Ertl 4n6x2w

Report on Summer Practical Training at

ERTL (N) Submitted to: Mrs. M. Bhati (Additional Director)

Submitted by: NITIN KUMAR GOLA N . C .COLLEGE OF ENGINEERING ISRANA (PANIPAT)

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Date: Aug 4, 2008

Contents Page no. •

Acknowledgements…………………………………………………………3

• • •

Abstract…………………………………………………………………….. 4 Certificate…………………………………………………………………...5 ERTL (N)…………………………………………………………………... 6 o 1. Introduction………………………………………………………7 o 2. Background……………………………………………………… 9 o 3. Accreditation and International Connections…………………… 10 Services offered………………………….………………………………… 11 o 1. Calibration………………………………………………………..12  1.1. Calibration (Electrotechnical)………………………….14  1.2. Calibration (HPCC)…………………………………….15  1.3. Calibration (Non-electrical)…………………………….16 o 2. Testing……..…………………………………………………….. 17  2.1. Components…………………………………………….18  2.2. Environmental………………………………………….25  2.3. EMI/EMC………...………………………………….....27  2.4. Safety…………………………………………………...29  2.5. Bio-medical Instrument………………………………...30  2.6. Equipment and System…………………………………31 o 3. Other Services……….…………………………………………...34

•

• •

Equipment and System……………………………………………………...35 Tests Carried Out……………………………………………………………42

• •

1. UPS Test………………………………………………………….45 2. Withstand/Insulation Test for Voltmeter……...………………….51 3. Energy Meter Test……………………………………………......54 Conclusion…………………………………………………………………. 62 References…………………………………………………………………..63 o o o

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Acknowledgement I express my heartfelt gratitude to all those who have enabled me to undergo and complete my summer practical training on aspect of testing and control of instruments at the SYSTEM LAB as per national/international specification. Mr. D. Basu, Director Mrs. M Bhati, Additional Director, Scientist ‘E’ Mr. R. K. Saini, TM ‘H’ Mr. Harcharan Lal, Scientist ‘D’ Mr. Ashok Kumar, Scientist ‘D’ Mr. S. N. Kachachhap, SO ’ Mr. Mahavir Singh, Scientist ‘C’ Mr. V. K. Arora, TM ‘H’ Mr. Yogesh And other of ERTL (N) who have taken lots of pain to enable me to learn all the practical requirements. And a special thanks to Mr. Harcharan Lal and Mr. Vimal Arora for their constant help and . And, with due respect to all others whom we have forgotten, thank you for all your help. Thank you all.

Delhi, India Aug, 2008

Nitin Kumar Gola

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Abstract This report gives an insight into one of the most important government testing lab in the north of India, ERTL (N). The various tests carried out and services offered are explained in brief. System lab has been dealt with in detail. Various instruments used and tests performed in the system lab are also included.

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Certificate This is to certify that NITIN KUMAR GOLA, a student of ELECTRONICS AND COMMUNICATION ENGINEERING, N C COLLEGE OF ENGINEERING, ISRANA (PANIPAT) has undergone summer practical training at ERTL (N) in the month of Aug, 2008.

Mrs. M. Bhati Additional Director

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1. Introduction

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Electronics Regional Test Laboratory (North), New Delhi, popularly known as ERTL (N), is one of the flagship laboratory of STQC Directorate, Department of Information Technology, Ministry of Communications & Information Technology, Government of India engaged primarily in providing Accredited Calibration and Testing facilities. It is one of the ERTL set up to serve small and medium scale electronic industries located in India. ERTL (North) serves the industries located in northern India with an aim of upgrading the overall quality of electronics products manufactured in India.

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2. Background Electronics Regional Test Laboratory (North), ERTL (N) was formerly functioning as Test, Evaluation & Calibration Centre at the National Physical laboratory, New Delhi before being shifted to its present location at Okhla Industrial area in the year 1982. It is one of the prime laboratories of the Standardization, Testing & Quality Certification Directorate (STQC), Ministry of Communication & Information Technology, Govt. of India. The laboratory is functioning under Govt. of India & is performing its activities, as an independent test laboratory, in the field of testing, calibration, developmental assistance & training through technically trained manpower using accredited facilities. The laboratory strives to identify the customer’s needs & update the facilities accordingly. The laboratory shall ensure quality of the results provided to customers by implementing checks, interlab comparisons and participation in proficiency testing.

OBJECTIVES OF ERTL (N) • To make Indian Electronics Industry a Global Player. • To bring the benefits of Electronics in every walk of life. • Improvement of Quality & Reliability of Electronic products. ERTL (N) aims at achieving these objectives by providing various services to the industry.

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3. Accreditation Connections

and

International

NATIONAL • By NABL for Testing and Certification in the field of Electronics and Electro-technical disciplines • By STQC for ‘S’ Mark and EMC Certification • BIS recognition for AC static Energy Meters, Capacitors, Electronic Ballast & Voltage Stabilizers

INTERNATIONAL •

• • • • • • • • •

NSI Laboratory under IECQ System CB Test Laboratory under IECEE-CB Scheme EMI/EMC Testing BY FCC (USA) Testing for EMI/EMC under telecommunication Certification Body Program and CRTs as per UL 1418 by UL (USA) Testing for Safety of Electronics/Electrical products by SASO Testing of cold chain equipment by WHO Calibration services by BASEEFA (UK) hips of IPC and NCSL Testing of equipment for CE marking under self declaration for manufacturers interested in export to Europe

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1. CALIBRATION Electronics Regional Test Laboratory (North) is a leading institution well known amongst the industries as an independent calibration and test laboratory. Keeping in view the ever growing needs of the industry, an exclusive centre offering high precision calibration has been established with state of the art calibration facilities maintaining unbroken chain of calibration traceability to National/International standards. To ensure quality of service, laboratory is maintaining a quality system based on international standards and the facilities are accredited to National standards. Non-electrical calibration facilities would meet the shop floor to end calibration and traceability needs. High Precision Calibration Centre (HPCC) has also become operational. Availing the services will: • keep the equipment in top working condition. • ensure controlling and improving quality of the end product. • fulfill the mandatory requirements of quality system standards such as ISO 9001, ISO 14001, ISO 17025, QS 9000 etc.

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Hierarchy of Calibration Standard  International Standards  NPL Delhi standards)

Echelon-1

(Primary

 ERTL (N) Echelon-2 standards)

(Secondary

 ETDC’s Echelon-3 standards)

(Tertiary

 Working standards

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DETAILS OF SERVICE 1.1. Calibration (Electrotechnical) METER/DMM/ANALYSER:

Voltmeter, Ammeter, Analog Multimeter, Wattmeter, Energy Meters, Sound Level Meter, Digital Multimeter (Upto 5.5 Digits), Distortion Analyzer, Spectrum Analyzer, Modulation Analyzer, Network Analyzer, Data Acquisition system, Logic Analyzer, Insulation Tester/Megger. LCR: Capacitance, Inductance, Resistances Stds. /Decade Current Shunt, LCR Meter & Bridge, Wheat Stone/Kelvin Bridge, Impedance analyzer/Bridge, Ohm Meter. FREQUENCY: Frequency Meter, Time Interval Meter. RF/LF: Synthesized Signal Generator, Oscillator, Function Generator, RF Voltmeter, Selective Level Meter, RF Power Meter, Attenuator, Oscilloscope, Navigational Eqpt., Video & Audio Test Eqpt. CALIBRATOR/AMPLIFIER: Oscilloscope, Voltage/Power. HIGH VOLTAGE: KV Meter, HV Probe/Divider, Break Down Tester, HV CRO Probe, HV Resistance STD. & Boxes, Transformer Oil Test Set.

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1.2. Calibration (HPCC) DMM/ANALYZER:

Nano Volt Meter, I-U Meter, Pico Ammeter, Digital Multimeter (6.5 to 8.5 Digits), Potentiometer, RF Power Meter, RF, Millivoltmeter. RESISTANCE: DC Resistance Standard, Current Shunt, Precision Resistance Bridge, High Resistance Meter. CALIBRATOR/AMPLIFIER: Multifunction Meter Calibrator, Nano Volt Source, Pico Ampere, High Current Amplifier, Voltage/Power Amplifier, Precision voltage Divider. REFERENCE STANDARD: Voltage & Current (Both DC/AC), Thermal Transfer Standard. POWER/ENERGY: Power/Energy Standard, Watt Converter, Power Meter/Analyzer (1Ф & 3Ф), Energy Meter (1Ф & 3Ф), Power Factor Meter (1Ф & 3Ф), Power Energy Calibrator, Meter Test Bench.

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1.3. Calibration (Non-electrical) PRESSSURE:

Pressure Calibrators, Gauges, Transducers, Vacuum & Compound Gauges. TEMPERATURE: Thermometers/Dial Gauges, Temperature Indicators with Sensors, Temperature Controller, Switches, RTDs Thermocouples. DIMENSIONS: Vernier Calipers, Micrometer, Height Gauge, Dial Gauge Calibrator. WEIGHT: Electronic Balance (Upto 20gm & 20Kg Capacity).

ELECTRONIC BALANCE: Weight (upto 200% 12000gms). VIBRATION: Vibration Meters & Systems, Bump Machines.

OTHER ITEMS:

Soldering Iron, Soldering Iron Calibrator, Wave Soldering Machine, Dry Block Furnace, Multifunction T/C, RTD Calibrators.

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2. TESTING Independent Third party Test laboratories network covering 1. Components 2. Environmental 3. EMI/EMC 4. Safety 5. Bio-medical Instruments 6. Equipments & Systems

STQC Test Laboratories are recognized by National accreditation by NABL under National laboratory accreditation programme 2. Test laboratories approved by BIS, DOT, RDSO, ISRO, DRDO, MNES, DG Mine Safety & Chief Controller Explosive and DG Shipping 3. Recognition of Test Reports by International agencies like UL VDE, CSA & FCC etc through mutual recognition arrangements Assistance in comparative testing and evaluation of consumer electronic/electrical products (for consumer associations) 1.

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2.1. Components ERTL (N), STQC Directorate has set up facilities for testing approval and screening of the electronic components. These facilities have been approved under IECQ system (International Electrotechnical Commission Quality Assessment System for Electronic Components). The laboratory has a team of Scientists/Engineers, highly qualified and dedicated to serve the electronic industries for improving the quality of the electronic complements. ERTL (N) is an approved Independent Test laboratory under IECQ System & NABL (National Accreditation Board for testing and calibration laboratories) as per ISO/IEC 17025.

Need for testing The quality & reliability of sophisticated electronic equipment & system depends on their design & components, as such the testing of components is very important. The testing of component will result in the following benefits: To assess the product quality and reliability  Improve the quality of component  Product Development  Promote Business

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Labs included:  Micro Electronics lab This lab deals with testing of active components such as transistor, diodes, SCR’s, microprocessors, MOSFET’s etc. The lab is approved by ICEQ. Various types of tests done in the lab are• Type test • Batch Acceptance test • Screening test Main equipments in the lab are• Curve Tracer • Ft measurement set with four stations • GEN RAD Digital test system • Noise Figure Meter • TESEC discrete Semiconductor test system

 LCR Lab The lab deals with testing of ive components such as resistors, capacitors and inductors. Maximum test frequency available is 1 GHz. Testing is done as per following codes: • BIS (Bureau of Indian Standards) • Defence Standards • t Service Specification (JSS) • IECQ • Japanese Industrial Standards (JIS) Following Instruments are used in this lab• Adjustable PC power supply • Component Linearity Test Equipment

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• Solder Bath

 PCB Testing Lab This lab deals with the testing of printed circuit boards and copper clad laminates. Quality of these items is tested via different aspects such as space margins and soldering etc. Main Equipments used in this lab are• Omega meter • MP 900 Beta-Back scatter • Cavidern cd-8

 EMI Lab This lab is involved in the testing of electromechanical components such as relays, switches, connectors, cables, etc. Electromechanical instruments such as ammeters, voltmeters, energy meters except digital meters are also tested here. Gaussmeter is used as an instrument over here.

 Audio Lab In this lab the various AC & DC parameters of audio equipments are tested. The equipment tested includes loud speaker, microphones, hearing aids, telephones, transducers, audio amplifiers, etc. Parameters associated with different equipments are• Loud speakers: Frequency response, Rated response, Intermodulation, difference in

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• • • • The • • • •

frequency, Directive response and Insulation resistance. Amplifiers: Frequency response, S/N ratio, Harmonic distortion, Complex impedance, Intermodulation of different frequencies. Tape recorders: Free response, Distortion, Wow & Flutter, Sine ratio. Hearing Aids: Acoustic gain, Frequency response, SATR sound pressure. Microphone: Frequency response, Impedance, Distortion. main equipments used in the lab areTelephone Test set Wow & Flutter Heterodyne Analyzer Baffle enclosure for testing loud speakers

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The group is engaged in testing of various types of electronic components as per National/International standards. Type testing/qualification tests and partial tests can be carried out as per requirements of customer. Active components: Transistors, diodes, zeners, integrated circuits digital upto 24 pins, hybrid microcircuits and Screening of devices. ive components: Resistors fixed and Variable, Capacitors, inductors and transformers, secondary battery, screening of devices. Electromechanical connectors.

components:

Relays,

switches,

Electro acoustic components: Speakers, microphones, SPL meters, ringer, telephone.

amplifiers,

Product Tested: Capacitors: Electrolytic, Tantalum, Ceramic, Plastic film capacitor. Resistors: Network, fixed resistors, Potentiometers. Transformers Step down and Step up, Isolation, Pulse, DCDC transformer. Connectors R type, C type & D type. Relays: Earth leakage, Air condition, battery earth fault, DC time delay. Filters, Switches, Choke, Coils. Cables: Co-axial cable, multi pair. Battery, Cells, ors Diodes, transistors, integrated circuits, LED, Digital Ics - QC 700000, CECC 90000, MIL 883C

23 Accreditations/approvals: The lab is accredited by NABL and It is independent test laboratory (ITL) under IECQ system Sr. No. Component 1 Diodes 2 3 4 5 6

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8 9 10 11 12 13 14 15

Applicable Standards QC 700000, CECC 50000, MIL750B QC 700000, Transistors CECC50000, MIL 750B QC 700000, CECC Digital ICs 90000, MIL 883C Optocoupler IEC 60747-5-3, Hybrid circuitQC 760000, CECC 63000 Resistors IS 5786(Pt-1), IEC:60115-1, JSS 50400, QC 400000 Potentiometer IEC 60393, JSS 50300, IS 8872, IS 2934, IS 2915, QC 410000 Capacitors IS 4317, IS 9256, IS 9638, IEC 603841, JSS 50200, QC 300000 Relays IS 5051, QC 160000, IEC 60255 Switches IS 3452, IS 6875, IS 4794 Connectors QC 010000, IEC 60130-1 Dry Batteries IS 586, IS 203 IS 8144 Secondary JIS C- 8702-1 battery Transformer IS 6297 Cables IS 5801, IEC 600961

BIS

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Major equipments available Name LCR Meter LCR Data Bridge High Resistance Meter Secondary Battery Tester(upto100A) Hipot tester Leakage Current Tester Automatic Relay test system, Automatic battery life cycle tester Universal Test System, Oscilloscope Discrete Component Test System

Model Make 4274/4275 HP 6471 Tinsley 4329A

HP

2K20357

Statcon

HD1400 CLC 203

Hipotronics Chenhwa

ARTS440 II Kocos BLCT-96

APLAB

M 3000

SZ

7854, Tektronics 8101/TT/A Tesec

2.2. Environmental

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All Laboratories are equipped to simulate different environmental conditions to find out the effects on Product/ Component performance. Environmental conditions such as high temperature, low temperature, humidity, corrosion, low air pressure, vibration, Impact (both repetitive and non-repetitive) can be simulated in the laboratories as per requirements of standards like IS, JSS, MIL, IEC etc. Multivariate environment to simulate real life usage conditions can be obtained from the wide inventory of Chambers possessed by the Laboratories. Test evaluation of products/Components can be done for Vibrations, Bump, Shock, Drop, Topple, Salt spray, Splash and rain. Testing for the Ingress Protection for Water and Dust can also be taken up. Highly accelerated testing Technologies (HAST: Highly accelerated Temperature and Humidity Stress) in of various combination of temperature and Humidity up to 175 degree Celsius and 100% RH with Gauge pressure up to 4 bar to reduce testing time is also available. Products Tested: All Electronics products.

Climatic

types

of

Electrical

and

26 S.NO TEST 1. Dry Heat

2.

Cold

3.

Damp Heat

4. 5. 6.

7.

RANGE CAPACITY Ambient To 180 °C400x485x500 mm 2200x3800x2400 mm (Walk-in chamber) Door size= 1000x2000mm b) Ambient To 400x100x100 mm -70°C* 2200x3800x2400 mm

a)5 To 90°C , RH 20 1000x1000x1000 mm To 95% 2200x3800x2400 mm b) Ambient to 85°C, RH85% Low Air Pressure Upto 60 Km 610x610x610 mm Corrosion (Salt Spray) Ambient To 50°C 890x940x880 mm Pressure 6 bar Max. Ingress Protection for enclosures up to IP66 Oscillating tubes-1000 and 400 mm Radius-200 mm Rate of rotation60°/sec Dust & Sand test Ambient To 50°C890x940x880 mm Max.Particle size 0.15 mm

Durability S.NO TEST 1. Vibration test System a) Sine

b) Random 2. 3.

4.

Shock test (Half Sine, Sawtooth, pulse) Constant Acceleration test a)Active components b)ive Components

RANGE Frequency Displacement Acceleration Max.Force Frequency PSD No Of Channels Acceleration SquarePulse duration Max Load

Bump (Half Sine pulse)

5. Drop, Topple and Free fall test 6.

Universal Testing Machine

2.3. EMI/EMC

CAPACITY 8 To 4.5 kHz 25.4 mm (pk-pk) 94g, 5338 N Upto 20 kHz 10-5 To 10 g²\ Hz 4 15 To 3000g 0.5 To 18 m sec. 90 Kg.

Max.acceleration 40,000g Max.Acceleration 5,000g No. of Slip rings24 Rating 10 Amp per Acceleration 10 To 1000g Pulse duration 30 msec (Max.), Max.load 800 Kg. Platform size 2 m X 1.5 m Height 1 Meter. Max.Load Cross Head Speed

1 KN 0.5 To 500 mm/min.

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Increased pollution in the form of EMI/RFI and other spurious signals created in some part by some of sophisticated Equipment/Component and radiated by interconnecting cables may create malfunction in TV, Radio, Computers, Airways Communications, Medical Equipment etc. Testing of the products for the EMI regulations is necessary in most of the countries. All the products need to be constructed so that it does not cause interference and in particular, does not interfere with radio and telecommunication equipments further, equipment must have an intrinsic immunity level to electromagnetic disturbances, which will enable it to operate as intended. Capability of an individual product to meet the EMC requirements can be verified by testing the product against laid out standards at our Laboratories. Products Covered: Industrial, Scientific, Medical, Automotives, Broadcast receivers, Household Appliances/Tools, Fluorescent Lights/Luminaries, Measuring Apparatus, Information Technology Equipment etc.

Test facilities available are:  Emission Tests:

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o Radiated: Radiated emission testing up to 18 GHz as per specifications like IS/FCC/CISPR etc. o Conducted: conductive emission testing as per above specifications.  Emission Tests  Radiated: ESD & FET tests.  Conducted: surge tests as per IEC-801,2,5 respectively. Main Equipments of the lab are:  Spectrum Analyzer  Different Antennas  G-B TRIP system  ESD simulator (1-15KV)  EFT Simulator

2.4. Safety

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In this department safety of materials is carried out which is necessary to prevent accidents. Safety test facilities for evaluating household consumer electronic products as per IS 616/IEC 65 and information technology products as per IEC 950 are available. Some of the typical items being tested are T.V. receivers, tape recorders, VCR’s, Xerox machines and PC’s. The underlying principle of safety is to understand to engineer safe equipment. Safety testing is required to prevent following hazards: ¢ Electric shock: It is due to current ing through the human body. Current of the order of mA can cause a reaction in persons good health and may cause indirect danger due to involuntary reaction. ¢ Energy hazards: Short-circuiting between adjacent poles of higher current supplies or high capacitance circuits may cause arching or ejection of molten metal, resulting in burns. Even low voltage circuits may be dangerous in this respect. ¢ Fire: Temperature, which could cause afire risk, may result from overloads, component failures, insulation breakdown, high resistance or loose connections. ¢ Mechanical and heat hazards: Requirements are included to prevent injury to the operator to ensure that the equipment is mechanically stable and structurally sound. To avoid the presence of sharp edges and points and to provide adequate guarding or interlocking of dangerous moving parts. ¢ Radiation hazards: The types of radiation that can be encountered are sonic, radio frequency, infrared, high intensity visible and coherent light, ultra violet, ionizing, etc. ¢ Chemical hazards: Hazardous chemicals cause injuries and damage through with them, their fumes and vapours.

2.5. Bio-medical Instruments

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Safety Testing and calibration facilities for Cardiac Defibrillators, High Frequency Surgical diathermy, Ventilators, Diagnostic Electro-cardiographs, Bedside monitors, Blood Pressure instruments, Pulse Oximeter, etc.

2.6.

Equipment & System

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Testing of Various equipments like  Power electronics  Communication Test Equipments  Consumer Electronics  Information Technology  Weight & Measures  Auto/Taxi Fare Meter, etc. as per National/International standards i.e.  IS: 13779  IS: 13010  IS: 14697  CBIP-88  IS: 13021  IS: 9538  IS: 4567  IS: 10662  IS: 3156  IS: 9177  IS: 8488  IS: 8847  IS: 9281  IS: 2321  IS: 2747 DOE/STQC/Computer  Consumer/Indentor’s specification  IEC: 60521  IEC: 60687  IEC: 61036  IEC: 61268  IEC/AS: 62052-11  AS: 1284.5  IEC/AS: 62053-11,21,22,23 Items:-

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            

Energy Meter UPS Invertors Voltage Stabilizer Electronic Ballast TV Receiver/Components Electronic Fan regulator Navigation light Industrial Transducer Computer & its peripheral (as per DOE Specs.) Weighing Machine (As per OIML-IR-76) Auto /Taxi Fare Meters Communication Test equipments

Parameters under tests are: General  Safety  Functional  Performance  Extreme Conditions  Reliability Equipments used: Phantom load  Reference meter  Sensors  Power analyzer  W/I auto tester  Impulsive voltage tester  Magnetic jig  Short time over current tester

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3. OTHER SERVICES Customer Care and Facilitation Cell (CCFC) or Customer Service Cell (CSC) The CCFC acts as a link between the customer and the organization. It functions in the following manner: o It asks the customer to fill a Service request Form in triplicate and accordingly a job card is made for the equipment he desires for testing. o Informs him about the cost of testing and a probable date of completion of the job when the customer can have his equipment and maintain its secrecy. o Make entries in the Job Record and Job Knowledge . o Sends the job to the concerned lab along with a tentative date of completion. o Receives the tested and calibrated instruments and the reports and hands it to the customer. Thus, the cell ensures single window service, confidentiality of the job and the test results, planning and scheduling of the job and quality of services.

Report Section

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The main task of this section is to issue report. Draft reports from various departments are verified by QA and sent to report section. A final report is prepared in this department for the customer and a copy of report is held with the department. On an average 7000 records per year are prepared. Records are destroyed by burning. Secrecy is maintained at all levels.

3.3. Quality Assurance Department Major responsibilities of QA are:  Approval of test/calibration procedures, jigs and fixtures  Conducting Quality Audits  Updating the Quality manuals  Dealing with customer complaints  Specification maintainance

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36 All electronics and system are tested for performance against national/International standards, DGS&D and customer specific standards. PRODUCT TESTED The main products tested and their clusters in the Equipment and Systems Group are as given below: Consumer Electronics Products TV Receiver, Electronic Ballast, Fire Alarm, refrigerator and other house hold items. Power Electronics Energy Meter (active and reactive), Voltage Stabilizer, Generator sets, Inverter & UPS IT Products Computer, Key board, Monitor, Printer etc. Equipment & subsystem Photocopier, Scanner, Fax Machine, Washing Machine, Tran-receiver, Test & Measuring instruments & Power Management Systems for telecom. Sr. No. 1

2 3 4 5 6 7 8 9

Product

Applicable Standards

Energy Meters IS 13010/13779/14697 IEC 62053-11,6205321,62053-22 and 62053-23 CBIP 88 Electronic 13021 Pt-V/IEC Ballast 60921/RDSO TV Receiver IS:10662 Electronic Fan IS 11037 Regulator Voltage IS 8447/8448/9815 Stabilizer Inverter/UPS IS 13314 Fire Alarm IS 2189 Weighing OIML IR 76/Weight & Machine Measure Deptt. Auto/Taxi Fare IS 2747 Meter

Major Test Facilities

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Name

Make

Energy Meter MTE Test Bench 3 Phase ZERA Standard Reference Meter HC 3 Phase Phantom Load

ZERA

Model ---

COM3003/TPZ 306 3100 MT3000

HEG Voltech

PLE10AS/100A

EM Test

UCS500M

Universal Power PM3300 analyzer Impulse EMC Partner MIG1203 generator

WI Auto Tester Radio communication Tester

KIKUSUI

860A

R &S

CMS

Major Clientele: State Electricity Boards, Regulatory Boards, Defence Organizations, Consumer Organization, DGS&D, BIS, Weight & Measure Dept., VOICE.

Equipments/Instruments in the lab 1. E M Test UCS – 500 M

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This is used for the Impulse Test. 2. MODULAR IMPULSE GENERATOR 3. MODEL 860 W/I AUTO TESTER This is used for the Withstand Test or High-voltage Test or Dielectric Strength Test and Insulation Test. PM 6000, PM 3300 Also called the Universal Power Analyzer. It is used to measure the various values of voltages, current, power and error. Below a PM 3000 model is shown. 4.

5. Voltage Dip Test & Voltage Interruption Test 6. Test set-up for Energy Meter 7.

Moving Test MT 3000

Modular and flexible concept for the meter test on site with reference standards and sources accuracy classes: 0.02% and 0.05%. Modules for all meter test purposes.

8. ZERA TP 2306 NR 97 – 338 – S Used for Energy Meter Test.

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9. PLE 10 A S Used for Energy Meter Test. 10. PLE 100 A Used for Energy Meter Test. 11. Three Phase Digital Power Model 3100 It is used to measure the various values of voltages, current, power and error.

12. Phantom Load Standby power, also called vampire power, phantom load, or leaking electricity, refers to the electric power consumed by electronic appliances while they are switched off or in a standby mode. A very common "electricity vampire" is a power adapter which has no power-off switch. While this consumption of power may be used to provide useful functions for appliances such as remote controls and digital clocks to the , most power consumed by non-operational devices is considered wasted. 13. MTE (Meter Test Equipment) or Workbench

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Energy meter test equipment is used to test energy meters that measure the correct amount of energy recorded, usually in kilowatt-hours or cubic feet of natural gas consumption. Electricity meter test equipment is used to determine the accuracy of energy meters that automatically record the time for any given number of revolutions (up to 99) of an electricity meter. The number of revolutions which it is desired to count is set on the dials. Each revolution of the meter element transmits an impulse to the counting mechanism through the medium of a photoelectric cell. A stopwatch is started by the first impulse after closing a starting switch and is stopped when the predetermined number of revolutions has been completed. Energy meter test equipment are also used to test electronic meters which enable data processing for complex tariffing purpose, mainly two-way communication for remote energy meter reading and intelligent load control for efficient energy use. In spite of Energy meter test equipment being used to maintain the accuracy of these energy meters, there is still a certain level of mistrust in using intelligent metering widely in many countries. In order to overcome these major disadvantages, energy meter test equipment is integrated in intelligent electricity meters for daily examination of correct operation.

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Stationary Meter Test Equipment

Modular test systems for all purpose, systems for volume production, meter type test equipment, units for calibration labs and for the R&D. All testing is acc. to IEC standards or country specific rules. System accuracy starting with 0.01%WinSAM

Easy-to-operate software platform for control of ZERA meter testing systems

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TESTS CARRIED OUT

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Note:•

Tests are carried out on a Test Data Sheet shown below with details. Test Data Sheet

Job No.: Started: Finished: 1. Test Parameter:

Item: Qty.: Test seq. no.:

Initial/Intermediate/Final Measurement Group: S. No.:

2. Specification: 3. Clause: 4. Test Method: 5. Test Conditions:

-Env: At Ambient Temp. -Elec.:

6. Test Requirements: 7. Range of Observed Values:

8. Remark: 9. Control Doc. No.: 10. Eqpt. Code Details:

Tested by

Checked by

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Details: 1. Job No. gives the name of the job as in the office record files 2. Item gives the item being tested. E.g. If a UPS is being tested then it

will be written ‘UPS 3KVA’. 3. Group gives the group of the job. 4. Started gives the date of starting. 5. Qty. or quantity gives the no. of jobs being tested. 6. S. No. gives the sample no. of all the jobs. 7. Finished gives the date of finish of their respective test. 8. Test seq. no. gives the sequence of test. 9. 1. Test Parameter gives the name of the test. 10. 2. Specification gives the national/international standard. 11. 3. Clause gives the further clause of the specification 12. 4. Test Method gives the method. 13. 5. Test Conditions gives the conditions under which the tests are performed. Env means environmental which is usually at ambient temperature i.e. 27°C. Elec. stands for electric in which the voltage or current range is mentioned. 14. 6. Test Requirements gives the requirements of the test. 15. 7. Range of Observed Values gives the observation table. 16. 8. Remark gives if the test carried out was successful or not. If it was successful then it is ‘satisfactory’ otherwise ‘not satisfactory’. 17. 9. Control Doc. No. gives the control document no. 18. 10. Eqpt. Code Details gives the equipments used with their model no. and make. •

•

Tests are carried out according to the specifications given by the customer, if the customer wants a complete test or only a few. The tests are carried out to the specifications given by the customer, according to the national/international standards. Tests can take a couple of days to a few months to years, so only those tests are explained which are performed others are just mentioned with the specifications, requirements or details. These are applicable for all the tests

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1. UPS TEST About UPS An uninterruptible power supply (UPS), also known as a continuous power supply (S) or a battery backup is a device which maintains a continuous supply of electric power to connected equipment by supplying power from a separate source when utility power is not available. It differs from an auxiliary power supply or standby generator, which does not provide instant protection from a momentary power interruption. Integrated systems that have UPS and standby generator components are often referred to as emergency power systems. There are three distinct types of UPS: off-line, line-interactive and double conversion (also called on-line). An off-line UPS remains idle until a power failure occurs, and then switches from utility power to its own power source, almost instantaneously. An on-line UPS continuously powers the protected load from its reserves (usually lead-acid batteries or stored kinetic energy), while simultaneously replenishing the reserves from the AC power. It also provides protection against all common power problems, and for this reason it is also known as a power conditioner and a line conditioner. While not limited to safeguarding any particular type of equipment, a UPS is typically used to protect computers, telecommunication equipment or other electrical equipment where an unexpected power disruption could cause injuries, fatalities, serious business disruption or data loss. UPS units come in sizes ranging from units which will back up a single computer without monitor (around 200 VA) to units which will power entire data centers or buildings (several megawatts).

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Common power problems There are various common power problems that UPS units are used to correct. They are as follows (with a typical example of damage that might be caused): 1. Power failure — Total loss of utility power: Causes electrical 2. 3. 4. 5. 6. 7.

8.

equipment to stop working. Voltage sag — Transient (short term) under-voltage: Causes flickering of lights. Voltage spike — Transient (short term) over-voltage i.e. spike or peak: Causes wear or acute damage to electronic equipment. Under-voltage (brownout) — Low line voltage for an extended period of time: Causes overheating in motors. Over-voltage — Increased voltage for an extended period of time: Causes light bulbs to fail. Line noise — Distortions superimposed on the power waveform: Causes electro magnetic interference. Frequency variation — Deviation from the nominal frequency (50 or 60 Hz): Causes motors to increase or decrease speed and line-driven clocks and timing devices to gain or lose time. Switching transient — Instantaneous undervoltage (notch) in the range of milliseconds to seconds: May cause erratic behavior in some equipment, memory loss, data error, data loss and component stress.

Harmonic distortion — Multiples of power frequency superimposed on the power waveform: Causes excess heating in wiring and fuses.

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AIM: To test a given 3KVA-180V, DSP Based, Single phase input, Single phase output online UPS according to the following parameters given by the customer. S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Parameters AC i/p Volt. range AC o/p Volt. range AC o/p freq. o/p waveform Full load

Specified Value (Acceptable Limits) 170V-280V 230V±1% 50 Hz±0.1Hz Pure sine wave 3KVA (0.8 P.F.) 2.4 KW Resistive Total Harmonic Distortion <3% At Full Load (resistive load) Transient Response ±5% recovery within 1.5 Cycle (For 100% Dynamic loading) Inverter efficiency At 100% Load >87% Crest Factor >4:1 Transfer Time Zero Overload Handling Capacity 110% for 5 min. 125% for 1 min. 150% for 10 sec. 200% for 2 sec. 300% for 1 sec. Load p.f. 0.8 lag to unity Battery charging current 1 Amp-10 Amp±1 Amp (Settable by Pot.) Max. Batt. Charging Volt. 204V±2V Nominal Batt. Volt./Ah 180V/7.2Ah-200Ah Batt. Low Alarm 165V±1V Batt. Low Protection 162V±1V Batt. High Protection 225V±1V O/p Volt. Low Protection 180V (22% below nominal volt.) O/p Volt. High Protection 253V (10% above nominal volt.) Short Circuit Protection Load>300% PC Load 12 PC with 15” CRT Monitors + 3 DeskJet Printers OR 18 PC with 15” TFT Monitor + 3 DeskJet Printers RS-232 Comm. Port YES UPS Dimensions (LХWХH) 475mmХ350mmХ610mm (without packing) UPS Weight 57.5 Kg. (without batteries) (without packing)

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APPARATUS USED: 1. Variac 2. Load - Heater - 6 Bulbs, 200W 3. 15 Batteries, 12V, 45 AH/20Hr. 4. Voltec PM3300 Universal Power Analyzer 5. Philips True FMS Digital Multimeter for current measurement 6. Auto-transformer, 3-φ, oil cooled

CIRCUIT DIAGRAM:

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PROCEDURE: 1. Circuit is connected as shown in the circuit diagram. 2. The tests are carried out as follows: 2.1.1. 2.1.2. 2.1.3. 2.1.4. 2.1.5.

2.1.6. 2.1.7.

(Test Parameter)AC i/p Voltage Range (Specification)Indentor’s (I){same for all} (Clause)- {same for all} (Test Method)I{same for all} (Test Conditions) -Env: At Ambient Temp. {same for all} -Elec.: (Test Requirements)shall be 170-280V (Range of Observed Values)

Input Voltage O/p volt. /current/PF/Energy 170V 229.3V,10.462A,1.00PF,2.399KW 281.2V 228.2V,10.537A,1.00PF,2.405KW (Remarks)Satisfactory 2.1.9. (Control Doc. No.)-{same for all} 2.1.10. (Eqpt. Code Details) AC/DC Power Analyzer VOLTECH PM3300 Details: - In this test the min. and max. voltage is applied as input and the UPS should function in this range. If it does not work within this range it is said to have failed the test. The output voltage, current, power factor (PF) and energy is noted. 2.1.8.

50 3.

The tests are the same as given in the parameters performa, so, only selected tests which were performed are enlisted.

3.1.4. Details: - o/p waveform was found to be pure sine wave using an oscilloscope, thus, satisfactory. 3.1.8. Details: - The efficiency was found to be 87.02%, thus, satisfactory. 3.1.16. Details: - The battery of the UPS was charged and then the load was added to the circuit. The alarm went ON when the battery became low and the voltage was found to be ‘166.19V’ which is in the specified limit. 3.1.22. Details: - This test was not performed in the lab but was performed on-site i.e. with the manufacturer due to the unavailability of the specified PCs together at one place.

RESULT: The overall result was found to be satisfactory.

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2. WITHSTAND / INSULATION TEST FOR VOLTMETER This test is performed to check that there is no conductance between the inner components or the circuit and the body of the voltmeter because if there is conductance there may be faulty reading in the voltmeter. Withstand Test is also called High-voltage Test or Dielectric Test.

AIM: To perform the Withstand/Insulation Test.

APPARATUS: 1. 2. 3.

Model 860a W/I Auto Tester Voltmeter Connecting wires

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CIRCUIT DIAGRAM:

PROCEDURE:

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1.

2.

Withstand Test a. Connections should be made as in the circuit diagram. b. The two terminals of the voltmeter should be short circuited and connected to the tester. c. The ground is connected to the body of the voltmeter. d. A very high voltage is applied. e. If there is tripping then there is conduction and the voltmeter fails the test. Insulation Test a. Connections should be made as in the circuit diagram. b. The two terminals of the voltmeter should be short circuited and connected to the tester. c. The voltmeter is wound by a copper sheet and then connected to the ground. d. A very high voltage is applied. e. If there is tripping then there is conduction and the voltmeter fails the test.

OBSERVATION: No tripping was found in both the cases.

RESULT: The tests were carried out successfully with the voltmeter showing satisfactory results.

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3. ENERGY METER TEST An energy meter or a watthour meter is a device that measures the amount of energy supplied to a residence or business. Energy utilities record these values measured by energy revenue meters to generate an invoice for the energy consumer. In the case of electricity, energy meter test equipment can also record other variables including the time of day (hence the term "time-of-use meters") when the energy was consumed. Modern electricity meters operate by continuously measuring the instantaneous voltage (volts) and current (amperes) and finding the product of these to give instantaneous electrical power (watts) which is then integrated against time to give energy used (joules, kilowatthours etc). These electricity meters fall into two basic categories, electromechanical and electronic.

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Types of meters 1. Single Phase Two Wire Energy Meter (1-φ, 2W)

2. AC 1-φ 2W static watthour meter

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3. Three Phase Four Wire Energy Meter (3-φ, 4w)

Energy meter can be further differentiated into I. Whole current meter where current is in whole form. E.g. (10-60) A. II. CT (Current Transformer) operated where less current is ed. E.g. (5-6) A. Ratio (CTR) is also given on the meter. Energy meters can be further classified on the basis of their class I. Class 1 II. Class 2 In accuracy testing the ‘+’ sign in the error means the meter is moving fast and ‘-‘ means it is moving slow.

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AIM: To test a given sample of 3-φ static Energy Meters according to the IS: 13779/99 specification.

APPARATUS: 1. Standard Reference meter make Zera/CALSAT 400 2. Static Phantom Load make PLE 100 A 3. Conventional Phantom Load 4. W/I Auto Tester 8614 make KIKUSUI 5. Immunity Test System, make EM Test ModelUCS-500 6. Test Jig 7. High-voltage Tester 8. MTE/Workbench/Testbench with CAMCAL (CC) program. CAMCAL stands for Computer Aided Meter Calibration. Many tests can be performed using the MTE just by a single connection as shown in the circuit diagram.

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CIRCUIT DIAGRAM:

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PROCEDURE: The tests carried out are: 1)Functional Test – To see if the meters are fully functional, it is made to work at ambient temperature and rated current and voltage. There are several ways to do this test but MTE is the best as many other tests can also be carried out using it. 2)

Impulse Voltage Test – The circuit diagram is shown. 6KV of voltage is applied to the meter. This is done in order that sometimes there are surges (large influx of voltage) in the line. The meter should be functional after this test.

3)AC Voltage Test 4)Insulation Test 5)Limits of error due to variation of current 6)Test of meter constant – Meter should comply with the marking given on the plate/front . 7)Test of starting conditions – The meter shall start and continue to . 8)Test of no load condition 9)Ambient Temperature Influence

60 10) Repeatability

maximum repeatability. 11)

error Test – Difference of and minimum error is the

Influence quantities a) Voltage Variation b) Frequency Variation c) 10% Harmonics in Current circuit d) DC & even harmonics in the AC circuit e) Continuous magnetic induction of external origin (67 mT) f) Magnetic induction of external origin (0.5T) g) Continuous abnormal magnetic induction (0.2T) h) Abnormal ac magnetic induction of external origin (10 mT)

12) Influence Quantity Reverse Phase sequence at 0.1Ib Voltage Unbalance Tb 13)

Power consumption

14)

Voltage variation Test

15)

Influence of supply voltage

16)

Short time over current

17)

Influence of self heating

18)

Influence of heating

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19)

Influence of Immunity to earth

20)

Functional Test (After Dry Heat Test)

21)

Functional Test (After Cold Test)

22) Insulation/Function Test (After Damp Heat Test) 23)

Insulation/Function Test (After Dust Test)

24)

Insulation/Function Test (After Water Test)

25) Visual Examination Functional Test After Vibration 26) Visual Examination Functional Test After Vibration 27) Spring Hammer Test – Meter should not sustain any damage which can affect the lone part and shall not be possible to touch live part. Slight damage is accepted which does not impair the portion against indirect or penetration of solid object, dust and water.

OBSERVATION: The tests were carried out successfully. RESULT: The Energy meter results were satisfactory and within the specification IS: 13799/99.

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Conclusions Having discussed the results, I can draw some conclusions from them. My conclusions should not only refer to my primary research, but they should be set in the context of my entire report. • ERTL (N) is striving to bring up the standards of the Indian electrical and electronic goods by quality and thorough testing and calibration which will eventually open up new avenues for our IT goods in national/international markets. • This shows that the testing procedure is very strict at the ERTL (N). • The various tests performed were successful showing satisfactory results. •

It was an excellent learning experience for trainees like me who came in touch with the industrial aspect of the trade.

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References 1. [email protected] 2. ERTL (N) Brochures 3. SQTC website 4. Report on calibration 5. Wikipedia

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Address ERTL (N) Electronics Regional Test Laboratory (North) N.S.I. Laboratory Standardization, Testing & Quality Directorate Department of Electronics, Govt. of India S-Block, Okhla Industrial Area, Phase-II New Delhi-110020 Phones: 011-26836219, 26831558, 26912489 Gram: STQCLAB Telex: 31-75113 ERTL IN Fax: 91 (11)-6821583