run by a compiled Labview™ application installed on the controller100. Labview™ is a commercially available program, marketed by National Instruments. An exemplary test script is set out in the Appendix set out in the incorporated file Test Script Example.txt. The compiled program processes the test scripts which are designed to perform the test sequences.FIG. 2Ais a functional block diagram of an exemplary embodiment of a compiled application300for executing the test scripts. The application includes a user interface module302, which is responsive to user interface devices associated with the controller100, such as a keyboard, mouse, touch screen, e.g. to process button pushes. The user interface module exchanges data with a system configuration module304, which stores data regarding the spa system configurations. A software data acquisition module306receives data from the module60, to provide spa current data to a script engine308. The script engine308is a Labview™ interpreter, which interprets and executes the test scripts comprising the test script files310. The script engine308sends commands to an ADCM interface module312, which formats the commands into appropriate serial data packets sent to the RS-232 serial port of the test computer connected to the adapter70, and which interprets data from the serial port. The interface module312also receives commands from, and sends ADCM data to the user interface module302. The script engine also provides test data to a reporting and logging module314, which services the test station display to provide data displayed on the test station monitor, provides test result files, and provides remote services, such as sending test result files to a remote server.

The controller100may be programmed to carry out a test sequence on a UUT.FIG. 5is a flow diagram of an exemplary test algorithm350which may be performed by an embodiment of the test system50. At352, the test operator is prompted to enter the UUT identification (ID). In an exemplary embodiment, the ID may be entered by scanning a bar code on the UUT with the scanner104(FIG. 2). If the unit with the ID is not under warranty at353A, in an exemplary embodiment, the test may be aborted, and the unit scrapped at353B. If the unit is under warranty, at354the controller may then match the information decoded from the bar code with a test script which is stored in memory for the UUT model or even the particular UUT. The test script, which is loaded, may then control the test sequence for the UUT. At356, the test system50prompts the operator to connect the UUT20to the system60, by cable connections. This prompting may include messages displayed on the display106, with images of the UUT and the housing for the system60.

At358, the system50performs an electronic verification procedure to verify that the UUT cable connections have been made properly. This may be done using the test loop back circuit220and multiplexer circuit68, to sequentially connect the connector ports on the system60to the DMM64. For each connection, the expected nominal parameter, e.g. resistance and/or capacitance, may be stored in memory for a proper connection. The actual measured parameter value may be compared against the nominal parameter value to determine if each connection has been properly made. This determination358may be made prior to applying AC power to the UUT.

At360, if the UUT is found to fail the connection, the test is aborted at362, and the operator may be notified of the suspected failure cause, e.g. which connection was found to be improperly made. Otherwise, if the UUT is properly connected to the test station, then at364, AC (and low voltage, if required for a particular UUT) power may be applied to the UUT, by actuating relays in the module80(FIG. 2). With the UUT powered up, for some types of UUTs, the firmware version of the UUT may be (optionally) read at366using its ADCM port, and verified against the version expected as a result of the ID entered at352. The system50then performs functional testing of the UUT at368. The test data may be sent to a remote server at370. A test report may be printed at372. At374, the operator is prompted to disconnect the UUT from the system50, and operation returns to352to commence another test operation.

An exemplary embodiment of a test sequence is set out below.

1.) Operator prompted to scan in UUT barcode.

2.) Operator scans barcode, controller will then load correct test script.FIG. 6Ais an exemplary screen shot generated from a Labview™ application programmed to perform the algorithm ofFIG. 5, showing an exemplary unit serial number captured by scanning the UUT barcode and the available test scripts. The test sequence depicted inFIG. 5may also indicate to the operator whether the UUT is in warranty, based on an algorithm illustrated inFIG. 7.

4.) Operator follows instructions on proper hookup for UUT.FIG. 6Bdepicts an exemplary screen shot showing an exemplary set of instructions for connecting the UUT to the test system.FIG. 6Cdepicts an exemplary screen shot of an image of exemplary test station connectors and LED indicator lights. In this example, depicted therein is the AC power cable for connection to the AC connectors of the test station housing.

5.) Impedance tests to verify proper cable connections.

6.) If all connection tests pass, continue with power-up. If any pre-power test fails then abort test and give operator description of failed test and possible causes for fail.FIG. 6Ddepicts an exemplary screen shot image showing an exemplary failed panel connection.

7.) Start Powered Functional Test:

8.) Apply AC power to UUT.

9.) Verify correct firmware installed input UUT.FIG. 6Eis an exemplary screen shot image depicting an outcome of a firmware ID test. At power up the UUT may display or output on the ADSM port or on the panel display a series of codes that is tested to verify that the correct firmware revision has been installed into the UUT. The code or series of codes may include, for example, a system software identifier (SSID), which in an exemplary embodiment may include a three digit OEM code, a two digit model code, and a two digit software revision code. An example of an SSID is 100 (OEM), 10 (Model), 03 (software revision).

10.) Measure input AC voltage is correct.

11.) Observe and Log the Board Configurations (programmed, or via DIP Switches. Save this information as “field configuration” if it is the first time the board has been tested.

12.) Configure the board to “factory”, or “Custom” settings to prepare for the test. Record this configuration in the test record. Custom settings may provide the ability to test more hardware on the board than what would typically be used.

13.) Command Pump1on and measure output voltage is correct.

15.) Measure Heater On & Off voltage while accelerated test mode is active.

16.) Measure Ozone On & Off voltage while accelerated test mode is active.

18.) Command Pump2on and measure output voltage is correct.

20.) Command Blower on and measure output voltage is correct.

21.) Measure Blower current

22.) Command Spa Light on and measure output voltage is correct.

23.) Test all Main Panel ports.

24.) Test all aux panel ports.

25.) Test Sensor A & B input voltage accuracy.

29.) Test the main Panel.FIG. 6Fdepicts an example screen shot of an image for an exemplary main panel test

30.) The operator may be offered the option of changing the configuration of the board (programmed, or DIP switch) to a different “shipping configuration” than what it was tested at. This shipped configuration is logged in the test report.

31.) End Powered Functional Test:

32.) Log data to server using FTP.

33.) Print test report.FIG. 6Gdepicts an exemplary screen shot of an exemplary test results page.FIG. 6Hdepicts an exemplary screen shot of a failed test report, with an image depicting an example suspected failure.FIG. 6Idepicts an exemplary screen shot of an exemplary test result summary page.

34.) Operator prompted to disconnect UUT test cables.

35.) Go to Step 1; Operator prompted to scan in next UUT barcode.

In accordance with a further aspect of this disclosure, a method is provided for establishing warranty status of a previously fielded spa controller board, e.g. in the event the spa controller board may require service. The method is illustrated in the flow diagram shown inFIG. 7. In an exemplary embodiment, the method400includes (i) electronically capturing an encoded bar code pattern on the controller board (402); (ii) entering the captured encoded bar code pattern in a computer algorithm to perform a warranty check on the spa controller board to determine whether the controller board is within a predetermined warranty period (404); (iii) in the event the controller board is under warranty, issuing a manufacturer return material authorization (RMA) for the controller board authorizing return of the controller board to the manufacturer (406). If the unit is out-of-warranty, a notification of this status may be issued for the user, or electronically transmitted to the manufacturer or service organization. In an exemplary embodiment, the algorithm may include decoding the bar code pattern to determine a warranty period expiration date for the controller board, and determining that the board is subject to a manufacturer warranty if the expiration date has not passed.

In an exemplary embodiment, the bar code pattern for a spa controller board may encode data identifying the board serial number and an assigned date of manufacture of the board, or other event which determines a start of a predetermined warranty period or length. Since the system50may have stored thereon a database defining a warranty period for a spa controller board (e.g. two years), which commences on the data of manufacture, the expiration of the warranty period for a particular spa controller board. Hence, by reading and interpreting data encoded on the bar code pattern, the warranty status of the particular unit may be determined. Alternatively, an internet connection to a manufacturer's server and database may be established, and the warranty status determined by comparison of the serial number information and other information on the bar code pattern used to determine the warranty status of the unit. Once the warranty status is determined, then a determination can be made as to whether the unit is still under warranty, and thus whether an RMA can properly be issued. This can reduce the number of unwarranted returns to a repair depot or to the manufacturer, significantly reducing costs.

Although the foregoing has been a description and illustration of specific embodiments of the invention, various modifications and changes thereto can be made by persons skilled in the art without departing from the scope and spirit of the invention as defined by the following claims.