Final Project Monu

ELECTRONICS AND COMMUNICATION

A TRAINING REPORT ON

“PRODUCTION OF ENERGY METER” TAKEN AT

( A KAILASH GROUP COMPANY )

From: 24th may to 24th june

GUIDED BY :-

SUBMITTED BY :-

Dhram pal Singh

Mahendra Agarwal B.E. IIIrd Year Electronics & Communication Engineering

GENUS Overseas Private Limited JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

JNIT DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING JAGAN NATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY JAIPUR (RAJASTHAN)

CERTIFICATE This

is

to

certify

that

the

report

entitled

“Production of Energy Meter” is submitted by Neelam Jangid, a student of B.E. in Electronics and Communication Engineering, in partial fulfillment for award of the degree of Bachelor of Engineering in JNIT, Jaipur during session 2008-2009. This report has been found satisfactory by me and is approved for submission. Date:

Mr. Deepak Chaturvedi

Place: Jaipur

H. O. D. E. C. E. Deptt. JNIT, Jaipur

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

ACKNOWLEDGEMENT

I feel highly privileged to express my sincere thanks and deepest sense of gratitude to my guides Mr.Dharam pal Singh of Genus, who has spared their precious time & guided me to complete this project. I sincerely acknowledge them for extending their valuable guidance, support for literature, critical review of report & above all the moral support they have provided mw at all stages of this work. I express my deepest sense of gratitude towards Mr. Deepak Chaturvedi, HOD Department of Electronics and Communication, JNIT, Jaipur. I also express my deepest sense of gratitude towards Mr. Deepak Agrawal, PTS, JNIT, Jaipur for clearing my doubts at any time of need and valuable inspiration during the seminar work. My thanks are extended to all staff members and persons who directly or indirectly helped me in achieving my goals. I could not have completed this work without the guidance of my parents. They deserve more credit than I can give for instilling in me a good work ethic and a desire to always learn more. My thanks are extended to all friends who gave me nice company and kept my spirit high throughout this work.

Mahendra Agarwal

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

PREFACE

This training report submitted by me is written on the basis of the practical gained during my training period. I had completed this report. It’s a great pleaser & satisfaction to develop energy meter. I lean to tackle different problems that come while developing any report. We have tried to include all those that are required for a good report. But, besides best effect, it may have few shortcomings.

Mahendra Agarwal

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

CONTENTS TOPICS

PAGES

1. INTRODUCTION……………………………………………………………………….1 - 3 1.1. APPLICABLE STANDARDS 1.2. QUALITY SYSTEM 1.2.1. QUALITY ASSURANCE 1.2.2. IS0 9001 CERTIFICATE OF REGISTRATION 1.2.3. SCOPE OF THIS CERTIFICATE 1.2.4. ISI MARK 2. ENERGY METER.................................................................................................3 -10 2.1. CONSTRUCTION 2.2. PRINCIPLE OF OPERATION 2.3. DISPLAY PARAMETERS 3. 1-PHASE ENERGY METER PRODUCTION PROCESS…………………………10 - 14 3.1. PROCESS 3.2. PROCESS FLOW FOR FINISHED GOOD & PACKING JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

4. 3-PHASE WHOLE CURRENT METER……………………………………………..14 - 19 4.1. PROCESS 4.2. FLOW CHART (F G LINE) 5. 3-PHASE WHOLE CURRENT METER……………………………………………..19 - 23 5.1. SALIENT FEATURES 5.1.1. MEASURED PARAMETERS 5.1.2. SELF- DIAGNOSTIC FEATURE 5.1.3. LOAD SURVEY 5.1.4. MAXIMUM DEMAND 5.1.5. COMMUNICATION 5.1.6. LEDS 5.2. DISPLAY DATA 5.3. ANTI-TAMPER FEATURES 5.4. INSTALLATION 5.5. SPECIFICATION SHEET 5.5.1. RATING 5.5.2. TAMPER DETAILS 6. ANNEXURE…………………………………………………………………………….23 - 28 6.1. PUSH BUTTON MODE 6.2. AUTO MODE 6.3. TAMPER THRESHOLDS (G336) 6.3.1. TAMPER PERSISTENCE TIME FOR OCCURANCE/RESTORATION 6.3.2. TAMPER LOGS 7. CONCLUSION………………………………………………………………………….29 - 29 8. BIBLIOGRAPHY……………………………………………………………………….30 - 30

LIST OF FIGURES JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

FIG. NO.

FIG. NAME

PAGE

(i)

3-PHASE STATIC WATT HOUR METER

9

( ii )

3-PHASE WHOLE CURRENT METER

19

( iii )

CONNECTION DIAGRAM OF 3-PHASE

22

WHOLE CURRENT METER

ELECTRONICS AND COMMUNICATION

1. INTRODUCTION GENUS was established in 1995 in the historic pink city of India, jaipur. We are a leading manufacturer of GENUS OVERSEAS ELECTRONICS LTD.: - An ISO-9001 company is a public limited concern with an investment of US$ 7 million. The company has been promoted by K.C.C. group of industries having interest in diversified fields, with a group turnover of more than US$ 65 millionthick film hybrid microcircuits in India. We have three SMT lines dedicated to manufacturing of PCB assemblies. The annual plant capacities of hybrid microcircuits and PCB assemblies are 4.50 million square inches respectively. The plant produces more than 2.4 million single phase and three phase electronics electricity meters annually.

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GENUS has the most modern plant with class 10,000 and 100,000 clean room work areas. The advanced design software, latest manufacturing equipment and automatic testing systems ensure highest quality products at competitive prices. As a result, many complex HMCs requiring high component count in a very limited area, while meeting increased reliability and robustness requirement for different applications including defence have been developed. GENUS is now supplying hybrids to telecom, Industrial, Defence, Consumer, Automotive, and informatics, power sectors and for metering products too. GENUS is also engaged in electronic manufacturing services, which besides contract manufacturing of SMT/Through-hole PCB assemblies includes supply of enclosures/ casings and accessories, wherever applicable. The workmanship of PCB assemblies has been well received by customers both in India and abroad. The strength of GENUS lies in its strong design and development team, instrumental in development of low end ASIC based electricity meters to high end programmable multifunctional intelligent single phase & three phase meters with in-built advanced security and antitamper features. Expertise in embedded software ensures that our products are customized as per the specific requirement. JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY ELECTRONICS AND COMMUNICATION

GENUS has a fully equipped modern tool room with the latest CAD/CAM software and CNC machines. Qualified teams of product designers rich experience in die and mould design, have enhanced our capabilities of offering customized products in HMC modules, assembled PCBs. Electronic energy meter and other metering solutions. GENUS is continuously updating its product portfolio with new products and solution. Recent developments are digital taximeter, prepayment meter, AMR enabled meters and several turnkey projects in related areas. GENUS has been accredited with ISO-9001, IECQ, EMC, ISI and C-DOT Certifications. The experience and exposure to international level of excellence has equipped GENUS to face and adapt to the challenges and opportunities emerging in the world today. JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

1.1 APPLICABLE STANDARDS For design manufacturing and testing of this meter following national and international standards have been referred to; (a) IEC 61036: (2000-09) Alternating current static watt-hour meters for active energy. (Class 1 and 2) (b) IEC 61010-1: Safety requirement for electrical equipment for measurement, control and laboratory use. (c) IS 13779:1999 a.c. static watt hour meters, class 1 and class 2 – specification (d) CBIP 88 Revised: a.c. static watt hour meters

1.2 QUALITY SYSTEM 1.2.1 Quality Assurance The Quality Policy at GENUS emphasize on offering the best quality products and services conforming to international quality standard, and is accomplished by making every individual responsible for quality.

In-house reliability tests are conducted on THERMAL SHOCK, HUMIDITY & BURN – IN chambers to ensure satisfactory performance and quality over the entire product range.

1.2.2 ISO 9001 Certificate of Registration: STQC Certification services, under ministry of information technology, government of India after verifying the quality system being followed, has certified that GENUS has established and is maintaining a quality system fulfilling the requirements of ISO 9001: 2000

1.2.3 The scope of this certificate covers: JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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● Design manufacturing & supply of thick film hybrid microcircuits.

● Design, contract manufacturing & supply of PCB (SMT and through hole assemblies. ● Design, manufacturing, supply & servicing of static energy meters.

1.2.4 ISI Mark: Bureau of Indian standards (BIS), a certification body established under the bureau of Indian standards act 1986 has given license to use standard mark of the bureau on GENUS make AC static watt-hour meters of following specifications as per IS 13779: 1999 AC STATIC WATTHOUR METERS, SINGLE PHASE, WHOLE CURRENT 2 WIRE 240V, 50Hz; different current ratings & class. AC STATIC WATTHOUR METERS, THREE PHASE, WHOLE CURRENT, 4 WIRE, 3X240V, 50Hz; different current ratings & class. Presence of certification mark known as standard mark (ISI) is an assurance of conformity to the relevant specification.

2. ENERGY METER •What is an Energy Meter? •Energy meter is a device to measure the consumption of energy by the consumer.

•How accuracy of the meter is defined? •As per IS 137779/ IEC61036/ ID13010 accuracy of the meter is defined by comparing the difference of energy consumption recorded by “Meter under test” and of “Reference Meter” JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

with the energy consumption recorded by a reference meter.

Accuracy(%)

=

(EMUT

-

ERef)

x

•The accuracy of both Mechanical and Electronic meter is defined by above equation.

•Which is more accurate- mechanical meter or electronic meter? JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

100

ELECTRONICS AND COMMUNICATION

•Electronic meters are more accurate than mechanical meter. The best mechanical meter can have an accuracy of 0.5% whereas electronic meter are available up to accuracy of 0.005%. Almost all meters for industrial, grid, transformers and for bulk consumers are electronic meter.

•How the meters are classified and what are the relevant technologies? •Meters are classified as following: •a.

Household single-phase meter - Mechanical/ Electronic meter

•b.

Household three-phase meter Mechanical/ Electronic meter

•c.

Commercial Meter - Electronic meter

•d.

Industrial Meter - Electronic meter

•e.

HT Meter - Electronic meter

•f.

Grid Meter - Electronic meter

•g.

Reference Meter - Electronic meter

•What is the meaning of fast meter? •In general if a meter is found recording more energy in comparison to other meter; it is called as fast meter. This comparison is quite misleading. As defined earlier a meter with positive accuracy error only should be called as fast meter

•Why electronic meter are considered as fast meter? •If two meters are accurate, than under the recommended reference conditions they will record same irrespective of the technology. However, due to following parameters it is observed that mechanical meter record less consumption: •a. High Starting current •b. Narrow Current range •c. Installation method •Aging process

•What are the various ratings of meter and how they are defined? •Various ratings of meter are as following: JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

Ratings

Range

• JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

2.5-5A (Mechanical)25mA-5Amp •5A-10A (Mechanical)

50mA-10Amp

•5A-20A (Mechanical)

50mA-20A

•10-40A (Mechanical)

100mA-40A

•5.

10-60A (Electronic) 20mA-60A

•* Typical starting current of Mechanical meter is 1% Ib (If old) and of BSES meter is 0.2%. •What is the effect of parameter “starting current” on energy consumption? •Since mechanical meter required an initial torque to start so mechanical meter do not record low consumption. Thus, the load with low consumption remains unrecorded. With electronic meter even low load can be recorded and thus, consumer feels that electronic meters are fast. •What is the effect of “current range” parameter on energy consumption? •Current range of meter is the working range over which the meter records the energy correctly. In general, the current range of mechanical meter is much narrow than electronic meter. If the load of the consumer is beyond the range of meter than the excess load remain unrecorded. Since, electronic meter has a wide current range so chances of consumer drawing the load beyond the permissible range are negligible and thus it records the actual power consumption. It is widely observed that consumers having decades old mechanical meters, presently having connected load far more than sanctioned load (and thus far beyond the current range of meter) are thus paying very low electricity charges as meter is not able to record the correct consumption. This is inspite of the fact that the meters are accurate. •What is the effect of installation parameter on energy recording? •In mechanical meter torque generated due to power consumption rotate the rotatory system, which is balanced on accurate but sensitive bearings. In case the meter is installed with a tilt either sideway or front/ back way than it affects the energy recording and which will be always lower than actual. This is one of the biggest drawbacks of mechanical meter. With electronic meter, since there is no moving part so the accuracy of same is independent of installation. •What is the effect of aging of energy consumption recording? •Since the mechanical meters have moving parts, so with use these have the tendency of wear and tear resulting in low energy consumption. Same is not applicable for electronic meter as it is a static device. JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

•Meters accuracy are defined at reference conditions.

However, in field voltage,

Frequency and Temperature are different. What is the effect of the same? •The permissible effect of field voltage, frequency and temperature on accuracy is defined in IS/ CBIP/ IEC standards. The energy meter in India, in general follows these standards. Although, there is an influence of the above parameters but the same is not highly significant. •Can the accuracy of meter be altered in field? •All service companies prefer to buy those meters in which the accuracy of the meters cannot be altered in the field. If the meter accuracy can be altered in the field by the service company than same can be altered by the consumer also. Service companies cannot take risk with such type of meters and thus only buy the meters, which are welded and cannot be altered in the field. •What are the responsibilities of ISI license holder? •After evaluating the product and the manufacturing capabilities, the Bureau of Indian Standard (BIS) issue the ISI license to the manufacturer. Meter manufacturer has to ensure all meters strictly follow the relevant IS and also test records of the same are maintained. The mis-concept that the service company can ask manufacturer to make meters with very high positive error (fast meter) is not possible as if it is found so, the ISI license of the manufacturer can be withdrawn by BIS. •What is the Maximum Demand Indicator (MDI)? What is its significance for consumer? •Maximum Demand Indicator is an indication about the maximum load used by the consumer for the duration of half-an-hour in the given period. This parameter is significant both for consumer and the service company to decide the sanctioned load and also to plan the network capacity. •What is the meaning of down loading of parameter? •Various parameters measured and recorded by the instrument are finally downloaded for billing/ monitoring purpose. The downloading of parameter means transferring the parameters from meter to the records of the service company. Downloading can be manual i.e. by reading the LCD display recording on a notebook or using some gadgets. •What is the meaning of MRI reading?

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•The gadget used for downloading of is called Meter Reading Instrument (MRI). The biggest advantage of MRI reading is that it avoids human error in recording/ transfer of data.

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•What is AMR system? •Downloading of the parameters using electronic gadgets, which are attached to the meter without manual intervention, is called Automatic Meter Reading (AMR) system. The gadget attached to the meter downloads the parameter and than automatically communicate to the computer of the service company. •What is the E/L LED? When it glows? •EL LED is an indication for unequal current flowing through phase and neutral. This mis-match can be either due to shortening of neural to earth/ leakage of current to earth/ the wire of two premises are touching each other. •What action consumer should take if EL- LED glows? •In case the EL.- LED found glowing, the consumer should get his wiring checked for the abovementioned defects. •What is the significance of REV LED? •REV LED indicates the reverse flow of energy from consumer to the grid. •What action consumer should take if REV LED glows? •In case REV LED is glowing than the consumer should ensure that generator/ inverter shall be totally isolated with the grid. Ever after that REV LED is found ON the consumer should call the service company for the check. Kindly note:- Glow of REV LED does not affect the accuracy of energy meters. Some time “REV” LED glows at “no load” condition and shall be ignored. •What is the role of “N cut” and what action consumer should take? •LED “N cut” (which is provided in few meters) indicates about loosening of wire at the meter end. In case consumer finds such LED glowing he should call the service company for retightening of all the wires in the meter to ensure proper supply to meter.

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2.1 CONSTRUCTION The line diagram of the three phase electronics meters is as shown in appendix –01 and the description of various parts is as follows: a)

Base & top cover are made of engineering plastic and meets the requirement

of IS: 13779. its manufacturing drawing is shown on appendix-01. b)

Current transformer (CT): - current transformer, 5000 turns are used. The

CT is placed in a PVC casing. An insulating cup separates the winding from PVC casing and connecting wires are soldered at connecting points. The PVC casing is then filled with a good quality epoxy (CIBA or Dr.Beck) the winding are used is 40 SWG super enameled copper and connecting wires are ISI marked good quality 7 strands. 36 SWG wires. Its manufacturing drawing is showing in appendix 01. c)

Counter: - the counter used is (6+1) liquid crystal display (LCD) type counter

of good quality & its manufacturing drawing is showing in appendix 01. d)

Terminal cover: - transparent terminal cover is made of engineering plastic

and its manufacturing drawing is shown in appendix-01. e)

Name plate: - the nameplate is fixed inside the meter on the topside of the

front face and is visible through the top cover. The arrangement is such that no manipulation on the nameplate is possible without opening the top cover. The nameplate provides information on the following. f)

Terminal Block: - the terminal block is used for making the external

connection between the incoming single-phase supply along with the neutral to the single-phase load with outgoing neutral terminal. The two terminal screws per terminal can be used to tighten the wires fully to avoid any over heating. Brass terminal are housed in the terminal block for the above purpose. The terminal block has been robustly designed for carrying 100% of Imax currents. g)

Sealing: - top cover and base can be sealed with the help of two sealing

screw provided. Terminal cover can be sealed with the help of one sealing screw. h)

Mounting: - the meter can be mounted with the help of two mounting screw,

one at top and two at the bottom within the terminal block. JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

2.2 Principle of operation This document covers operation of three phase four wire. 3 x (10-100) A. static watt-hour meter, class 1.0 accuracy of GENUS makes. Used for measurement of energy (kilowatt-hour) consumption. The operation of the meter is simple but still GENUS recommends thorough reading of the document for proper use of the meter. Also by going through the document, all the features of the meter could be put into full use. The GENUS WHOLE CURRENT kWh meter is intended for three phases. Four-wire system of rating 3x240v, 3x(10-100) A, 50hz. GENUS three phase, four wire WHOLE CURRENT kwh meter is powerful data acquisition and digital signal processor (DADSP) and micro-controller based electronic energy meter, meeting all three-phase power and energy meter measurement requirements. The meter consists of a fast data acquisition and digital signal processor and a micro-controller with flash memory to store the metering program and data. A resistor divider network scale down the three phase voltages measured by the meter. Meter measures total energy (kwh) i.e., fundamental plus harmonics. Line currents are sensed through current transformers. A 6-channel digital signal processor bit A-D converter digitized and current signals and sends the data to the DADSP. The DADSP stores the acquired digitized current and voltage and signals in its internal data memory for computation of various parameters. The micro-controller manages all the peripherals including the non volatile memory, LCD display. In addition to peripheral management, the micro-controller performs the complete data management also. Meter is factory calibrated, therefore no external calibration is required for this meter

Block Diagram (i) +10V

-5V

R-Phase CT Y-Phase CT

Crystal

B-Phase CT

R-Phase

Digital signal processor Timing & control unit

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LCD Energy register

ELECTRONICS AND COMMUNICATION

Y-Phase B-Phase Micro Controller

Neutral

EPROM

+5V -5V -2.5V

Crystal

O/P, CAL Phase

2.3 Display parameters The GENUS –WH meter is capable of measuring and displaying following energy parameters. Cumulative active energy

:

KWh

GENUS make Three Phase, Four Wire, Whole Current four-quadrant electricity meter is based on a powerful multiprocessor (metrology ASIC & control processor) platform. A dedicated ASIC sample the voltage and current waveform of each phase in parallel using six separate.∑∆ (sigma delta) analog to digital converters. This ensures true RMS calculation up to 30 th harmonic of the power line frequency. The sampling Rate is 320K samples per second. The control processor simultaneously carries out the real time calculation of parameters, manages the memory, display, RTC and the serial communication. Resistor divider networks are used to sense three Phase voltages & DC tolerant Current transformers are used to sense Load currents. ASIC does the computation of power based on input voltage & current signals & transfer digital data to control processor. Two communication ports are provided in the meter for data downloading. a. An optical port for transfer of meter data to PC / CMRI. b. An Isolated wired RS232 port (RJ11) for remote meter reading.

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2. 1-Phase Energy Meter Production Process 3.1 PROCESS (Specific project -: Base and PCB ) Put NL and PL terminal in T. Block

Tight screw M4X8 of lower side of NL & PL terminals

Put PS & NS terminals in Jig

Put glue stick between Ph & Nu primary in Power CT

Tight Shunt, Ph wire, MOV & 10nF in PS with M4X6 screw

Tight Nu primary, Nu Wire, MOV & 10nF in NS with M4x6 screw

Place the PS and NS terminals assy in Base

Tight M4X8 screws in PS & NS terminals

Put Metal CT in Nu primary & tight in meter base with 4x9.5 ST screw

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Connect Nu primary on NL and shunt on PL with M4X6 screws

ELECTRONICS AND COMMUNICATION

Tights remaining M4X8 screws in PL & NL terminals Put 4mm sleeve on CT wires & Shunt wires

Put PVC sheet on base with double sided tape

Insert PCB in base slot Solder Ph, CT and Shunt Wire on PCB Meter LT on Jig 1) Put Meter on CT lead of Jig 2) Tight Meter on Jig with help of handle 3) Phase crocodile on PS Terminal & Nu crocodile on n1 on PCB 4) Ph Nu on & load give to Meter in normal condition, check Volt in Display & Cal LED start blink 5) Give earth load to Meter with help of earth switch of Jig, check Earth in Display, Volt in Display & Cal blink 6) Earth switch of Jig put in normal 7) Give reverse load to Meter with help of reverse switch of Jig, check Rev in Display, Volt in Display & Cal LED blink 8) Give earth & reverse combined load to Meter with help of earth & reverse switch of Jig, check Volt in Display, Rev in Display, Earth in Display & Cal LED blink

If Meter is passed in LT tests, then Meter keep in the Meter Rack for Meter testing or if it is failed, then send to rework for rectification JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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3.2 Process flow for Finished good and Packing

Take tested Meter for FG

Remove Bergstick from N1 (PCB)

Solder Nu wire N1 on PCB with proper wire routing

Meter LT on Jig 1) Put Meter on CT lead of Jig 2) Tight Meter on Jig with help of handle 3) Phase crocodile on PS Terminal & Nu crocodile on NS Terminal 4) Ph Nu on & load give to Meter in normal condition, check Volt in Display & Cal LED start blink 5) Give earth load to Meter with help of earth switch of Jig, check Earth in Display, Volt in Display & Cal blink 6) Earth switch of Jig put in normal 7) Give reverse load to Meter with help of reverse switch of Jig, check Rev in Display, Volt in Display & Cal LED blink 8) Give earth & reverse combined load to Meter with help of earth & reverse switch of Jig, check Volt in Display, Rev in Display, Earth in Display & Cal LED blink

Check error on Jig

Put the Name plate on Meter JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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Put Button in Top Cover

Meter Top Cover fixing

Ultrasonic welding

Socking Note initial reading before socking & final reading after socking of Meter & Ref Meter Check display parameter, digit cut, display blinking

FG file run through optical port by computer

Check error on Jig

Check display parameter

Tight Screw for fixing Meter Top & Base

Meter Sealing JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

Tight Ter Cover Screw on Ter Block & Put Ter cover in base on LHS

.

QA check point

Meter mount in Enclosure with Ultrasonic riveting

Mount communication cable from Meter to Enclosure

Check communication thru communication Cable

Put Accessories in Enclosure

Put polythene with Meter, TC & accessories into Corrugated Meter Box

Put Corrugated Meter Box in Corrugated Master Box

General Points to be taken care during Production: 1. All Measuring Instruments and Jigs should be duly calibrated with valid calibration certificate. 2. Screwdrivers, Wire strippers, Tweezers, Nose Pliers etc. should be in good working condition. 3. Tip of the Solder Iron should be fine. JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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4. Lighting arrangement should be adequate. 5. Air pressure for Pneumatic Tools should be maintained. 6. Proper Earthing should be at all points. 7. Antistatic arrangement should be proper at all relevant workstations. 8. Proper House keeping.

4. 3-Phase Whole Current Meters 4.1 PROCESS (Base-PCB Line Specific Project: G336) Put CT Terminals in TB

Tight CT Terminal Screw on Terminals

Mount Base Shielding in Meter Base

Mount Hanger Plate in Meter Base

Mount Insulation Sheet in Meter Base

Mount Base plate in Meter Base

Put TB in Meter Base

Tight I-Patti for TB mounting at both ends

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CT mount & tight on Terminals

Mount Line filter

Tight below screw of TB for LT & QA Inspection

Solder Phase wire (RYBN) on SMPS

Solder R-CT, Y-CT, B-CT wire on Main PCB

Mount PCB Assy on Meter Base

Tight Nu wire on Nu CT Terminal & QA Inspection

Meter LT on Jig 1) Put Meter on CT lead of Jig 2) Tight Meter on Jig with help of handle 3) Phase crocodile (RYB) on PT wire (RYB) 4) Switch on R Ph & Nu in normal condition check R Ph LED glow & Cal LED starts blinking 5) Give reverse load with help of reverse switch of Jig, check R Ph LED glow, tamper LED glow & Cal LED starts blinking 6) Repeat steps 4 & 5 for Y & B Ph also 7) Switch on RYBN in normal condition check RYB Ph LED glow & Cal LED starts blinking 8) Give reverse load with help of reverse switch of Jig, check RYB Ph LED glow, tamper LED glow & LED starts blinking

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If Meter is passed in LT tests, then keep the Meter in the specified Rack for Testing. If failed, then send to rework for rectification

4.2 FLOW CHART (FG Line ) Take tested Meter for FG

Tight Ph wire (RYB) on CT Terminal

Remove LCD Tape

QA Inspection

Meter LT on Jig 1) Put Meter on CT lead of Jig 2) Tight Meter on Jig with help of handle 3) Switch on R Ph & Nu in normal condition check R Ph LED glow & Cal LED starts blinking 4) Give reverse load to Meter with help of reverse switch of Jig, check R Ph LED glow, tamper LED glow & Cal LED starts blinking 5) Repeat steps 4 & 5 for Y & B Ph also 6) Switch on RYBN in normal condition check RYB Ph LED glow & Cal LED starts blinking 7) Give reverse load to Meter with help of reverse switch of Jig, check RYB Ph LED glow, tamper LED glow & Cal LED starts blinking

FG file run optical port by computer

Name plate fixing on Meter JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

ELECTRONICS AND COMMUNICATION

Put Top cover on Meter Base

Soaking Note initial reading before socking & final reading after sacking of Meter & Ref Meter Check display parameter, digit cut, display blinking QA Inspection

Check error on Jig

Tight Sealing Screw for fixing Meter Top & Base

Terminal Cover fixing on Meter with help of Hinge Pin

Mounting Meter in Enclosure Base with use of bottom Pillar of Enclosure

Terminal Cover fixing with help Terminal Screw

Communication Cable fixing on Meter Top (with use of Pillar) to Enclosure Base

Check display parameters & QA Inspection

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Put Enclosure Top on Enclosure Base

Put Enclosure Assy (with Meter & Accessories) into polythene Bag

Put polythene with Meter into Corrugated Meter Box

Put Corrugated Meter Box into Master Box

General Points to be taken care during Production: 9. All Measuring Instruments and Jigs should be duly calibrated with valid calibration certificate. 10. Screwdrivers, Wire strippers, Tweezers, Nose Pliers etc. should be in good working condition. 11. Tip of the Solder Iron should be fine. 12. Lighting arrangement should be adequate. 13. Air pressure for Pneumatic Tools should be maintained. 14. Proper Earthing should be at all points. 15. Antistatic arrangement should be proper at all relevant workstations. 16. Proper House keeping.

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5. 3-Phase Whole Current Meters

Fig (ii)

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5.1SALI ENT

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5.1.1 Measured Parameters: Meter measures following parameters: a)

Active energy

b)

Reactive Energy (lag)

c)

Reactive Energy (lead)

d)

R-Phase Irms

e)

Y-phase Irms

f) B-phase Irms g)

R-N Vrms

h)

Y-N Vrms

i) B-N Vrms j) Frequency 5.1.2 Self-Diagnostic Feature Meter has inbuilt capability to perform self-diagnostic & display

error if any for following: -

a. Time and date on meter display b. All display segments on meter display c. Real time clock status in meter reading print outs at BCS end d. Non-volatile memory (NVM) status in meter reading print outs at BCS end. e. Battery Status 5.1.3 Load Survey: Meter record following parameters on FIFO basis with Date & Time stamp: a. Active Power/Energy (kW / kWh) b. Apparent Power/ Energy (kVA/ kVAh) c. Reactive Power/ Energy(kvar/ kvarh) (lag and lead) d. Power Factor e. Phase voltages (R, Y, B) f. Phase currents (R, Y, B) 5.1.4 Maximum demand: JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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The meter continuously monitors and calculates the average demand in kW & kVA during the integration period set and maximum out of these shall be stored. MD is calculated on real time basis ½ hr. 5.1.5 Communication: The meter has serial communication port supporting all PC activities. An optical communication port is installed on front panel for serial communication. The Baud rate for optical communication is 9600 bps. One more optional RS232 port is provided in terminal block for AMR communication. 5.1.6 LEDs The meter has the provision for 6 LEDs. There functions (from left to right) are:  Active Energy Calibration LED: The LED acts as the metrological output for the

Active

energy Register.  R phase LED: The LED acts as an indication to the availability of R Phase Voltage.  Y phase LED: The LED acts as an indication to the availability of Y Phase Voltage.  B phase LED: The LED acts as an indication to the availability of B Phase Voltage.  Tamper LED: The LED indicates the presence of one or more tampers/ Anomalies.  Reactive/ Apparent Energy Calibration LED: The LED acts as the metrological output proportional to either Apparent or Reactive Energy ( Configurable & Optional)

5.2 DISPLAY DATA: Please refer to the attached annexure for the display details of this model.

5.3 ANTI-TAMPER FEATURES: Below is an exhaustive list of anti tamper detection / evidence features. 

Current Polarity Reversal- The meter is capable of detecting and recording

occurrences and restoration of CT polarity reversal of one or more phases. When any current polarity is reversed, it is treated as current polarity reversal.  CT open/short or bypass detection: The meter has the capability to detect opening or bypassing of one or two current circuits connected to the meter along with date and time. JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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 External Magnetic Tamper detection: The meter has the capability of detecting and recording if an abnormal external magnetic field is induced so as to affect the functioning if the meter..  Meter will indicate tamper when phase voltage or any other spurious signal is fed to neutral or if the neutral is disconnected. Meter will log date and time of tamper occurrence & restoration along with snapshots of various parameters such as kWh, kVAh, Net PF, phase voltages and phase current.

5.4 INSTALLATION: Connection diagram (iii) : -

After installation, the following things must be verified: The tamper led must not be glowing. If it does

Check for the source of anomaly on the display of the meter.



In case of Current reverse the respective phase LED will blink, Check the polarity of the connections.



If phase sequence error, check the connections for phase sequence anomalies.

 Check if the Phase LEDs are glowing and not blinking. If not, check if the connections are proper.

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5.5

Specification Sheet:

5.5.1 Rating: Voltage Rating: 3x 240/ 415 volts Current Rating: 10-60 A 5.5.2 Tamper Details: Missing Potential Phase Polarity Reversal Ct Open/ Bypass Magnetic Tamper Detection Neutral Disturbance Split Phase Neutral open Top Cover Open Current Reverse Voltage Unbalance Current Unbalance Over Voltage Over Current THD

6. ANNEXURE 6.1 Push Button Mode ALL SEGMENT DISPLAY LCD check 

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ερρ

Ρ Τ Χ ΦΑ Ι Λ RTC check

δ:µδµ:ψ ψ

δο τ ε 1

Real Date

τΙν ε

η:µηµ :σ σ

2

Real Time

0 0 0 0 0 0

Σρµ ο 3

Serial No.

04

ρδχ τ

0 0

4

Reading count

05 5

ρ σ τ 0 0

MD reset count

MD

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0

06

000 0 0

6

.0 Cumulative kvarh - Lag

CUM kVAr h

0

07

000 0 0

7

.0 Cumulative kvarh - Lead

CUM kVAr h

0

08

0 0 .0 0

8

0 Cumulative MD kW

CUM MD kW

09 9

0 .0 0

Instantaneous Power Factor

0 PF

υοΛΤ ρ 10

11

0 0 0

υοΛΤ

ψ

.0

Instantaneous R Phase Voltage

Instantaneous Y Phase Voltage

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0 0 0

.0

β

υοΛΤ

0 0

0 .0

12

Instantaneous B Phase Voltage

Χ υ ρ ρρ

0

13

.0 0 ψ

Χυ ρ ρ

0

14

0 16

.0 0

0

Instantaneous Y Phase Current

.0 0

0

Instantaneous B Phase Current

β

Χυ ρ ρ 15

Instantaneous R Phase Current

0

Π

0 0 0 0 0

16

Active Load Watts

W 17

17

νο

Tamper status

τ π

ρ JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

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18 τΧ

0 0 0

18

Cumulative Tamper counts

CUM

βψπσ

19 τΧ

0 0 0

19

Cumulative Bypass Tamper counts

CUM 2 0 τ ΧΧ

τρ Cumulative CT reverse Tamper

0 0 0

20

counts

CUM

ΧτΟ

21 τΧ

0 0

0

21

Cumulative CT open Tamper counts

CUM

µο γ τ

22 τΧ

0

22

0 0 Cumulative Magnet Tamper counts

CUM 2 3 τ Χσ 23

πη

Cumulative Split phase Tamper

0 0 0

counts

CUM

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24 24

000 0 0 0

.0 CUM

kWh

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Cumulative kWh

ερρ ELECTRONICS AND COMMUNICATION

ΡΤΧΦΑ Ι Λ RTC check

01

0 0 0 0 0 0 Cumulative kWh

CUM kWh

02β 1

000 0 0 0

.0

Billing kWh

BP kWh

03β 1

000 0 0 0 BP

.0

Billing kVAh

KVA

h

04β 1

0 0

00

.

BP MD

Billing MD kW

0 kW

ΑΥ Γ

05β 1

0 .0 0

Billing Average power factor

0 BP PF

06

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0 0

.0 0

0

MD kW

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6.2 Auto Mode:

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6.3 Tamper thresholds (G336) (3 Ph 4W 3x240 V, 50 Hz, Class 1) S. No.

1

2

Tamper Type

Store Thresholds

Restore Thresholds

Current direction –ve

Current direction +ve

Current

Net PF > 0.2

Net PF > 0.2

Reversal

Ix > 10% Ib

Ix > 10% Ib

Vx > 40 % Vref

Vx > 40 % Vref

Any one voltage < 10 %

All three voltages>

Vref

75 % Vref

Split Phase

Other two voltages > 75 % Vref Two Phases currents > 10 % Ib Difference between two currents < 500 mA

3

Magnet

Meter Under Magnetic field

Interference

4

CT Open

Meter Not Under Magnetic field

Vx > 40 % Vref

Vx > 40 % Vref

Ix < 0.1 % Ibasic

Ix > 0.1 % Ibasic

Difference between two currents> 30 % Ibasic

5

CT Bypass

Iavg > 10% Ibasic

Ibypass < 20 %

Ibypass > 30 % Ibasic

Ibasic

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6.3.1 Tamper Persistence time for Occurrence / Restoration: Programmable, by default 5 minutes(For Occurence) and 2 Minutes(Restoration) is programmed. For magnetic tamper, persistence time is 15 sec. 6.3.2 Tamper Logs: Each Block can store 160 events, i.e. 80 store and 80 restore. Meter will log Date & Time of tamper occurrence & restoration with snapshots of kWh, kVah, Phase Wise PF, Voltages (R, Y,B) & Current (R,Y,B) Vref = 240 Volts,

Imax = 60 A, Ibasic = 10 Amp

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7. CONCLUSION

At the last I conclude that my training under such an organization proud to be very beneficial for me. I learnt quite a lot about Electronic Department ,and Electronic Energy Meters , Hybrid Micro-electronic Circits and other electronic devices which are used in our daily life. The project has been completed with great dedication and sincere efforts. We have some limitations that can be overcome as a measure of further enhancement of the project and increase its utility.

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8. BIBLIOGRAPHY

•

"Handbook of Electricity Metering" by The Edison Electric Institute-- The Bible of electric meters, continuously updated since electricity was invented.

•

http://en.wikipedia.org/wiki/Electricity_meter

•

www.google.com

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