Automation engineers often find themselves writing more PLC code than expected when leak testing is part of the system. Standard testers typically offer only basic “program linking” – if one test fails, move to another. That leaves the integrator responsible for handling clamps, valves, reject bins, and timing logic inside the PLC. Every added line of code is another potential point of failure at FAT, and another hour spent debugging instead of building.

Building Complex Sequences with Automation Director

Astra Dash changes this with Automation Director, its built-in sequencing engine. Instead of relying on external PLC logic, Automation Director allows intra-step and intra-channel dependent control directly within the tester. This means you can build complex sequences – like a multi-lumen catheter test that verifies occlusion in one channel, leak integrity in another, and then makes a reject/pass decision – all inside Astra Dash without custom PLC code.

The technical advantage comes from the tester’s generous I/O capabilities. Each channel includes 16 digital inputs and 16 digital outputs, plus a global set of I/O shared across the system. Combined with native support for protocols like Ethernet/IP, Modbus, and Profinet, Automation Director can directly manage actuators, clamps, sensors, and reject systems. For many automation projects, that means you can eliminate an external micro-PLC entirely or at least simplify its role to higher-level coordination rather than test control. 

Reduce Risk at FAT

This built-in intelligence is more than convenience – it helps project managers reduce risk at FAT. By consolidating test sequencing and part handling into Astra Dash, there are fewer moving pieces to validate. Engineers can troubleshoot test logic directly on the tester’s 22” touchscreen HMI, using widgets and real-time diagnostics to verify outcomes. Instead of flipping between tester software and PLC code, the entire sequence can be observed, tuned, and approved in one environment.

Consistency Across Multiple Industries

For automation houses working across multiple industries, Automation Director offers consistency. Whether testing automotive valves or medical tubing, the same sequencing framework applies. That means engineers can reuse approaches from one project to another, reducing development time and avoiding duplicated effort. For project managers, it translates to faster project delivery, smoother FATs, and less ongoing support burden once the system is in the field.

The Astra Dash is the world’s first modular, multichannel leak tester with pneumatically isolated, asynchronous channels developed by Uson by PAC. It represents a dramatic leap forward for instrument uptime, technical accessibility, and flexible, scalable manufacturing. Learn more about Astra Dash.

Standardized Workflows That Scale Across Projects

Another key advantage is the standardized interface and controls across all projects. Once your engineers learn Astra Dash’s touchscreen workflows, widgets, and Automation Director, they can apply the same approach to every new build. That commonality reduces training overhead, speeds up system commissioning, and keeps development cycles predictable. Instead of tailoring your controls for every customer’s unique tester, you gain a repeatable foundation that scales across projects.

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