Wi-Fi Power Statistics Socket Production Test Process

Last Updated on : 2021-08-12 03:15:45download

Purpose

Testing Wi-Fi module and its communication with control panel.

Application

It applies to power statistics socket (220 V and 120 V) that new production test process is applied to, and online OEM power statistics socket schemes.

Preparation

Prepare at least one Wi-Fi router that supports 2.4 GHz band, and power it up. Internet access is not necessary. (TP-LINK 2.4 GHz router is recommended.)
Change the router SSID to tuya_mdev_test1 (for test of stage one) or tuya_mdev_test2 (for test of stage two). And then check the Wi-Fi name on your mobile phone. Password setting depends on your needs.
Place the router near the test rack/product, with a distance of 3-5 meters.
One test rack (including voltmeter) corresponding to the test board. (For finished-product test, it is not necessary.)

Note: the voltmeter is powered by independent supply (isolated switch mode power supply).
For 220 V socket, prepare one 560 R/100 W/1% ceramic resistor as the test load. For 120 V socket, prepare one 144 R/200 W/1% ceramic resistor as the test load. Connect the ceramic resistor to the output live wire (LOUT) and neutral wire (N) on the test board. (Dissipating heat and prevent scalding.)
One AC regulated power supply (with adjustable voltage of 220 V and 120 V, and the output power can be viewed). Connect it to the input live wire (LIN) and neutral wire (N) on the control panel.

Testing process

Testing 120 V/220 V power statistics socket – stage one

Note:

For stage one, the router SSID is set to tuya_mdev_test1.
The test device is powered on for the first time, or runs in low-power mode or fast-flashing mode. (Not the low-power product)
The test device has connected to the ceramic resistor.

For 120 V socket, the test load is one 144 R/200 W/1% ceramic resistor.

For 220 V socket, the test load is one 560 R/200 W/1% ceramic resistor.
The test device has connected to the 120 V/220 V AC regulated power supply.
After finishing stage one, it cannot be entered again.

Testing 120 V/220 V power statistics socket – stage two

Note:

For stage two, the router SSID is set to tuya_mdev_test2.
The test device runs in low-power mode or fast-flashing mode. (Not the low-power product)
The test device has connected to the ceramic resistor.

For 120 V socket, the test load is one 144 R/200 W/1% ceramic resistor.

For 220 V socket, the test load is one 560 R/200 W/1% ceramic resistor.
The test device has connected to the 120 V/220 V AC regulated power supply.
You can enter stage two only after finishing stage one. And stage two can be repeatedly entered.

Testing power statistics socket (120 V/220 V)

Wi-Fi Power Statistics Socket Production Test Process

Checking item	Normal Status	Troubleshooting
Device is powered on.	None	None
The relay is properly powered.	For 5 V relay: 4.6 V < test device voltage < 6 V. For 12 V relay: 11 V < test device voltage < 13V.	Check if the voltmeter or test device works properly.
3.3 V voltmeter works properly.	3 V< test device voltage < 3.6V	Check if the voltmeter or test device works properly.
Determining if low-power status exists.	By default, when the module is powered on for the first time, it runs in low-power mode or fast-flashing mode. In low-power status, the Wi-Fi indicator light is off, and relay indicator light flashes according to the status.	None
Determining if the module runs in low-power mode.	None	If the module executes network configuration, the Wi-Fi indicator light will continuously flash fast or slow.
The module automatically finds the test router.	None	None
The test router is successfully found.	The router SSID for stage one is tuya_mdev_test1, and for stage two is tuya_mdev_test2.	1. If the Wi-Fi indicator light continuously flashes fast, it indicates the router is not found (for low-power product, the Wi-Fi indicator light is always off). 2. If the Wi-Fi indicator light flashes very fast (100 ms/time), it indicates the signal value of the router is below -60 dBm.
The module is successfully authorized.	None	If the Wi-Fi indicator light flashes very fast (100 ms/time), treat it as faulty device.
If the power calibration is proceeded, the relay will close or open the contacts, and Wi-Fi indicator light flashes slow by 2 times every 3 seconds.	It indicates the module successfully receives the production test signal and is authorized. During power calibration, the parameters of regulated power supply are as follows: 220 V ± 3 V, 392 mA ± 15 mA and 87 W ± 2 W.	None
The power is calibrated successfully.	1. The Wi-Fi indicator light is always on. 2. The relay is disconnected.	If calibration fails, the Wi-Fi indicator light is always off, and the relay is disconnected. 1. Check if the calibration follows the standard process, and if the hardware indicator light and relay work properly. 2. Check if the load matches the required resistance. 3. Check if the calibration voltage is consistent with the operating voltage. 4. Check if the device hardware has exceptions. 5. Check if the module has exceptions.
Production test is completed.	None	None
Proceed aging test (if necessary).	None	None
Device is powered off manually.	After power on again, configure the network on the app under the environment of test1.	None

Note:

1. The initial power-on status of the product after delivery (without the environment built by the router for production test) depends on its hardware settings.

If the product supports “Wi-Fi indicator light flashes fast when powered on”, when it is powered on for the first time after delivery, this indicator light will flash fast.
If “low-power status” exists, when the device is powered on for the first time after delivery, the Wi-Fi indicator light flashes in two ways: it is off by default, or flash fast (custom firmware).

2. For products with low-power status, there are three ways to enter this status.

If the module is powered on for the first time (never configuring the network), it is in the low-power status by default.
Press the button for 5 seconds to reset the device. Then, power off the device after at least 10 seconds. It will enter low-power status after power on again.
After finish network configuration on the app, click Remove device in the control panel. Then, power off the device after at least 10 seconds. It will enter low-power status after power on again.

3. If two routers are used for the test, generally only test1 needs to be executed.

For products with one-stage test, test1 can be repeated. For products with two-stage test, to avoid influencing productivity, it won’t enter test1 again once it passed.
Under the environment built by the router for test1, you can finish test1 and the network configuration of test1 device at the same time, which will remove the interference from the router to network configuration.
With the router for test2, the device can enter production test repeatedly due to exceptions, such as product rework.

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