HBL Power Systems Ltd. Electronics Groupengg.hbl.in/qms/pdfs/Formats/QC/EG-QC-FT-301 Rev0 IPS...

HBL Power Systems Ltd.Electronics Group

JOB No : IPS / System Sl No :

INTERNAL TEST REPORT.

Name of the Item: SMPS BASED INTEGRATED POWER SUPPLY Specification No.: RDSO/SPN/165/2012. Version: 3.0

1. Visual Inspection/Compliance report (Clause 10.1) Annexure-I

2. Insulation resistance in Mega ohms (Cl. 10.2) Annexure-II

3. Applied High Voltage Test (Cl. 10.3) Annexure-III

5. Switching ON & OFF of IPS with Static switch (Cl. No. 3.1.1 & 4.1.5)

IPS performance at 150 V IPS performance at 275 VSystem

disconnectLimit

Systemreconnect

LimitSystem

disconnectLimit

Systemreconnect

Limit

< 150 V 170 V > 275 V < 275

6 Alarm and indication of DSA Unit (Cl. 4.2.4)

SN Description Nomenclature Visual Audio Observation Remarks

1 Mains available Mains Indication2 Mains fail Mains fail Indication3 Load voltage

highOutput voltage high

Alarm / Indication

4 Mains out of range

Mains volt low/high

Alarm / Indication

5System overload Over load

Alarm / Indication

6 Mains 'ON' battery discharging

Mains on & batteryon load

Alarm / Indication

7 Low voltage battery disconnect

Battery discharged & isolated

Alarm / Indication

8 Battery/Load fuse fail

Fuse failAlarm / Indication

9 Battery Disconnected from circuit

Battery disconnected

Alarm / Indication

Note: Audio alarm shall be resettable with a push button switch and all the protection and alarm shall be within tolerance of ± 0.012V/cell for voltage and ±1% in case of current.

Tested By : Witnessed By :

EG-QC-FT-301 Rev:0 of 22

HBL Power Systems Ltd. Electronics Group


6.1 Failure of DSA unit ( Cl. 4.2.4.6)

Details Observation RemarksIn case of DSA fails, the IPS system shall work in float mode of working

7. Performance of FRBC (Cl.4.1 & 10.5.1) (N/2 modules/min one module) Annexure-V

7.1 Load Sharing by FRBC (Cl. 4.1.21) Annexure VI/1

7.2 Alarm/Indication/Control adjustment of FRBC (Cl. 4.1.23) Annexure VI/2

7.2.1 Fan Fail (Cl. 4.1.7)

Description Observations SMR NoShall be temperature controlled, and shall haveautomatic protection to switch off the module at 70 o Cand restore automatically with reduction in temp.

Switch on at oCSwitch off at oCAny damage

7.2.3 Short circuit protection (Cl. 10.6.1)

Description Observations SMR NoSMR shall be fully protected against short circuit andshall resume their function automatically after shortcircuit is removed. Short circuit current shall be<105% of rating.

Short circuit currentResumed automaticallyAny damage

Short Circuit at bus bar. MCB trip/ Any damage

7.2.4 Soft start (Cl. 4.1.17)

Description ObservationOutput voltage shall reach its nominal value slowly within 10 to 20 Seconds.

7.2.5 Voltage over shoot/undershoot with battery disconnected (Cl. 4.1.18)

SN Description SMR No1 With switch ON and OFF of DC output for any load 25% to 100%2 For step change in AC input say in 50V step.3 For step load change of 25% to 100%.4 Limit < ±5%

7.2.6 DC Over voltage protection (Cl. 4.1.22)

Description SMR NoDC output voltage shall not exceed 2.37/2.5V per cells for VRLA /LM batteries. The over voltage shall shut off the module and restore automatically or through reset push button switch without any damage.

7.2.7 Reverse Leakage current (Cl. 5.1.30.5)

Description ObservationThe reverse leakage current through SMR shall be less than 100 mA when module is in off condition.

Reverse leakage current……………..Any damage………………





7.2.8 Reverse battery protection (Cl. 10.6.1)Description Observation

Shall be protected against reverse battery and reverse polarity indication shall be near the terminals.

Any damage………….Protected………………..RPI provided………………

8. Battery path current setting (Cl. 4.1.14)Description Observations

a) Float / boost battery current limit adjustable between 50% to 100% for 2V to 2.5V/cell.b) Battery path current shall be automatically controlled by the I/P current in such a way that input current shall not exceed the set limit. c) Provision shall be made for full utilization of power when DG set is operated.

9. Performance of Inverter (N/2 modules/min one module) (Cl.4.3 & 10.5.2)

9.1 Test for output regulation & performance characteristics {Clause 4.3)

i) Output regulation and performance Annexure VIIii) Alarms indication / protection (Clause 4.3)

Inverter Module No……….. Date

SN Description Visual Moduletrip

Setpoint

Protections /Additional facilities

Remarks

1. Input ON Output overload2. Output ON Output Short circuit3. Output under voltage Overshoot (<20%)4. Output over voltage Under shoot(<20%)5. Inverter on load Capable of taking 125% load for

4hrs.6. Output fail Withstand 20 cycles/ hr. of

1.5min. each ON/OFF at rated load.

7. Overload8. Input under voltage9. Input Over voltage

Inverter module No……………

1. Input ON Output overload2. Output ON Output Short circuit3. Output under voltage Overshoot (<20%)4. Output over voltage Under shoot (<20%)5. Inverter on load Capable of taking

125% load for 4hrs.6. Output fail Withstand 20 cycles/ hr. of

1.5min. each ON/OFF at rated load.

7. Overload8. Input under voltage9. Input Over voltage





10. Performance for Automatic Voltage Regulator (Cl. 4.4) (N/2 modules/min one module)10.1 Output Regulation and performance (Clause 4.4) Annexure-VIII10.2 Voltage Regulation with reference to frequency (Clause 4.4.12)

SN

Load Hz I/PVoltage

O/PVoltage

%R

SN

Load Hz I/PVoltage

O/PVoltage

% R

1. 100% 50 230 1 100% 50 2302 100% 47.5 230 2 100% 47.5 230

3. 100% 52.5 230 3 100% 52.5 230

Note: (i) The output voltage of 100% load, 50Hz, 230V input will be taken as reference voltage for outputvoltage regulation.

(ii) The output voltage of regulator shall be maintained within ±3% corresponding to ±1 Hz frequency variation.

10.3 Response time (Cl. 4.4.14)

S.No Variation Setting time (ms) for output voltage of 230±5% i.e.218.5-241.51.2.3.

For 50 AC Input Voltage i.e.180V-230V

X1X2X3

X=X1+X2+X3------m sc 3

4.5.6.

For 25% to 75%Load variation

X1X2X3

X= X1+X2+X3------m sc 3

10.4 Voltage Regulation with lagging PF (0.8) (Cl. 4.4.18)

Load Hz I/P Voltage O/P current PF O/P Voltage % distortion % Reg.100% 50 230100% 50 160100% 50 270

10.5 Short Circuit Test (Cl. 4.4.19)Date

Description S.No. S.No.The regulator shall withstand short circuit for one hour continuously without any damage.

10.6 Voltage across capacitor (Cl. 4.4.20)

Description S.No. S.No.Voltage across capacitor at 52.5Hz and 270V input shall be <480V





11. Performance of DC-DC Converter (Cl. 4.5) (N/2 modules/min one module)

11.1 Performance of DC-DC Converter and additional facilities (Cl. 4.5) Annexure-IX

12. Performance test of Step Down Transformer (Cl. 4.6) Annexure X(N/2 modules/min one module)

13. Overall functioning of IPS (Cl. 10.8.1) (One IPS of the same lot )

13.1 The test will be carried out along with Battery health monitoring with constant current discharge atC/10 rate on battery with ASM panel for 8 hours. After completion of the test the IPS shall be checkedas per Clause 10.8.2., 4.3.4 & 4.4.22

Description ObservationMains to standby and vice-versa

Call (S&T) indication for failures in FRBC, Inverter, DC-DC Converter and Step Down Supply Transformer Signal AVR remains switched ONcontinuouslyCreate failure in inverter changeoverarrangement by disconnection ofcommunication cable or disturbance inpower supply distribution. The load ofsignal shall shift to AVR within 60 ms Inverter Change Over Arrangement throughStatic Switch

Specifiedchangeover time

ObservedChangeover time

OK / Not OK

From Inverter 1 to inverter 2 vice versa < 60 ms

From Inverter 2 to inverter AVR vice versa <60 ms

From Inverter 1 to AVR vice versa < 60 ms

*************************





Annexure-IVisual Inspection/Compliance report (Clause 10.1): (One IPS of the same lot) Visual Inspection/Compliance report shall be submitted by the firm and shall be verified by the inspectingofficials (I/O). DateCl. Description Remarks

1.1 Suitable for wayside & medium size signalling installations a) RE 4/6 Lineb) Non RE 4/6 Linec) RE/NRE 10 Lined) RE/NRE LC gate/IBS

1.2 Suitable for work witha) Low maintenance cells (IRS:S 88/93)b) Valve Regulated Lead Acid Cells (IRS:S 93/96)

2.1 General configuration as per sketch no. . SDO/IPS/..../ 001 to 008 or as per consignee approved drawing

2.1.1 SMPS based float cum boost charger (FRBC) panel consists ofa) FRBC moduleb) Distribution Supervisory Control Alarm (DSA) unitc) Metering section

2.1.2 AC Distribution panel consists of(a) Inverter (b) FRVR (c) Transformer (d) Meter section

2.1.3 DC Distribution panel consists ofa) DC-DC Converterb) Common Digital Voltmeter

2.1.4 Status Monitoring Panel for ASM room consists ofa) Indications b) Alarmsc) Wall mounting type monitoring paneld) Space to accommodate DC-DC Converter for block tele

2.1.5 Suitable for charging of 110V battery bank (LMLA/VRLA)2.1.9 Tool kit placed inside the rack2.1.10 12" Exhaust fan 230V AC included with IPS2.2.1 Provision for accommodating optional DC-DC Converter

a) For axle counterb) For SSIc) For Data logger

2.2.4 Provision for DC-DC Converter for 60V metal to metal relay (as per requirement of Railways)a) Relay internalb) Relay external

2.2.5 a) Spare (cold standby) provided b) Provision for cold standby in the IPS rackc) Spares kept in suitable box /bag (if supplied with IPS)

2.3 Suitable to work properly upto 50 deg.C and RH 95%3.1.1 Suitable for working from 150V to 275V AC with frequency

variation from 48Hz to 52Hz single phase3.1.4 a) Protected from accidental short circuit at input feeder

b) Free from any damage to IPS system if accidental over voltageoccurs.





Cl. Description Remarks3.1.5 The system has automatic arrangement

a) For disconnecting the mains within 500mS if input voltage isbeyond the specified operating limits with suitable alarm indication

b) To resume normal working when input supply is restored within theworking limit

3.3.1 The size of system is as per the dimensions given belowa) overall dimensions = 2000 mm*750mm*750 mm maximumb) Additional distribution panel for DC-DC Converter in case number

of DC-DC Converters are morec) Minimum 10mm thick anti vibrating padd) 75mm x 5 mm bottom channel

3.2.2 Space available to keep the spare modules in the rack3.2.3 The rack structure / modules are

a) Rigid frame work of steel profileb) Front door hinged typec) Rear panel with proper ventilation arrangementd) DC fan provided in rack for forced cooling in running condition

3.2.4 The cabinets area) Robust constructionb) Cubicles made of cold rolled closed annealed mild steel sheet of

thickness not less than 1.6mmc) 3mm size ventilating opening

3.3.5 The rack s and modules are treated with Zinc chromate primer and small metal parts chrome plated

3.3.6 The racks and modules area) Free from sharp edgesb) Free from sharp corners

3.3.7 a) Doors are providedb) Cabinet sides are having 3mm louvers covered with wire mesh or

notc) Enclosures are provided to protect from reptile / insects to enter in

the IPS cabinetd) The magnetic latches / handle provided on the door.

3.3.8 The racks and modules designed for a) Easy maintenanceb) Easy installation

3.3.9 Facility is provided at the top of the racka) To connect external AC powerb) To connect lightning arrestorsc) Rubber grommets to protect cable from damage if passes through

metal panel3.3.10 The modules are

a) Modular typeb) Easily mounted or removed from the front side of the rack.c) Suitable to slide into the rackd) AC I/P, DC output connections are easy to connect or disconnecte) Control / Alarm & Interface cable are easy to maintain without

causing any interruption / damage to supply and working module





Cl. Description Remarks3.3.11 Workmanship and professional quality suitable for MTBF requirements3.3.12 a) Input and output terminals are accessible only after removing the

coverb) All the terminals are clearly, neatly and indelibly markedc) Numbering / marking is as per the diagram

3.3.13 a) Input and output connections of modules are made using plug and socket of adequate rating having power pins and locking arrangements

b) Male connector are mounted on the device and female connector are terminated on the cable

c) Use of terminal blocks for input and output connection is not accepted

3.3.14 a) Rack and doors - Pebble grey RAL 7032 b) All IPS modules - shall harmoniously match with rack colour

3.3.15 AC/DC distribution cabinet are clearly identified or not3.4.1 a) ICs, Diode, Transistors & SCRs are of industrial grade

b) Resistors and capacitors as per RDSO/SPN/144/20063.4.2 The solid state components de-rated to not more than 50%.

Firm will submit certificate of undertaking.3.4.2 The semiconductor power devices used are not operated at more than

50% of the rated maximum peak voltage and at not more than 50% of the rated maximum average current.

Firm will submit certificate of undertaking.3.4.4 The components are used as per the recommended list given in

Annexure-VI of specn.3.5 Printed Circuit Board is as per RDSO/SPN/144/20063.6.1 The cables and wires confirms

a) IRS:S 76/89/ IS 694 of grading 1100V b) Aluminium wires not to be usedc) Current density does not exceed 3A /mm.Sq.d) Colour scheme for rack wiring confirmedAC line – Yellow, AC neutral- Black, Earthing-Green, DC positive-RedDC negative-Black, Control wiring-Grey

3.6.2 The connections are througha) Crimped eyeletsb) Numbered with PVC cable master ringsc) Soldering only where use of crimped eyelets is not possible

3.6.3 Non current carrying metal parts earthed3.6.4 a) Wiring is in bunching or strapping form

b) Rubber grommets provided in metal hole3.6.5 Any exposed wiring outside of the cabinet or not3.7.1 a) Power transformers and chokes are class F or of higher grade

insulation.b) Transformer & chokes are wound with copper.

3.7.1 Current density of transformer & chokes shall be less than 2A/mm.Sq.3.7.2 All exposed metal parts are protected against corrosion





Cl. Description Remarks3.8.1 Following potential free contacts are provided for extension of alarms at

remote placesa) Inverter 1 fail (b) Inverter 2 fail (c) FRBC fail (d) DC-DC Converter fail (e) Mains fail (f) Call S&T staff(g) Battery low (50% deep discharge)

3.9.1 Accuracy of 3 1/2 D. Digital meters used in the IPS cabinets shall be ±1%, ±3D or better

3.9.2 The meters are provided on the top of FRBC, ACDP, DCDP panels as per sketch no. SDO/IPS./Layout/001

3.10.1 The plug in connectors are non-interchangeable3.10.2 Fuse holder identification includes details of fuse rating and type3.10.3 All power fuses confirm to spec. IS 13703/ 92243.11.2 IPS sub system is immune to any kind of EMI interference and is not

producing any hum in the peripheral devices3.12.1 The protections are provided at

a) Stage 1 Protection –At input of IPS ,(Class B) Line to Neutral & Neutral to Earth

b) Stage 1 Protection –At input of IPS(Class C) Line to neutral

c) Stage 2 Protection -Protection at the output of IPS for following circuits (Class C in common and differential mode)

i) Relay External ii) Axle counter

iii) Inverter Output iv) Point machine

3.13.1 Each module has earth terminal

Float Cum Boost Charger

Clause Description Remarks4.1.1 FRBC modules 110V /20A4.1.2 Number of FRBC modules 4.1.3 Switching frequency for FRBC4.1.4 Resettable fuses provided in control/ sensing circuit4.1.5 Delay/ Hysteresis provided during switching ON/OFF4.1.6 Switching ON and OFF the fan temperature controlled4.1.7 Automatic protection provided to switch off the module above 70 deg. C4.1.8 FRBC modules forced cooling provided4.1.9 Screen printed procedure for adjustment of float voltage, boost voltage,

battery current limit provided4.1.10.1 Digital meter of 3 ½ digit with LCD/LED display having 12mm

numerical display height provided on the front door of the rack fora) AC Volt/ Ampere meter to read AC input voltage & currentb) DC Volt/Ampere meter to read system voltage, battery voltage,

system total current and battery current.4.1.10.2 Battery discharge current displayed on DC Ampere meter with negative

sign4.1.17 Slow start feature provided





Cl. Description Remarks4.1.24 a) The AC input connection to the FRBC module by means of plug and

socket arrangement.b) The DC output connection taken through irreversible plug and socket

having power pins with locking arrangement. c) The output of each FRBC in the positive lead taken through the HRC

fuse of 1.5 times of rated capacity of FRBC. d) In all cases, the male connector mounted in the FRBC module and the

female connector terminate the cable. e) To prevent hazards or damaging conditions, all plug-in components

non-interchangeable.f) All the connections between DSA unit and FRBC through proper

rated cables only. g) Circuit breakers at the input of each FRBC easily accessible and rated

to 25A for 110V/20A module.h) Proper termination for AC at the input of the circuit breakers and its

output to the FRBC.

Distribution Supervisory Control & Alarm Unit

Cl. Description Remarks4.2 The unit shall comprise of the following:

a) Termination for the batteries.b) Termination for the load (DC-DC converter & Inverters).c) Termination for AC input to the rack.d) Termination for AC and DC to FRBC modules.

4.2.1 a) The termination points easily accessible from front or rear. b) AC and DC terminals separated by physical barriers to ensure

safety.c) All the terminals except AC earth electrically isolated.

4.2.2 a) The input terminals clearly marked as L & N for mains supply voltages.b) AC input termination suitably protected against accidental

touch/contact with the working staff for their protection and shall alsohave clear and prominent ‘DANGER’ Marking.

4.2.3 a) Connection between the FRBC and DC distributions through aproper rated lugged cable.

b) The DC output to battery and load through bus bar or cable.c) Battery fuse of 1.5 times of maximum current that passes to / from

battery.d) Fuse at the O/P of FRBC rack of 1.5 times the designed O/P current

required for the system.e) All the AC, DC and Control/Alarm cabling supplied with the rack. f) All DC positive & negative terminals clearly marked and shall be

suitable for minimum 10-sq. mm cable size. All conductors properlyrated to prevent excessive heating.

Inverter4.3.4 a) Provision of Inverter changeover arrangement using Static switch

b)Failure of any inverter indicated using LED4.3.5 a) Inverter switched ON without manual pre-charging

b) Suitable for ON line application





Cl. Remarks Description4.3.6 Input & output of inverter isolated from each other4.3.7 DC MCCB / MCB provided for connecting DC input4.3.8 DC fan MTBF 70000 hours at 40 deg.C4.3.9 The following LED indications shall be provided on front panel:

a) Input ON - Amberb) Output OK - Greenc) Inverter fail - Redd) Inverter ‘ON load' - Greene) Fan fail indication - Red (In case of forced cooling)

Automatic Voltage RegulatorCl. Remarks Description

4.4.2 Completely static without any moving parts.4.4.3 Suitably screened from other electronic equipment 4.4.4 Natural air-cooled type 4.4.5 Shock proof and mounted on anti vibrating padding.4.4.6 AC Metal Can Capacitors of 600V rating provided 2 inches away

from the main transformer’s top plate 4.4.7 Output tapping at 0, 220, 230& 240V provided. 4.4.8 Winding wires (class F or higher grade) current density ≤1.6

amps/sq.mm at 50Hz. 4.4.9 Two pole ON/OFF rotary switch provided for input to the regulator.4.4.10 A LED lamp to indicate 'ON' provided on the front panel.

DC-DC ConverterClause Remarks Description4.5.2 DC- DC converters are connected in the following order:

(i) Relay internal (ii) Relay external (iii) Axle Counter(iv) Block local UP (v) Block Local DN (vi) Panel indication(vii) Block Line UP (viii) Block Line DN (ix) Block Tele UP(x) Block Tele DN

4.5.3 Heat sinks provided for 3W or more power dissipating elements. 4.5.4 a) A toggle switch/push button for switching ON/OFF the unit

b) Plug in arrangement for DC input & output. are provided .4.5.5 Visual indication on front panel for the following

i) Input Power ON indication - Amberii) DC-DC Converter output OK - Greeniii) DC-DC Converter fail - Red

4.5.17 Voltage testing sockets provided on front panel for the purpose ofoutput voltage measurement in the common voltmeter

4.5.18 A 10-turn potentiometer provided inside for adjusting the outputvoltage





Step Down TransformerClause Remarks Description

4.6.1 a) Terminals , screws made of nickel-plated brassb) Top screw pillar typec) Securely fixed

4.6.2 Double wound4.6.3 The transformer separate input and output windings provided4.6.4 a) Primary winding tapping 230V

b) Secondary winding tapping at 0, 100, 110, 120 & 130 volts4.6.5 Current density of winding wires ≤2A/mm sq4.6.6 ON/OFF Rotary switch of 10A or above provided4.6.9 Earth terminal provided with marking 4.6.11 Input and output voltage engraved 4.6.12 An HRC fuse of appropriate rating provided at the input of

transformer.4.6.13 The following LED indications provided on the front panel:

a) Input ON - Amberb) Output ON - Greenc) Transformer fail - Red

Requirement of SMPS based Float Rectifier Cum Boost Charger Panel (FRBC)

Cl. Remarks Description4.7.1 3 ½ Digit digital meter with LED/ LCD display having 12mm

numerical display provided on top of the charger panel. a) AC Volt meter 0-300V b) AC Ammeter 0-50A c) DC Voltmeter 0-200V d) DC Ammeter 0-50A e) A selector switch provided for reading Total/ Charge / Dischargecurrent.

4.7.2 DC meters work even when the AC supply not available. 4.7.3 Provided with microprocessor based control & supervisory unit for

indication / measurement Requirement of AC Distribution Panel (ACDP)

Cl. Remarks Description4.8.1 AC digital volt meter (0-300V) of 3 ½ D with LED/ LCD display

having 12mm numerical display provided on the front panel with a 8position selector switch for Inverter 1 Inverter 2 AVR Signal AVR Track Transformer (Up) signal Transformer (Dn) signal Transformer (Up) track Transformer (Dn) track





Cl. Remarks Description4.8.2 All Digital ammeter 0-20A provided with LCD/LED display having

12mm numerical display for the total Signal load 4.8.3 a) Output of Inverter, step down transformer & AVR brought to one

place at the rear of the cabinetb) TB type termination of 30A capacity

4.8.4 Provided with microprocessor based control & supervisory unit forindication / measurement

Requirements of DC Distribution Panel (DCDP)Clause Remarks Description

4.9.1 DC digital voltmeter of 3 ½ digit with LCD/LED display having12mm numerical display height provided with extendable cords

4.9.2 a) Output of DC-DC converters are brought to one place at the rear of thecabinet.

b) TB type termination of 30A capacity4.9.3 Provided with microprocessor based control & supervisory unit for

indication / measurementStatus Monitoring Panel

Clause Remarks Description4.10.1 Following alarms and indications provided

Run Gen set 50% DOD REDEmergency start generator 60% DOD REDSystem shut down 70% DOD REDCall S & T staff Equipment fault REDStop Gen Set FRBC change over to float GREEN

Labelling and Marking

Cl. Remarks Description6.1 a) Each electrical/solid state components located in layout/circuit

drawingb) Wiring clearly and permanently marked with designation/ standard colour codec) For non standard colour code, labelling at both the ends

6.2 Screen printed cabling / wiring diagram provided at convenient placefor ready reference of maintenance staff

6.3 a) Screen printed Do's & Donts' adjustment procedure and operating procedure provided at convenient place on front panelb) Laminated block diagram provided at convenient place inside the front door.

6.4 Layout of components / wiring easily accessible for inspection, repair/replacement

6.5 a) marking legible and durableb) Label marking metallic / screen printedc) Label placed in the vicinity of the components

6.6 IPS cubicles marked with common serial number.6.7 Each cubicle provided with appropriate name plate / label

a) SMPS IPS-AC distribution panelb) SMPS IPS-DC distribution panelc) SMPS IPS- SMPS based FRBC panel





Cl. Remarks Description6.8 a) Each module marked with its name & rating on front panel

b) Each module marked with its application for the purpose ofappropriate replacement

6.9 a) Rating plate fixed outside at a conspicuous place in IPS cubicle b) Rating indelibly etched, engraved or screen printed with the

following minimum information

(i) Name and trade mark of the manufacturer(ii) Specification No.(iii) Nominal AC input voltage and frequency(iv) Serial number and year of manufacturing(v) SMPS power plant adjusted for VRLA / low maintenance cells.

6.10 Input and output terminals clearly identified by using proper nametags/labels.





Annexure-IIInsulation Resistance in Mega ohms (Cl. 10.2) Date……………RT…………..RH………

Des. Before H.V After H.VI/P& E O/P & E I/P & O/P I/P& E O/P & E I/P & O/P

FRBC

Inverter

DC-DC Conv.

Limit 10 10 10 10 10 10AVR

Tx

Limit 1000 1000 1000 1000 1000 1000





Annexure-IIIApplied High Voltage Test (Cl.10.3)

Des. I/P & E O/P & E I/P & O/PObservation (withstood / not

withstood)FRBC

Inverter

DC-DC Conv.

AVR

Tx





Performance test of FRBC {Cl. 10.5}Annexure-V

FRBC Module S.No

Float Mode:……………..Float voltage 123.8V for VRLA and 118.25 for LM batteries.

Input Output

Voltage(V AC)

Current(A rms.)

I - THD%

V - THD%

Power(W)

PFcos

Voltage(V)

% of loadCurrentActual

(A)

Power(W)

Ripple(mV)RMS

Ripple(mV)P - P

Efficiency%

PSO noise(mv) rms

150 25230 25275 25150 50230 50275 50150 100230 100275 100

Boost Mode : Boost Voltage 126.5V for VRLA and 133.1V for LM batteries.

150 25230 25275 25150 50230 50275 50150 100230 100275 100

Limits: I-THD - From 50% to 100% load <10%, V-THD - <10%, cos - >0.95 at rated I/P and F/L & >0.9. for 25% load to F/L and 150 to 275V input. Output Voltage – Shall be within ±1% for 25% load to F/L, Ripple p-p <300mV, Efficiency % - >90% at rated I/P and F/L. >85% at 25% load to F/L and 150-275V I/P.





Load Sharing by FRBC /Parallel operation (Cl. 4.1.21) Annexure VI/1

SN SMR conditions Load sharing by modules Unbalance <±10%MOD-1 MOD-2 MOD-3 MOD-4 MOD-1 MOD-2 MOD-3 MOD 4

123456789

Alarm / Indications/ Control adjustment of FRBC front panel (Cl. 4.1.23) Annexure VI/2

SN Description Module S.No…………… Module S.No…………… Module S.No…………… Module S.No……………

Visual AudioModTrip

SetPoint

Visual AudioModTrip

SetPoint

Visual AudioModTrip

Setpoint

Visual AudioModTrip

Set Point

1. Mains ON2.Float Mode3. Boost Mode4. DC U/V5. DC O/V6. Over Load7. Output fail8. Fan Fail9. AC input U/V

Note: All the audio alarms shall be resettable.

a. Float Voltage settability range: __________ __________ ___________ ___________b. Boost voltage settability range: __________ __________ ___________ ___________c. Float current settability range: __________ __________ ___________ ___________d. Boost current settability range: __________ __________ ___________ ___________e. Overload current setting __________ __________ ___________ ___________





Performance Test for Inverter {Clause 10.3.2 (e)} Annexure VII

Module SN ……………………..…..

Input Output

VDC Current Power VAC Frequency V.THD % Load Current Power %age Eff. %age Reg.

Actual %

98V 0110V 0138V 098V 50110V 50138V 5098V 100110V 100138V 100

Module SN ………………………….…

98V 0110V 0138V 098V 50110V 50138V 5098V 100110V 100138V 100

NLC <10% 230±1% 50±1Hz <8% >85% ±1%





Performance test for Ferro Resonant type Automatic Voltage Regulator (Cl. 4.4) Annexure VIIIFor 230V/230V Voltage Regulator with resistive load

AVR SN………………

S.No Load Hz Input Output %Distortion % efficiency % Regulation

Voltage Current Power Voltage Current Power Load Line1. NL 50 2302. 25% 50 2303. 100% 50 2304 100% 50 2705 100% 50 1606 100% 50 1507 25% 50 150

AVR SN………………

1. NL 50 2302. 25% 50 2303. 100% 50 2304 100% 50 2705 100% 50 1606 100% 50 1507 25% 50 150

Limit:1. No load current less than 25% of rated input current2. No load power <10% of rated output power3. Percentage distortion less than 8%4. Percentage efficiency >85% 5. Load regulation 230± 1% for 25% load to full load 6. Line regulation 230± 1% for 160V to 270V





Performance test of DC-DC Converter (Clause 4.5) Annexure-IXSN………….. Rating SN…………. Rating SN……….. RatingOutput volt. Settability: Output volt. Settability: Output volt. Settability:

I/P Volt. (V) 98V 110V 138V 98V 110V 138V 98V 110V 138V

Load % NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL

I/P Current (A)O/P volt.(V)O/P Current (A)Ripple (mV)Psopho. NoiseEfficiency (%)INDICATIONS Observation PROTECTIONS Observation

SN………… SN……. SN……….. SN….. SN……… SN………Input ON O/P free from overshootOutput ON Short circuit protectionOutput Fail Over voltage protectionOver load Overload protection

Lightning /Surge protectionPerformance Report

SN………….. Rating SN…………. Rating SN……….. RatingOutput volt. Settability: Output volt. Settability: Output volt. Settability:

I/P Volt. (V) 98V 110V 138V 98V 110V 138V 98V 110V 138VLoad % NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL NL 10% FL

I/P Current (A)O/P volt.(V)O/P Current (A)Ripple (mV)Psopho. NoiseEfficiency (%)INDICATIONS Observation PROTECTIONS Observation

SN……….. SN……..: SN……… SN…….. SN………….. SN……..Input ON O/P free from overshootOutput ON Short circuit protectionOutput Fail Over voltage protectionOver load Overload protection

Lightning /Surge protectionLimits: a) No load current: < 10% (b) % of efficiency: for 50VA-150VA >70% & for 150VA >80% for 10-50VA > 40% (c) O/P regulation: ±1% of set value from 10% to 100% load (d) Ripple: <50mVp-p (e) Psophometric <4mV for Block tele and Block line.





Performance of Step Down Transformer (Cl. 4.6) Annexure-Xi) Open Circuit Test Date

SN of TxInput

voltageN.L. Current Secondary tap Voltages in Volts

230V 0-110V 0-120V 0-130V

Limit <10% of ratedinput current

±1.5%

98.5-101.5 108.35-111.65 118.2-121.8 128.05-131.95

ii) Voltage regulation test: Date

SN voltageat fullload

Rated full load Full load O/Pvoltage

No load O/Pvoltage (V)

Percentage Regulation(Limit < 5 %)

110 V

iii) Efficiency Date

SN Rated inputvoltage

Inputcurrent

Inputpower

OutputVoltage

Full load O/Pcurrent

Outputpower

Percentage Efficiency>85%

230V



HBL Power Systems Ltd. Electronics Groupengg.hbl.in/qms/pdfs/Formats/QC/EG-QC-FT-301 Rev0 IPS...

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