Final Project Monu

ELECTRONICS AND COMMUNICATION

ATRAINING 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 & CommunicationGENUS Overseas Private Limited EngineeringJAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY


JNITDEPARTMENT 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, JaipurJAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY


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


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



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

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



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


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.

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 multi-

functional intelligent single phase & three phase meters with in-built advanced security and anti-

tamper features. Expertise in embedded software ensures that our products are customized as

per the specific requirement.



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, pre-

payment 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.

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:

● 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”


with the energy consumption recorded by a reference meter.

Accuracy(%) = (EMUT - ERef) x 100

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

•Which is more accurate- mechanical meter or electronic meter?



•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: -


Ratings Range

•



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.




•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?

•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.




•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 above-

mentioned 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.

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.

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

Y-Phase

B-Phase

NeutralJAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

Digital signal processor

Timing & control unit

Micro Controller EPROM

LCDEnergy register


+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.

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

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

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

Place the PS and NS terminals assy in Base

Tight M4X8 screws in PS & NS terminals


3.2 Process flow for Finished good and Packing


Meter LT on Jig1) Put Meter on CT lead of Jig2) Tight Meter on Jig with help of handle3) Phase crocodile on PS Terminal & Nu crocodile on n1 on PCB4) Ph Nu on & load give to Meter in normal condition, check Volt in Display & Cal LED start blink5) Give earth load to Meter with help of earth switch of Jig, check Earth in Display, Volt in Display & Cal blink6) Earth switch of Jig put in normal7) Give reverse load to Meter with help of reverse switch of Jig, check Rev in Display, Volt in Display & Cal LED blink8) 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

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

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

Solder Ph, CT and Shunt Wire on PCB



Remove Bergstick from N1 (PCB)

Meter LT on Jig1) Put Meter on CT lead of Jig2) Tight Meter on Jig with help of handle3) Phase crocodile on PS Terminal & Nu crocodile on NS Terminal4) Ph Nu on & load give to Meter in normal condition, check Volt in Display & Cal LED start blink5) Give earth load to Meter with help of earth switch of Jig, check Earth in Display, Volt in Display & Cal blink6) Earth switch of Jig put in normal7) Give reverse load to Meter with help of reverse switch of Jig, check Rev in Display, Volt in Display & Cal LED blink8) 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

Put the Name plate on Meter

Put Button in Top Cover

Take tested Meter for FG

Check error on Jig

Solder Nu wire N1 on PCB with proper wire routing


.


Socking

Note initial reading before socking & final

reading after socking of Meter & Ref Meter

Check display parameter, digit cut, display

blinking

Meter Top Cover fixing

Ultrasonic welding

Check error on Jig

Check display parameter

Tight Screw for fixing Meter Top & Base

Meter Sealing

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

FG file run through optical port by computer


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.

4. Lighting arrangement should be adequate.

5. Air pressure for Pneumatic Tools should be maintained.

6. Proper Earthing should be at all points.


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

Put Corrugated Meter Box in Corrugated Master Box

Meter mount in Enclosure with Ultrasonic riveting

QA check point

Put Accessories in Enclosure

Mount communication cable from Meter to Enclosure

Check communication thru communication Cable


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

Put TB in Meter Base

CT mount & tight on Terminals

Mount Base Shielding in Meter Base

Tight CT Terminal Screw on Terminals

Mount Base plate in Meter Base

Mount Insulation Sheet in Meter Base

Mount Hanger Plate in Meter Base

Tight I-Patti for TB mounting at both ends



Meter LT on Jig1) Put Meter on CT lead of Jig2) Tight Meter on Jig with help of handle3) Phase crocodile (RYB) on PT wire (RYB)4) Switch on R Ph & Nu in normal condition check R Ph LED glow & Cal LED starts blinking5) Give reverse load with help of reverse switch of Jig, check R Ph LED glow, tamper LED glow & Cal LED starts blinking6) Repeat steps 4 & 5 for Y & B Ph also7) Switch on RYBN in normal condition check RYB Ph LED glow & Cal LED starts blinking8) Give reverse load with help of reverse switch of Jig, check RYB Ph LED glow, tamper LED glow & LED starts blinking

Mount Line filter

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

Tight below screw of TB for LT & QA Inspection

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 )


Remove LCD Tape

Meter LT on Jig1) Put Meter on CT lead of Jig2) Tight Meter on Jig with help of handle3) Switch on R Ph & Nu in normal condition check R Ph LED glow & Cal LED starts blinking4) Give reverse load to Meter with help of reverse switch of Jig, check R Ph LED glow, tamper LED glow & Cal LED starts blinking5) Repeat steps 4 & 5 for Y & B Ph also6) Switch on RYBN in normal condition check RYB Ph LED glow & Cal LED starts blinking7) Give reverse load to Meter with help of reverse switch of Jig, check RYB Ph LED glow, tamper LED glow & Cal LED starts blinking

Put Top cover on Meter Base

FG file run optical port by computer

Take tested Meter for FG

Tight Ph wire (RYB) on CT Terminal

Name plate fixing on Meter

QA Inspection



SoakingNote initial reading before socking & final reading after sacking of Meter & Ref MeterCheck display parameter, digit cut, display blinking

Check error on Jig

Tight Sealing Screw for fixing Meter Top & Base

Terminal Cover fixing on Meter with help of Hinge Pin

Check display parameters & QA Inspection

QA Inspection

Terminal Cover fixing with help Terminal Screw

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

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

Put Enclosure Top on Enclosure Base


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.


Put polythene with Meter into Corrugated Meter Box

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

Put Corrugated Meter Box into Master Box


5.1SALIE NT

FEATURES:JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY

5. 3-Phase Whole Current Meters

Fig (ii)


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:



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.



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.

5.5 Specification Sheet :JAGANNATH GUPTA INSTITUTE OF ENGINEERING & TECHNOLOGY


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

LCD check


ALL SEGMENT DISPLAY


RTC check

1 Real Date

2 Real Time

3 Serial No.

4 Reading count

5 MD reset count


::

::

MD


6 Cumulative kvarh - Lag

7 Cumulative kvarh - Lead

8 Cumulative MD kW

9.

PFInstantaneous Power Factor

10.

Instantaneous R Phase Voltage

11.

Instantaneous Y Phase Voltage

12.

Instantaneous B Phase Voltage

13.

Instantaneous R Phase Current

14 . Instantaneous Y Phase Current


.

CUM kVAr h

.

CUM kVAr h

.

CUM MD kW


15.

Instantaneous B Phase Current

16

WActive Load Watts

17

Tamper status

18

CUM Cumulative Tamper counts

19

CUM Cumulative Bypass Tamper counts

20

CUM

Cumulative CT reverse Tamper

counts

21

CUM Cumulative CT open Tamper counts

22

CUM Cumulative Magnet Tamper counts

23

CUM

Cumulative Split phase Tamper

counts


24.

CUM kWhCumulative kWh

RTC check

Cumulative kWh

.

BP kWhBilling kWh

.

BP KVA hBilling kVAh

.

BP MD kWBilling MD kW

.

BP PFBilling Average power factor

.

MD kWMD kW

.

kVARsisng Demand kVA

:

BP Power On hours

CUM kWh


6.2 Auto Mode:

6.3 Tamper thresholds (G336)



(3 Ph 4W 3x240 V, 50 Hz, Class 1)


S.

No.Tamper Type Store Thresholds Restore Thresholds

1 Current

Reversal

Current direction –ve

Net PF > 0.2

Ix > 10% Ib

Vx > 40 % Vref

Current direction +ve

Net PF > 0.2

Ix > 10% Ib

Vx > 40 % Vref

2 Split Phase

Any one voltage < 10 %

Vref

Other two voltages > 75 %

Vref

Two Phases currents > 10

% Ib

Difference between two

currents < 500 mA

All three voltages>

75 % Vref

3 Magnet

Interference

Meter Under Magnetic field Meter Not Under

Magnetic field

4 CT Open Vx > 40 % Vref

Ix < 0.1 % Ibasic

Difference between two

currents> 30 % Ibasic

Vx > 40 % Vref

Ix > 0.1 % Ibasic

5 CT Bypass Iavg > 10% Ibasic

Ibypass > 30 % Ibasic

Ibypass < 20 %

Ibasic


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




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.



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


Final Project Monu

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