AUTOMATED CONTROL APPROACH FOR INDUSTRIAL W'ELDING TRANSFORMER TO MINIMIZE THE IDLING POWER LOSS A dissertation submitted to the Department of Electrical Engineering, University of Moratuwa in partial fulfillment of the requirement for the degree of Master of Science by ALAHAKOONGE, DON MIKE JEETH Supervised by Dr. Nalin Wickramarachchi Department of Electrical Engineering University of Moratuwa Sri Lanka 2009 93952 Abstract Main objective is to design and implement automated control circuit to switch ON & OFF main power feeding contactor of industrial welding transformer, depend on the work pattern. Voltage sensing at the out put terminals of secondary winding of welding transformer is used as a one and only input signal for the control circuit. Reduced voltage 24 VAC is supplied to primary during idling and during operation it converts in to 400 VAC, and this conversion takes place automatically. By that, able to reduce idling power loss on primary winding due to open circuit core loss & iron loss. During designing of new system special attention was made, not to change existing conventional welding procedure and not to introduce additional external sensors and cables other than conventional welding electrode and welding cable. New system was practically implemented in yard and tested for long period of time in different work conditions in Colombo Dockyard PLC. System was tested with existing conventional welders but no behavioral changes were observed during welding operation after implementing new system. Successful trails were carried out and proved it uninterrupt operation. Under guidance and instructions of my project supervisor I worked and finally able to came up with practically feasible solution. This report describes problem identification, how the design concept developed, power saving and cost benefits .to yard after implementation of new system. The report starts with an introduction as a 1st chapter where describe the current welding practice at Colombo Dockyard PLC, how to reduce idling power loss by implementing new method and final goal of my project. 2nd chapter describes the statement of the problem and problem identification, new solution and how it affects to save energy. The 3rd chapter consists with gathered technical data and its analysis during execution of design approach. Next 4th chapter describe about proposed and implemented solutions for the identified problem and evolution of design concept. Fifth chapter describes the energy saving calculations and cost benefit analysis. Finally, in the conclusion, I have explained practically and economically viability of new product as a industrial product. D E C L A R A T I O N T h e w o r k s u b m i t t e d i n t h i s d i s s e r t a t i o n i s t h e r e s u l t o f m y o w n i n v e s t i g a t i o n , e x c e p t w h e r e o t h e r w i s e s t a t e d . I t h a s n o t a l r e a d y b e e n a c c e p t e d f o r a n y d e g r e e , a n d i s a l s o n o t b e i n g c o n c u r r e n t l y s u b m i t t e d f o r a n y o t h e r d e g r e e . c - - < : f _ . / J - ! A . D . M . J e e t h D a t e : A p r i l 3 0 , 2 0 0 9 - W e · / I e n d o r s e t h e d e c l a r a t i o n b y t h e c a n d i d a t e / / ( ( \ - - - - - ~2 '('~" r-;:;-;~-y-- P r o j e c t s u p e r v i s o r : D r . N a l i n W i c k r a m a r a c h c h i C O N T E N T S D e c l a r a t i o n A b s t r a c t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v A c k n o w l e d g e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v 1 1 T a b l e o f c o n t e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . 1 1 L i s t o f F i g u r e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v 1 1 1 L i s t o f T a b l e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I X 1 . I n t r o d u c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . 1 B a c k g r o u n d a b o u t C o l o m b o D o c k y a r d P L C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . 2 B a s i c I n t r o d u c t i o n f o r c u r r e n t w o r k p r a c t i c e a t C o l o m b o D o c k y a r d P L C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . 2 . 1 C u r r e n t w e l d i n g p r o c e d u r e w h i c h i s p r a c t i c i n g a t y a r d . . . . . . . . . . . . . 1 1 . 2 . 2 E n e r g y w a s t a g e d u r i n g i d l e p e r i o d d u e t o o p e n c i r c u i t c o r e l o s s & i r o n l o s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 . 2 . 3 S p e c i f i c a t i o n & g e n e r a l c o n f i g u r a t i o n o f W e l d i n g T r a n s f o r m e r a t C o l o m b o D o c k y a r d P L C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 . 2 . 4 U t i l i z a t i o n o f a r c w e l d i n g t r a n s f o r m e r s i n C o l o m b o D o c k y a r d P L C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1 . 3 G o a l s a n d S c o p e o f p r e s e n t w o r k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 . S t a t e m e n t o f t h e P r o b l e m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 . 1 P r e l i m i n a r i e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 . 2 P r o b l e m i d e n t i f i c a t i o n & T h e s i s s t a t e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 1 3 . G a t h e r e d t e c h n i c a l d a t a a n d i t s A n a l y s i s d u r i n g e x e c u t i o n o f d e s i g n a p p r o a c h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3 . 1 C T o u t p u t c u r r e n t a n d v o l t a g e m e a s u r e m e n t s w h i c h R e l e v a n t t o e a c h o f C T u n d e r c u r r e n t s e n s i n g d e s i g n a p p r o a c h . . . . . . . . . . 8 3 . 2 M e a s u r e d p a r a m e t e r s d u r i n g v o l t a g e s e n s i n g d e s i g n 3 . 3 F o l l o w i n g a r e t h e m e a s u r e d v a l u e s o f p r i m a r y a n d s e c o n d a r y p a r a m e t e r s w h e n s e c o n d a r y u n d e r l o a d 3 . 4 B e h a v i o r a l s t u d y o f w e l d i n g t r a n s f o r m e r b y c o n n e c t i n g v a r i o u s t y p e s o f s t e p d o w n t r a n s f o r m e r s p a r a l l e l t o p r i m a r y 1 0 1 1 w i n d i n g o f w e l d i n g t r a n s f o r m e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 . 5 M e a s u r i n g o f t o t a l i d l i n g t i m e a n d s t u d y o f o p e r a t o r ' s b e h a v i o r a l p a t t e r n w h i c h r e l e v a n t t o e a c h w o r k l o c a t i o n 3 . 5 . 1 W h y i d l i n g c a n n o t e l i m i n a t e d u r i n g s t e e l 1 4 f a b r i c a t i o n p r o c e s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 3 . 5 . 2 I n s t r u m e n t u s e d t o m e a s u r e t h e i d l i n g t i m e a n d t o s t u d y o p e r a t o r ' s w o r k p a t t e r n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 3 . 5 . 3 S a m p l e s c r e e n s h o t s d u r i n g s t u d y o f o p e r a t o r ' s w o r k p a t t e r n f r o m a b o v e S C O P E m e t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 3 . 5 . 4 D a t a c o l l e c t e d w h i c h r e l e v a n t t o e a c h w o r k l o c a t i o n t o m e a s u r e t o t a l i d l i n g t i m e f o r 1 0 h o u r s o f t o t a l t i m e p e r i o d . . . . 1 7 3 . 5 . 5 S t u d y o f o p e r a t o r ' s w o r k p a t t e r n d u r i n g g e n e r a l w e l d i n g o p e r a t i o n i n o r d e r t o d e c i d e t h e b e s t t i m e r s e t t i n g w h i c h r e l e v a n t t o v o l t a g e s e n s i n g a p p r o a c h . . . . . . . . . . . . . . . . . . . . . . . 2 1 4 . 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C o n c l u s i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 R e f e r e n c e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 A P P E N D I X - A S a m p l e s c r e e n s h o t s d u r i n g s t u d y o f o p e r a t o r ' s w o r k p a t t e r n f r o m F L U K E S C O P E m e t e r . . . . . . . . . . . . . . . . . . . . . . . . 4 4 A P P E N D I X - B L i t e r a t u r e a b o u t i n s t r u m e n t a n d e q u i p m e n t s w h i c h w e r e u s e d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9 I V A c k n o w l e d g e m e n t [ l ' ' , p r e s s m y s i n c e r e t h a n k s t o a l l t h e f o l l O \ v i n g i n d i v i d u a l s , t h o s e w h o c o n t r i b u t e d t c l \ \ a r c l s t h e c o m p l e t i o n o f m y t i n a ! p r o j e c t s u c c e s s f u l l y u n d e r m y M . S c / P G D i p l o m a i n I n d u s t n a l A u t o m a t i o n 2 0 0 6 / 0 7 c o u r s e . \ t t h e \ c r : b e g i n n i n g 1 1 1 ) g r a t i t u d e g o e s t o t h e p r o j e c t s u p e n i s o r D r . ~a! i n \ \ i d . r a m a r a c h c h i . s e n i o r l e c t u r e r , d e p a r t m e n t o f e l e c t r i c a l e n g i n e e r i n g , U n i v e r s i t y o f M a r a t u w a . I a m i n d e b t e d t o m y p r o j e c t s u p e r v i s o r f o r h i s i m m e n s e g u i d a n c e a n d e x c e l l e n t t e c h n i c a l a d v i c e s f o r s u c c e s s o f m y p r o j e c t . I w o u l d l i k e t o e x t e n d m y s i n c e r e t h a n k s t o P r o f J . R o h a n P r o 1 " . I L Y . R a n j i t l ) , ; r c r a , H e a d d e p a r t m e n t o f e l e c t r i c a l e n g i n e e r i n g P r o f J . P . I~_ > 0!!1~ -~.,l-t-$11~ > < ! f i ' ¢ , < \ C O < t t --1~118/.:'000: l~ , . 1 1 B 2 9 P M Y S c a l e , . 2 0 < f / 0 , . . . ( A t ' S O J 4 " 4 0 0 0 V :...:sr.~l! ~ ; o ; i O N t A t f J \ · 0 0 1 8 5 1 " - S m - . , 3 0 C { 5 5 0 1 1 M~ . . (\'ri'<'lo~ Mnt~--..lt'l, 0 0 i ) V r ; A c M e > : Ro;37~ZJ N l f t f j i ( § f ® H t M I ; t i H E U P f i * · H : M D t _ f U ] ' i ~ _ j k - ~$)( ~3t 1 2 0 0 0 1 0 0 0 0 O O O C > & 0 0 0 4 D O O V . ! ( J [ i f j D O O : · n o o 4 D O O I F > : ' ; . M : _ . l : l s - ' O ! Y - - - · - c:,-S>~- - >- C1 -2 1 - >- 22 0V AC C1 -1 - >- I - lh' - I I - I - I - I 24 VA C - I I I L _ _ _ _ j MC B 63 A C1 -1 C1 -2 WE LD ING T RA NS FO RM ER ~ ) - - l:- C1 -7 CT -1 (10 0/S A) - < >- . . . . _ ~ >- ~ CU RR EN T TR AN SF OR ME R ~ CT -2 ( 40 0/S A) \ C1 -4 ~ 1~ C UR RE NT rR AN SF OR ME R C1 -3 ( ~ - E2 A1 I (+ ) C1 -5 R1 -1 (-) . . . . _ C1 -8 ~ M ,- lf-- 1 /12 C1 -6 I . . . . _ CU RR EN T SE NS ING R EL AY (R 1) FI G . - 4. 1 CO NT RO L CI RC UI T FO R IN DU ST RI AL W EL DI NG TR AN SF O RM ER TO IS OL AT E PR IM AR Y W IN DI NG FR OM TH E 44 0V A C M AI N SU PP LY D UR IN G ID LI NG (D ES IG N- 2) IC 1 1 -2 ~- 4 . 4 D e s i g n c o n c e p t - 3 ( V o l t a g e s e n s i n g a p p r o a c h N o - 1 ) H e a r a l s o r e d u c e v o l t a g e i s f e d t o p r i m a r y w i n d i n g a n d s u b s e q u e n t l y t r i e d t o d e v e l o p e d c o n t r o l s t r a t e g y b y s e n s i n g t e r m i n a l v o l t a g e a t s e c o n d a r y w i n d i n g . O n e s t e p u p p o w e r t r a n s f o r m e r w i t h p r i m a r y 5 V A C & s e c o n d a r y 2 4 V A C a n d o n e s t e p d o w n p o w e r t r a n s f o r m e r w i t h p r i m a r y 8 0 V A C & s e c o n d a r y 2 4 V A C w e r e i n t r o d u c e d t o t h e s y s t e m i n o r d e r t o p r o v i d e s e n s i n g s i g n a l s . 4 . 4 . 1 O p e r a t i n g p r o c e d u r e S t e p - 1 ; i n i t i a l l y m a i n p o w e r f e e d i n g c o n t a c t o r i s a t d e - e n e r g i z e d s t a t e . S t e p - 2 ; 2 4 V A C s u p p l y c o n n e c t w i t h p r i m a r y w i n d i n g o f t h e w e l d i n g t r a n s f o r m e r t h r o u g h a u x i l i a r y c o n t a c t s ( N C ) o f m a i n p o w e r f e e d i n g c o n t a c t o r . T h e n s u b s e q u e n t l y 5 V A C o u t p u t v o l t a g e s g e n e r a t e s a t t h e o u t p u t t e r m i n a l s o f s e c o n d a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r . T h i s 5 V A C c o n v e r t e d i n t o 2 4 V A C b y t h e s t e p u p p o w e r t r a n s f o r m e r a n d s u b s e q u e n t l y r e s u l t a n t 2 4 V A C c o n n e c t s w i t h c o n t r o l r e l a y ( h a v i n g 2 4 V A C r e l a y c o i l ) t h r o u g h a u x i l i a r y c o n t a c t s ( N C ) o f m a i n p o w e r f e e d i n g c o n t a c t o r . I n o r d e r t o i n c r e a s e t h e s e n s i t i v i t y u s e d 5 V A C I 2 4 V A C s t e p u p t r a n s f o r m e r . S o s u b j e c t e d c o n t r o l r e l a y g e t s e n e r g i z e d d u r i n g i d l i n g a n d s u b s e q u e n t l y r e s u l t a n t s i g n a l f e e d s t o t h e t i m e r t h r o u g h " N C " c o n t a c t o f c o n t r o l r e l a y . S t e p - 3 ; I f w e l d e r w a n t s t o s t a r t h i s w e l d i n g o p e r a t i o n n o r m a l l y h e t o u c h e s t h e w e l d i n g e l e c t r o d e w i t h t h e g r o u n d a n d s u b s e q u e n t l y t e r m i n a l v o l t a g e o f s e c o n d a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r d r o p s a n d t h e n a b o v e c o n t r o l r e l a y g e t s d e - e n e r g i z e d a n d r e s u l t a n t s i g n a l s e n d s t o t i m e r a n d s u b s e q u e n t l y t i m e r g i v e s s i g n a l t o e n e r g i z e m a i n p o w e r f e e d i n g c o n t a c t o r . S t e p - 4 ; T h e n 4 0 0 V A C c o n n e c t s w i t h p r i m a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r . - 2 9 - S t e p - 5 ; N o w w e l d i n g t r a n s f o r m e r i s r e a d y f o r a c t u a l w e l d i n g o p e r a t i o n . S t e p - 6 ; A t t h i s s t a g e o p e n c i r c u i t v o l t a g e a t t e r m i n a l s o f s e c o n d a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r i s 8 0 V A C . T h i s 8 0 V A C g e t s c o n n e c t w i t h s t e p d o w n p o w e r t r a n s f o r m e r w i t h p r i m a r y 8 0 V A C & s e c o n d a r y 2 4 V A C t h r o u g h t h e a u x i l i a r y c o n t a c t s ( N O ) o f m a i n p o w e r f e e d i n g c o n t a c t o r . T h i s r e s u l t a n t 2 4 V A C c o n n e c t s w i t h s a m e a b o v e c o n t r o l r e l a y c o i l a n d s u b s e q u e n t l y i t g e t s e n e r g i z e d . D u e t o e a c h a c t u a l w e l d i n g o p e r a t i o n a b o v e c o n t r o l r e l a y g e t s d e - e n e r g i z e d a n d r e s u l t a n t s i g n a l f e e d s t o t i m e r a n d s u b s e q u e n t l y t i m e r g e t s r e s e t a n d s h i f t s i t s t i m e c o u n t i n g . T h a t m e a n s a l o n g w i t h e a c h w e l d i n g o p e r a t i o n t i m e r g e t s r e s e t a n d s h i f t s f o r w a r d . S t e p - 7 ; I f a b o v e r e s e t s i g n a l i s f a i l e d t o p r o v i d e w i t h i n t h e s e t t i m e p e r i o d t h e n t i m e r g i v e s s i g n a l t o m a i n p o w e r f e e d i n g c o n t a c t o r t o d e - e n e r g i z e d a n d s u b s e q u e n t l y a g a i n 2 4 V A C s u p p l y c o n n e c t w i t h p r i m a r y w i n d i n g o f t h e w e l d i n g t r a n s f o r m e r t h r o u g h a u x i l i a r y c o n t a c t s ( N C ) o f m a i n p o w e r f e e d i n g c o n t a c t o r . S t e p - 8 ; N o w t h e s y s t e m c o n v e r t s b a c k t o i n i t i a l c o n d i t i o n . - 3 0 - 44 (_) VA 1 C1 -2 • • C1 -M AI N CO NT AC TO R. C1 -1 ST EP U P PO WE R TR AN SF OR ME R C1 -1 C1 -2 C1 -1 - 2 4 V A C - R1 -2 ST EP D OW N PO WE R TR AN SF OR ME R 22 0V AC I ~~ 12 4V A C , G ~>--r: _ _ ___,,- ---+.- ~~ L _ _ _ _ j MC B 63 A ST EP D OW N PO WE R TR AN SF OR ME R R2 T R2 R1 FI G ;- 4. 2 CO NT RO L CI RC UI T FO R IN DU ST RI AL W EL DI NG TR AN SF O RM ER TO IS OL AT E PR IM AR Y W IN DI NG FR OM TH E 44 0V A C M AI N SU PP LY D UR IN G ID LI NG (D ES IG N- 3) :-. I - 0 - 4 . 5 D e s i g n c o n c e p t - 4 { F i n a l } , V o l t a g e s e n s i n g a p p r o a c h N o - 2 4 . 5 . 1 D i f f e r e n c e b e t w e e n D e s i g n c o n c e p t - 3 & D e s i g n c o n c e p t - 4 F o l l o w i n g i s t h e o n l y d i f f e r e n c e b e t w e e n D e s i g n c o n c e p t - 3 & D e s i g n c o n c e p t - 4 H e a r a v o i d e d o n e a b o v e s t e p d o w n p o w e r t r a n s f o r m e r w h i c h h a v i n g p r i m a r y 8 0 V A C & s e c o n d a r y 2 4 V A C . I n s t e a d o f a b o v e s t e p d o w n p o w e r t r a n s f o r m e r , h e a r i n t r o d u c e d v a r i a b l e r e s i s t e r w h i c h i s s e t a t 5 7 5 n i n o r d e r t o c o v e r a l l o p e r a t i n g r a n g e s . D u r i n g o p e r a t i o n 4 0 0 V A C c o n n e c t s w i t h p r i m a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r a n d r e s u l t a n t 8 0 V A C g e n e r a t e s b y t h e s e c o n d a r y w i n d i n g . A b o v e 8 0 V A C g e t s c o n n e c t w i t h a b o v e s a m e c o n t r o l r e l a y c o i l t o g e t h e r w i t h s e r i e s v a r i a b l e r e s i s t a n c e t h r o u g h t h e a u x i l i a r y c o n t a c t s ( N O ) o f m a i n p o w e r f e e d i n g c o n t a c t o r . R e s u l t a n t i s a g a i n 2 4 V A C s u p p l y t o c o n t r o l r e l a y c o i l a n d r e s t 5 6 V C A d r o p s t h r o u g h a b o v e v a r i a b l e r e s i s t a n c e . D u e t o e a c h a c t u a l w e l d i n g o r a t i o n a b o v e c o n t r o l r e l a y g e t s d e - e n e r g i z e d a n d r e s u l t a n t s i g n a l f e e d s t o t i m e r a n d s u b s e q u e n t l y t i m e r g e t s r e s t a n d s h i f t s i t s t i m e c o u n t i n g . T h a t m e a n s a l o n g w i t h e a c h w e l d i n g o p e r a t i o n t i m e r g e t s r e s e t a n d s h i f t s f o r w a r d . S a m e p r o c e d u r e a s D e s i g n c o n c e p t - 3 R e s t o f a l l o t h e r s t e p s o f o p e r a t i o n s e q u e n c e s a r e s a m e a s D e s i g n c o n c e p t - 3 - 3 2 - 1 ' 4U 0V AI /~---- ------ --~--- ---~-- ------ ------ ------ ------ r----- ---t-- ------ --- ~ '" J ST EP D OW N PO WE R TR AN SF OR ME R(T F-2 ) . ,. . C1 \ -- -- -~ ~II j I I I I I 22 0V AC I I I I I - J - - - ~llr l j I I I ~1\ ~_j 24 VA C I MC B 16 A TR AN SF OR ME R ST AN D- BY C1 -1 _ _ . . _ C1 -2 _ _ . . _ ' - - - - - - - - - - , - - - - W _ E L _ D _ IN _ _ ,G TR AN SF OR ME R(T F - 1) 1 ~) 1 ~ V1 ~ V2 {5 VA C OR B OV AC ) \ I ~,f. < ' (24 VA C OR 4 00 VA C) I ~ I - o- __ ,_ _ C1 -3 - 5 V A C - ST EP U P PO WE R TR AN SF OR ME R r 'fY YY YY Y' - {T F- 3) Fl( 1 A ) ill ill F2 ( 1A ) 1 K V AR IAB LE R ES IST ER { VR ) (SE T AT 5 75 J L ) - 3 I L r t y ~- -- -~ ~--o ---- ---J C1 -1 1 -~ - - B O V A C - - L _ _ _ - 5 6 V A C - - 2 4 V A C -I I I 1 V3 R2 C1 -4 (24 VA C OR O VA C) I R2 TR AN SF OR ME R ON R1 PO WE R ON ** C1 -M AI N CO NT AC TO R. ** T- TIM ER (R ES ET 1 YP E) ** R1 & R2 - RE LA YS . DE SIG NE D BY : A.D .M .JE ET H AU TO MA TIO N EN GI NE ER CO LO MB O DO CK YA RD P LC . F IG .- 4. 3 CO NT RO L CI RC UI T FO R IN DU ST RI AL W EL DI NG TR AN SF O RM ER TO IS OL AT E PR IM AR Y W IN DI NG FR OM TH E 44 0V A C M AI N SU PP LY D UR IN G ID LI NG (D ES IG N- 4) - 33 - 4 . 5 . 2 C a l c u l a t i o n o f r e s i s t e r v a l u e f o r V a r i a b l e r e s i s t e r w h i c h h a s u s e d i n c o n t r o l c i r c u i t . 2 4 V A C R e l a y C o i l V a r i a b l e r e s i s t o r R 1 Z ! _ R ? Z 7 v 1 V ? v F i g u r e 4 . 4 - R e s i s t o r a r r a n g e m e n t t o m a i n t a i n r e q u i r e d v o l t a g e a c r o s s r e l a y ( R 1 ) S p e c i f i c a t i o n o f s u b j e c t e d r e l a y ( R 1 ) M a k e : O M R O N T y p e : M Y - 4 R a t e d s u p p l y c o i l v o l t a g e : 2 4 V A C R e s i s t o r v a l u e o f r e l a y c o i l : 1 5 6 n R 1 - R e s i s t o r v a l u e o f 2 4 V A C r e l a y c o i l = 1 5 6 n R 2 - R e s i s t o r v a l u e o f V a r i a b l e r e s i s t o r V 1 - V o l t a g e d r o p a c r o s s R 1 V 2 - V o l t a g e d r o p a c r o s s R 2 V - T o t a l v o l t a g e d r o p a c r o s s R 1 & R 2 O p e n c i r c u i t v o l t a g e ( d u r i n g i d l i n g ) a c r o s s s e c o n d a r y w i n d i n g t e r m i n a l s o f w e l d i n g t r a n s f o r m e r i s v a r y f r o m 6 8 V A C t o 7 5 V A C d e p e n d o n t r a n s f o r m e r c u r r e n t s e t t i n g . - 3 4 - S h o r t c i r c u i t v o l t a g e ( d u r i n g w e l d i n g o p e r a t i o n ) a c r o s s s e c o n d a r y w i n d i n g t e r m i n a l s o f w e l d i n g t r a n s f o r m e r i s v a r y f r o m 2 3 V A C t o 5 7 V A C d e p e n d o n t r a n s f o r m e r c u r r e n t s e t t i n g . M i n i m u m v o l t a g e ( V ) t h a t c a n a p p l y a c r o s s b o t h R 1 & R 2 t o e n e r g i z e r e l a y d u r i n g o p e n c i r c u i t ( w h e n t r a n s f o r m e r i n i d l i n g ) = 6 8 V A C M a x i m u m v o l t a g e ( V ) t h a t c a n a p p l y a c r o s s b o t h R 1 & R 2 t o d e - e n e r g i z e r e l a y d u r i n g s h o r t c i r c u i t ( w h e n t r a n s f o r m e r i n o p e r a t i o n a l ) = 5 7 V A C B y m e a s u r i n g f o l l o w i n g c h a r a c t e r i s t i c s w e r e f o u n d f o r r e l a y c o i l ; M i n i m u m v o l t a g e t o e n e r g i z e d s u b j e c t e d r e l a y = 1 6 V A C M a x v o l t a g e t o d e - e n e r g i z e r e l a y = 1 0 V A C U s i n g o h m s l o w [ 6 ] a n d d o i n g r e p e a t e d c a l c u l a t i o n s f o r d i f f e r e n t v a l u e s f o r R 1 f o u n d b e s t v a l u e f o r R 1 = 5 7 5 n , i n o r d e r t o c o v e r a l l a b o v e v o l t a g e r a n g e s d e p e n d s o n a l l c u r r e n t s e t t i n g s . 4 . 6 O p e r a t i o n p r o c e d u r e a c c o r d i n g t o t h e f i n a l d e s i g n . O p e r a t i o n P r o c e d u r e ; ( A ) I n i t i a l c o n d i t i o n : 1 . C 1 a t d e - e n e r g i z e c o n d i t i o n 2 . 2 4 V A C c o n n e c t s w i t h t h e p r i m a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r ( T F - 1 ) t h r o u g h t h e " N C " o f C 1 3 . O u t p u t v o l t a g e o f s e c o n d a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r i s a r o u n d 5 V A C 4 . A b o v e 5 V A C c o n n e c t s w i t h p r i m a r y w i n d i n g o f s t e p u p t r a n s f o r m e r ( T F - 3 ) a n d i t g e n e r a t e s 2 4 V A C o u t p u t a t t h e s e c o n d a r y w i n d i n g o f T F - 1 a n d i t c o n n e c t s w i t h R 2 ( 2 4 V A C r e l a y ) a n d R 2 g e t s e n e r g i z e d . 5 . R e s e t s i g n a l f o r t i m e r ( T ) g e t s o p e n t h r o u g h " N C " c o n t a c t o f R 2 - 3 5 - ( B ) H o w i t c o n v e r t s t o r u n n i n g c o n d i t i o n ; I . O n c e w e l d i n g e l e c t r o d e t o u c h e s w i t h g r o u n d 2 . R 2 g e t s d e - e n e r g i z e . 3 . R e s e t s i g n a l f o r t i m e r g i v e s t h r o u g h " N C " c o n t a c t o f R 2 a n d t i m e r s t a r t s c o u n t i n g . 4 . T i m e r g e t s e n e r g i z e d a n d i t g i v e s s i g n a l t o e n e r g i z e C I 5 . 4 0 0 V A C c o n n e c t s w i t h p r i m a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r ( T F - I ) t h r o u g h t h e " N O " o f C I 6 . N o w T / F i s r e a d y f o r w e l d i n g o p e r a t i o n 7 . A f t e r c o n n e c t s 4 0 0 V A C w i t h p r i m a r y , o u t p u t v o l t a g e o f s e c o n d a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r i n c r e a s e s u p t o 8 0 V A C 8 . A b o v e 8 0 V A C c o n n e c t s w i t h s e r i e s c o m b i n a t i o n o f R 2 & v a r i a b l e r e s i s t e r ( s e t a t 5 7 5 ' Q ) a n d r e s u l t a n t 2 4 V A C o u t p u t c o n n e c t s w i t h R 2 . T h e n R 2 g e t s e n e r g i z e . 9 . A g a i n r e s e t s i g n a l f o r t i m e r ( T ) g e t s o p e n t h r o u g h " N C " c o n t a c t o f R 2 I 0 . I f w e l d i n g o p e r a t i o n p e r f o r m s ( w e l d i n g e l e c t r o d e t o u c h e s w i t h g r o u n d ) a b o v e 8 0 V A C g e t s d r o p s a n d R 2 g e t s d e - e n e r g i z e . I I . R e s e t s i g n a l g e n e r a t e s f o r t i m e r ( T ) a n d t i m e r g e t s r e s e t a n d s t a r t s c o u n t i n g . I 2 . D u e t o e v e r y w e l d i n g o p e r a t i o n t i m e r g e t s r e s t a n d k e e p s o n c o u n t i n g a n d s h i f t s f o r w a r d . 1 3 . I f i t f a i l s t o g e n e r a t e n e x t r e s e t s i g n a l f o r t i m e r w i t h i n t h e s e t t i m e ( 3 m i n u t e s ) t h a t m e a n s n o w e l d i n g p e r f o r m s , t h e n T g e t s d e - e n e r g i z e d . C 1 a l s o d e - e n e r g i z e d . A g a i n 2 4 V A C c o n n e c t s w i t h t h e p r i m a r y w i n d i n g o f w e l d i n g t r a n s f o r m e r . T r a n s f o r m e r a t i d l e c o n d i t i o n a n d c o n v e r t s i t t o i n i t i a l c o n d i t i o n . - 3 6 - 4 . 7 F u n c t i o n a l b l o c k d i a g r a m a c c o r d i n g t o t h e f i n a l d e s i g n . S t a r t I n i t i a l l y m a i n p o w e r f e e d i n g c o n t a c t o r i s a t d e - e n e r g i z e d s t a t e . 2 4 V A C s u p p l y c o n n e c t w i t h p r i m a r y w i n d i n g o f t h e w e l d i n g t r a n s f o r m e r t h r o u g h a u x i l i a r y c o n t a c t s ( N C ) o f m a i n p o w e r f e e d i n g c o n t a c t o r . C h e c k t h e o u t p u t v o l t a g e a t s e c o n d a r y w i n d i n g O V A C 5 V A C P r o v i d e s i g n a l t o e n e r g i z e t h e m a i n p o w e r f e e d i n g c o n t a c t o r a n d s u b s e q u e n t l y 4 0 0 V A C c o n n e c t s w i t h p r i m a r y w i n d i n g a n d g e t s s t a r t t o c o u n t C h e c k t h e o u t p u t v o l t a g e a t s e c o n d a r y w i n d i n g O V A C 8 0 V A C P r o v i d e r e s e t s i g n a l f r o m c o n t r o l r e l a y t T i m e r & s u b s e q u e n t l y s h i f t t h e t i m e r s e t t i n g f o r w a r d F i g u r e 4 . 5 - F u n c t i o n a l b l o c k d i a g r a m a c c o r d i n g t o t h e f i n a l d e s i g n . C h e c k t h e t i m e v a l u e o n t i m e r > 3 M i n u t e s < 3 M i n u t e s - 3 7 - C h a p t e r 5 E n e r g y s a v i n g c a l c u l a t i o n s a n d c o s t b e n e f i t a n a l y s i s . 5 . 1 M a t e r i a l u s e d f o r c o n t r o l c i r c u i t a n d t h e i r c o s t M a t e r i a l s f o r p r o p o s e d c o n t r o l c i r c u i t I t e m D e s c r i p t i o n Q t y U n i t p r i c e T o t a l p r i c e N o R s . R s . 1 T i m e r w i t h r e s e t f a c i l i t y , s u p p l y : 2 2 0 V A C 1 N o 3 , 0 0 0 . 0 0 3 , 0 0 0 . 0 0 2 M a g n e t i c c o n t a c t o r , s u p p l y 2 3 0 V A C c o i l , 2 P o l e 1 N o 6 , 0 0 0 . 0 0 5 , 0 0 0 . 0 0 3 C o n t r o l r e l a y M Y - 2 , 2 4 V A C 1 N o 2 5 0 . 0 0 2 5 0 . 0 0 4 C o n t r o l R e l a y , 2 2 0 V A C C o i l v o l t a g e , 2 P o l e 1 N o 3 5 0 . 0 0 3 5 0 . 0 0 5 S t e p d o w n p o w e r t r a n s f o r m e r , P r i m a r y 4 0 0 V A C & S e c o n d 2 4 V A C , 2 3 0 V A C 1 N o 7 0 0 . 0 0 7 0 0 . 0 0 6 S t e p u p p o w e r t r a n s f o r m e r , P r i m a r y 5 5 0 0 . 0 0 5 0 0 . 0 0 V A C & S e c o n d 2 4 V A C 1 N o 7 V a r i a b l e r e s i s t e r , 1 K 1 N o 4 0 . 0 0 4 0 . 0 0 8 P o w d e r c o a t e d w e a t h e r p r o o f m e t a l 1 , 3 2 5 . 0 0 1 , 3 2 5 . 0 0 e n c l o s u r e S i z e : 4 0 0 x 3 0 0 x 1 5 0 m m 1 N o T o t a l R s . 1 1 , 1 6 5 . 0 0 T a b l e 5 . 1 - M a t e r i a l l i s t f o r o n e u n i t w i t h t h e i r p r i c e s - 3 8 - 5 . 2 M e a s u r i n g o f a c t u a l a c t i v e p o w e r c o n s u m p t i o n o f w e l d i n g T / F w h e n i d l i n g w i t h o u t i m p l e m e n t i n g n e w s y s t e m I t w a s m e a s u r e d b y u s i n g a c t i v e p o w e r e n e r g y m e t e r . S p e c i f i c a t i o n s o f u s e d e n e r g y m e t e r a s f o l l o w s . S p e c i f i c a t i o n s o f t h e u s e d e n e r g y m e t e r : M a k e : P o l y p h a s e E n e r g y m e t e r T i m e R e a d i n g o n e n e r g y m e t e r ( k W h ) 0 8 . 3 0 H o u r s 2 . 5 4 1 3 . 5 3 H o u r s 6 . 5 5 1 8 . 4 8 H o u r s 1 0 . 9 6 T a b l e 5 . 2 - M e a s u r e d d a t a a b o u t a c t i v e p o w e r c o n s u m p t i o n o f w e l d i n g T / F w h e n i d l i n g w i t h o u t i m p l e m e n t i n g n e w s y s t e m A s p e r a b o v e t a b l e a c t i v e p o w e r c o n s u m p t i o n f o r 1 0 . 5 h o u r s = I 0 . 9 6 - 2 . 5 4 = 8 . 4 2 k W h 5 . 3 E n e r g y s a v i n g c a l c u l a t i o n [ 7 ] D u r i n g g e n e r a l s t e e l f a b r i c a t i o n o p e r a t i o n , I f t r a n s f o r m e r u s e s f o r a v e r a g e 1 0 h o u r s p e r d a y g e n e r a l l y i t w i l l i d l e a r o u n d 6 h o u r s ( 6 0 % ) . a s p e r t h e m e a s u r e m e n t t a k e n a s m e n t i o n e d u n d e r c h a p t e r 4 . 6 . 4 P o w e r l o s s d u r i n g a b o v e i d l i n g 6 h o u r s [ 8 ] = ( 8 . 4 2 k W h I I 0 . 5 h o u r s ) x 6 h o u r s 4 . 8 1 k W h F o r o n e T / F p o w e r l o s s p e r d a y = 4 . 5 k W h - 3 9 - T o t a l N o o f T / F i n y a r d i n o p e r a t i o n a l = 6 8 5 N o s T o t a l p o w e r l o s s p e r d a y f o r a l l t r a n s f o r m e r u n i t s = 6 8 5 x 4 . 5 = 3 0 8 2 . 5 k W h T o t a l l o s s = 3 0 8 2 U n i t s C E B a v e r a g e c h a r g e p e r u n i t = R s . 7 . 0 0 T o t a l l o s s p e r d a y = 3 0 8 2 x 7 = R s . 2 1 , 5 7 4 . 0 0 S a y N o o f w o r k i n g d a y s p e r m o n t h : 2 5 d a y s T o t a l N o o f w o r k i n g d a y s p e r y e a r = 3 0 0 d a y s A v e r a g e a n n u a l l o s s f o r a l l 6 8 5 N o s o f t r a n s f o r m e r s = 3 0 0 x 2 1 , 5 7 4 . 0 0 = R s . 6 , 4 7 2 , 2 0 0 . 0 0 5 . 4 C a l c u l a t i o n o f s i m p l e p a y b a c k p e r i o d [ 7 ] A v e r a g e a n n u a l l o s s = 3 0 0 x 2 1 , 5 7 4 . 0 0 = R s . 6 , 4 7 2 , 2 0 0 . 0 0 T o t a l m a t e r i a l c o s t t o m a k e o n e c o n t r o l u n i t f o r o n e u n i t = R s . 1 1 , 1 6 5 . 0 0 T o t a l N o o f T / F i n y a r d i n o p e r a t i o n a l = 6 8 5 N o s T o t a l m a t e r i a l c o s t f o r a l l 6 8 5 N o s o f u n i t s = R s . 7 , 6 4 8 , 0 2 5 . 0 0 S i m p l e p a y b a c k p e r i o d = = R s . 7 , 6 4 8 , 0 2 5 . 0 0 I R s . 6 , 4 7 2 , 2 0 0 . 0 0 1 . 2 y e a r s 5 . 5 C o m p a r i s o n b e t w e e n a c t i v e p o w e r c o n s u m p t i o n o f w e l d i n g T / F w h e n i d l i n g w i t h & w i t h o u t i m p l e m e n t i n g n e w s y s t e m f o r o n e m a c h i n e . T i m e R e a d i n g o n e n e r g y m e t e r R e a d i n g o n e n e r g y m e t e r ( k W h ) w i t h o u t ( k W h ) w i t h i m p l e m e n t i n g i m p l e m e n t i n g n e w s y s t e m n e w s y s t e m 0 8 . 3 0 H o u r s 2 . 5 4 1 0 . 9 6 0 1 3 . 5 3 H o u r s 6 . 5 5 1 1 . 1 8 3 1 8 . 4 8 H o u r s 1 0 . 9 6 1 1 . 4 0 7 T a b l e 5 . 3 - R e a d i n g o b s e r v e d f r o m e n e r g y m e t e r - 4 0 - T i m e R e a d i n g o n e n e r g y m e t e r R e a d i n g o n e n e r g y m e t e r ( k W h ) w i t h o u t ( k W h ) w i t h i m p l e m e n t i n g i m p l e m e n t i n g n e w s y s t e m n e w s y s t e m 0 8 . 3 0 H o u r s 0 . 0 0 0 . 0 0 0 1 3 . 5 3 H o u r s 4 . 0 1 0 . 2 2 3 1 8 . 4 8 H o u r s 8 . 4 2 0 . 4 4 7 T a b l e 5 . 4 - A c t u a l e n e r g y c o n s u m p t i o n a f t e r d e d u c t i n g i n i t i a l m e t e r r e a d i n g . S u m m a r y B e f o r e i m p l e m e n t i n g n e w s y s t e m a c t i v e p o w e r c o n s u m p t i o n f o r 1 0 . 5 h o u r s = 1 0 . 9 6 - 2 . 5 4 = 8 . 4 2 k W h A f t e r i m p l e m e n t i n g n e w s y s t e m a c t i v e p o w e r c o n s u m p t i o n f o r 1 0 . 5 h o u r s = 1 1 . 4 0 7 - 1 0 . 9 6 0 = 0 . 4 4 7 k W h P o w e r s a v i n g f o r 1 0 . 5 h o u r s , b e t w e e n n e w a n d o l d c o n v e n t i o n a l s y s t e m = 8 . 4 2 0 - 0 . 4 4 7 = 7 . 9 7 3 k W h - 4 1 - C h a p t e r 6 C o n c l u s i o n N e w s y s t e m w a s p r a c t i c a l l y i m p l e m e n t e d a n d t e s t e d f o r l o n g p e r i o d o f t i m e i n d i f f e r e n t w o r k c o n d i t i o n s i n C o l o m b o D o c k y a r d P L C w i t h e x i s t i n g c o n v e n t i o n a l w e l d e r s b u t n o b e h a v i o r a l c h a n g e s w e r e o b s e r v e d a f t e r i m p l e m e n t i n g n e w s y s t e m . K e y p o i n t i s d u r i n g d e s i g n i n g m a d e s p e c i a l a t t e n t i o n n o t t o c h a n g e e x i s t i n g c o n v e n t i o n a l w e l d i n g p r o c e d u r e a n d n o t t o i n t r o d u c e a d d i t i o n a l e x t e r n a l s e n s o r s a n d c a b l e s o t h e r t h a n c o n v e n t i o n a l w e l d i n g e l e c t r o d e a n d c a b l e . A f t e r i m p l e m e n t i n g p r o p o s e d s y s t e m f o r a l l w e l d i n g t r a n s f o r m e r s i n y a r d i t w i l l b e a g r e a t e c o n o m i c a l b e n e f i t t o y a r d a n d b y s a v i n g e n e r g y i t w i l l b e a s o l u t i o n a n d b e n e f i t t o e x i s t i n g p o w e r c r i s i s o f S r i L a n k a . E v e n i t c a n m a n u f a c t u r e a n d s e l l a s a c o m m e r c i a l p r o d u c t . V o l t a g e s e n s i n g b o a r d s [ 9 ] , w h i c h a r e c u r r e n t l y a v a i l a b l e i n m a r k e t , c a n b e u s e d i n o r d e r t o s e n s e v o l t a g e l e v e l s a t t h e o u t p u t t e r m i n a l s o f s e c o n d a r y w i n d i n g . S u b s e q u e n t l y c a n p r o d u c e s i g n a l s f o r c o n t r o l s y s t e m . B u t o n l y p r o b l e m i s t h o s e v o l t a g e s e n s i n g b o a r d a r e v e r y e x p e n s i v e . A n d d i f f i c u l t t o u s e t h o s e i n r u g g e d e n v i r o n m e n t , l i k e s h i p b u i l d i n g i n d u s t r y . S o s u g g e s t e d d e s i g n i s v e r y c h e e p a n d i t c a n u s e a n d a l r e a d y p r o v e d i t s o p e r a t i o n i n r u g g e d e n v i r o n m e n t . - 4 2 - R e f e r e n c e s : [ 1 ] h t t p : / / w w w . e s a b i n d i a . c o m / , O f f i c i a l W E B o f E S A B I n d i a . [ 2 ] h t t p : / / w w w . i n d i a m a r t . c o m / a r d e n t e n g i n e e r s / p c a t - d o c s / s t a n d a r d - a r c - e q u i p m e n t 1 0 6 7 9 9 1 4 . p d f , O E M S p e c i f i c a t i o n s o f a i r c o o l e d a r c w e l d i n g t r a n s f o r m e r M a k e : E S A B I n d i a L i m i t e d K o l k a t a , M o d e l : T r a n s w e l d 4 0 0 . [ 3 ] h t t p : / / w w w . s a i l . c o . i n / I P S S / 1 - 0 7 - 0 0 1 - 9 5 . p d f , I N T E R P L A N T S T A N D A R D - S T E E L I N D U S T R Y , S P E C I F I C A T I O N S F O R A R C W E L D I N G T R A N S F O R M E R S ( T H I R D R E V I S I O N ) . [ 4 ] U s e r M a n u a l o f s u b j e c t e d a r c w e l d i n g t r a n s f o r m e r , M a k e : E S A B I n d i a L i m i t e d K o l k a t a , M o d e l : T r a n s w e l d 4 0 0 . [ 5 ] U s e r M a n u a l o f F l u k e S c o p e M e t e r 1 0 5 B S e r i e s I I , 0 / 1 - M a r - 1 9 9 6 . [ 6 ] h t t p : / / w w w . p h y s i c s . n c s u . e d u / c o u r s e s / p y l a b s / 2 1 2 / d o c s / 2 1 2 O h m s L a w . p d f , O h m s L o w a n d C o m b i n a t i o n s o f R e s i s t o r s , P Y 2 1 2 . [ 7 ] M o n c e f K r a r t i , " E N E R G Y A U D I T O F B U I L D I N G S Y S T E M S , A n E n g i n e e r i n g A p p r o a c h , O c t o b e r 2 0 0 0 . [ 8 ] h t t p : / / e n . w i k i p e d i a . o r g / w i k i / A C p o w e r , C a l c u l a t i o n o f A C P o w e r . [ 9 ] h t t p : / / w w w . r o s s e n g i n e e r i n g c o r p . c o m / v o l t a g e _ l e v e l _ s e n s o r . h t m , R O S S E N G I N E E R I N G C O R P O R A T I O N , V O T A G E L E V E L S E N S O R / I N T E R L O C K C I R C U I T S A N D M O D U L E S . - 4 3 - A P P E N D I X - A : S a m p l e s c r e e n s h o t s d u r i n g s t u d y o f o p e r a t o r ' s w o r k p a t t e r n f r o m F L U K E S C O P E m e t e r A . l S a m p l e s c r e e n s h o t s ~ b . $ l i . . . . J L _ . j i . . . . J l & i l l ~ 1 1 r n ; A C 1 2 0 0 0 1 0 0 0 0 o o r o 5 1 ) 0 0 4 0 0 0 Y 2 ! J O O 0 0 0 . . . . . . . . . . . n . . • • • • • • • • • • • _ j 2 0 0 0 4 0 0 0 • J J : : ' Fwke¥l.,.SooJ>!oi!ote<·~i!'M 1 1 1 l ! J O O O I 1 : l $ : 2 9 l > M . : . d I E J . [ J G J u : J C D E : J . · [ ] [ ] D [ ] D l&ill.~ ~~ ~ n m A C 1 2 { ) \ ) J 1 0 0 0 0 8 0 0 0 I ' w m 4 0 0 0 \ i 2 0 0 0 o m : x J [ ( ] 4 0 0 0 • l ' l " - ' f ? _ -~J]N~ D~~ iOIS!~ • 1 2 / H ' l / : X O S i f \ " ' e , . , H l : S f ' M : v s c a l l l ! . . 2 0 \ < . - t > w ; Y A I ' S t t ; " < W O O V " ' 3 0 i/Or~ " ' 0 1 0 3 0 0 . . ) . ) G ( 5 0 0 7 J ~ M < ! ! > « l u r t ' " 0 . . - a l o < l d ' . , • h r w r n u m • 0 0 0 V ~ " " " " " " " " ; - j rmtAC • 0 7 4 2 \ 1 . . . J --~ · " " · · 8 . - . -D~ablod .~J!Nam6 . . ~A( ' 0 $ e o o l 2 / 1 f 1 ' 2 0 0 3 i l l l ' e * - l l S d S P M i Y S t ' * " ' 2 0 V / D ! V " Y A ! S O " ; . " 4 0 0 0 \ i !xsca~e z 3 0 ~/0"' : • : . 4 . 1 0 \ , . 1 ) 1 C C ' 4 8 , > : S~t~ , . " . : 0 0 1 5 1 2 E J iMa>~Ol~ oc .. ~sx AOOOt ""X0Sl'V.J.. "·lOlA 0Z ,. .. os f HdSt'J~ l"' < Oitl~N '+~~0 Qr.-~~8;~~~ ."'.000 ,. I,!Jni~H ~IW"0"'WI~H IOCZSl OOC"' .o:;?ls :< 9£ts00"' ~rv:_._ JJ(I/S oc ... •:;s :··· /I.OOOt ··mlV/ "!at,\ az .. ~s .\ \"kk&ZSL l" liiJ.Jl BOOl/8\.lZ~., "'~!J ]\i~»l" WRN -PO!~~ a i< ll!it:s. . ! ·r~ ~~~-~~~"~J fiu~(t!;: 8Hf.fiJ OOOt OOD AOOOt> IXIO':l OOOOl OODZl OODt OODZ ooc OOK AOO or 00 09 0000 00 OOl 00 OC:l L!-~Ls!i;I<'W~ ,\((1(1 "''.UOlU'.JI~ ~~1\Qzu.BltllU<~H (t(l';f;:!l)((" a::'!S!' lStHTJJ" %0~> "JU/~ oc " ~·::>s >~ "'".0SlV/. "'•'5/ V4-:H2<:ltl"' ~! 81Xl&"Bl/Zl"' ~~() ! J'lf'illll,. ~N l___.tpq~!li'IJ lliiiil" 1)(10'-... : 1&>:- ElOi'l:. u 00 oz 0011 oo o;:: AOOOt 0003 IXIOB 00 OOl F gnt.Ji''l':t,:~tafJtiiQ@!i@¢1¥§1##'@ oou.: 000 oooz 00 08 0000> oo oz• F lidiS·IQI·l·:.r;t:l#iWJQ.i@¢.#§1@@1@ L\ £UO .. )~ rupw:\:1 '"'~H . /\((10 ,. M>llMH ~01'*'"0'"'~H (9(:gsj Of£ ,. "ZIS X €£9~:00,. ".1ll"1X "'10/"-oc .. ~~s x hOOO• '"40SfV.J., MIJI,'\ 0Z " .OS,.l, Hd6C3~l"' ow.1 oox:tSllll" #rl~ /\OOO "I)JnUJI!.~w ~~I091 ooc. Bt>lO.()J"" ()( . /d)10t 00(!3 OOO:t F '·€*·4·''*:1~ ,tii:lfi¥QQ!IM'·f4¥$4'N 000 00 oz 0000 OOOZl F ttkifJ.IQI:t.:.rJj~l!tdQf4l1@¢·#§i@QiN A P P E N D I X - B : L i t e r a t u r e a b o u t i n s t r u m e n t a n d e q u i p m e n t s w h i c h w e r e u s e d B . l A t t a c h e d f o l l o w i n g a r e s o m e l i t e r a t u r e a b o u t i n s t r u m e n t a n d e q u i p m e n t s w h i c h w e r e u s e d d u r i n g m y p r o j e c t . 1 . T i m e r 2 . C u r r e n t s e n s i n g r e l a y 3 . C u r r e n t T r a n s f o r m e r s ( C T ) 4 . I n f o r m a t i o n a b o u t S C O P E M e t e r w h i c h w a s u s e d f o r d a t a l o g g i n g . 5 . I n f o r m a t i o n a b o u t v o l t a g e s e n s i n g a v a i l a b l e i n m a r k e t [ 9 ] - 4 9 - ~ll e l i ' \ < _ t o E S A B I n d i a . . . D D D D O : R e e l a m a t t o n C o n s u m a b l e s " " ' " " ' A r c E q u i p r n e n t I n d u s t r i a l G a s , . E q u t p m e n t " " ' E n v i : - o n m e n t P r o d u c t s T r a n s w e l d 4 0 0 - A i r c o o l e d w e l d i n g t r a n s f o r m e r f S i " - \ r r a n s w e l d 4 0 0 i s a 4 0 0 A m p M a n u a l A r c W e l d i n g T r a n s f o r m e r t h a t c O r ' 1 0 < n e s u n i q u e f u n c t i o n a l a n d s a f e t y f e a t u r e s . E n s u r e s e x c e l l e n t w e l d i n g q u a 1 , t y w i t h e c o n o m y . I t s n a t u r a l a i r - c o o l e d e n s u r e s n o n - s t o p p e r r o r m a n c e e v e n i n t h e m o s t u n c e r t a i n d i f f i c u l t c o n d i t i o n s . I d e a l f o r u s e a t " ' ' f ' o r i n a w o r k s h o p . S p e c 1 a l F e a t u r e s • N a t u r a l a i r c o o l e d m a c h i n e e n s u r e s m a x i m u m s a f e t y P a g e 1 o f 2 C u t t t i n g S y s t e m s " " ' " " ' • C u r r e n t a v a i l a b l e i n s i n g l e r a n g e . C u r r e n t i n d i c a t o r a n d c u r r e n t c o n t r o l h a n d l e b o t h o n f r o n t p a n e l • R o b u s t a n d c o m p a c t c o n s t r u c t i o n a b i l i t y t o w i t h s t a n d r o u g h h a n d l i n g a t s i t e s • H o r i z o n t a l s h u n t c o r e t r a v e l e n s u r e s p r e c i s e s e t t i n g a f t e r p r o l o n g e d u s e • C l a s s ' H ' i n s u l a t i o n p r o v i d e s l o n g e r c o i l l i f e O r d e r i n g N o . 4 6 1 - 0 6 4 1 - 4 0 0 T e c h n i c a l S p e c i f i c a t i o n s I n p u t S u p p l y V o l t a g e R a t e d I n p u t C u r r e n t R a t e d I n p u t K V A O u t p u t O p e n C i r c u i t V o l t a g e ( M a x i m u m ) R a n g e o f W e l d i n g C u r r e n t M a x i m u m C o n t i n u o u s H a n d W e l d i n g c u r r e n t a t 6 0 % d u t y c y c l e ( R a t e d w e l d i n g c u r r e n t ) T y p e o f w e l d i n g c u r r e n t r e g u l a t i o n T y p e o f c o o l i n g N e t W e i g h t ( A p p r o x ) . A p p r o x . D i m e n s i o n 1 p , , \ \ W . e s a b i n d i a . c o m / t r a n s w e l d 4 0 0 . h t m 4 1 5 V , 2 L i n e s o f 3 P h a s e s , 5 0 H z A C 6 3 A m p s 2 6 K V A 8 0 v 8 0 - 4 0 0 A m p s 3 0 0 A m p s S t e p l e s s N a t u r a l A i r C o o l e d 1 1 5 K g s 6 0 0 x 4 1 0 x 7 2 0 m m 4 / 2 6 / 2 0 0 9 S p e c i f i c a t i o n a b o u t c u r r e n t c o n t r o l r e l a y t h a t h a s u s e d - 4 4 , . * ' ' " " ' ' * ' . . , ~>'At Q f . J , t t ! • \i~-·~ H R U n I > M e m o r y H R : n T t ~-T1 , _ _ - _ , . J t _ ~ i J . d 2~- - · _ _ n b ' t _,~,~y u p o n s t a r t u p , a d J u s t a b l e o n f r o n t p a n e l ) I T 1 t e m p o n s a t 1 o n d ' h m 1 b 1 t i o n a u d e m a r r a g e ( r e g l a b l e e n f a 9 a d e ) " k , 1 1 1 g s v e r z 6 g e r u n g ( a n F r o n t s e i t e e i n s t e l l b a r ) I T i : t e m p o n z a c i 6 n d e 1 n h 1 b i c i 6 n e n e l a r r a n q u e ( a J u s t a b l e e n f a c h a d a ) c p c r H . J ' m l b l z l o n e a l l ' a v v 1 a m e n t o ( r e g o l a b i l e s u i p a n n e l l o a n t e n o r e ) ' : h - a f t e r t h r e s h o l d o v e r s h o o t ( a d j u s t a b l e o n f r o n t p a n e l ) I T t t e m p o n s a t 1 o n a l ' o u v e r t u r e a p r e s f r a n c h i s s e m e n t d u s e u d ( r e g l a b l e e n f a y a d e ) P ' 1 1 n a c h U b e r s c h r e 1 t u n g d e s G r e n z w e r t s ( a n F r o n t s e i t e e m s t e l l b a r ) I T t . t e m p o n z a c 1 6 n e n I a a p e r t u r a l u e g o d e l p a s o d e u m b r a ! ( a J u s t a b l e e n f a c h a d a ) r e · 1 · • e ~~l'apertura d o p o i l s u p e r a m e n t o d e l l a s o g l i a ( r e g o l a b i l e s u i p a n n e l l o a n t e n o r e ) ) H r _ \ . . t ! ' c ' ~- ' r _ , - , > l o s c h e n ! A p a g a d o / S p e n t a A O n I A l l u m e e I B r e n n t 1 E n c e n d 1 d o I A c c e s a * ~8~ B l i n k i n g / C l i g n o t a n t e I B l i n k t / l n t e r m i t e n t e I L a m p e g g 1 a n t e ' I ' > I U n Q 9 , : ) F F R ~) ~n~ R Q 9 h = 1 O F F ~ R ~) ~dr ' · ) N I > I < © ) N I < I < ~ T t ( 1 ) @ - ) N I < I < ~ T t ( 2 ) · . ) N I < I < ~ T t ( 2 ) < I - M o m , J : ; ) I ----~---j J N I > I < ~! '~~~~ I ~I : _ _ @ ~111 ~~ iR~SCJ ! : = N " I ~ 2 : ! N ' T ~~ ~~·~ON A ~,.: ~~ 1 < 1 > © ~ ~:8 O N I > 1 > '8~ ~~~- , , , ~~ON I > I > ®~ > J 1 rvic'''"'~~ 1 rv!com,JCvQ~ ~Tt(1) @ i T t ( 2 ) • r ; > J ¥ g O N Un~ ~·.·· _ _ - I > I > R ® 0 -~ i T t ( 2 ) i f ' J . _ - , , . ; ! _ j _ _ :x;r-~ . '----~ : ~ . . . : : " , ; r . r · ; , , , l , v : : , • r c · l r y ~ ~--~ ~~ON 1 < 1 > ® § · r o g r e s s T e m p o n s a t i o n e n c o u r s / Z e i t l a u f t / T e m p o r i z a c i 6 n e n c u r s o I T e m p o r i z z a z i o n e i n c o r s o ~! : B J n ; s ; t I N ' T '~ ~ @ ~111 I~ ' N , ~ ; I I~ ~ R ~) ~n~ iN~:~ I~ I N 7 I~ ~ e , e t t 1 m e d e l a y ( a d J u s t a b l e o n f r o n t p a n e l ) I F i n d e I a c o n s i g n e d e t e m p o n s a t i o n ( r e g I a b l e e n fa~ade) I E n d e d e s S o l l w e r t s d e r V e r z o g e r u n g , , ' t e l • b a r ) F i n d e I a c o n s 1 g n a d e t e m p o r i z a c t 6 n ( a j u s t a b l e e n f a c h a d a ) I F 1 n e d e l l ' i s t r u z i o n e d i t e m p o r i z z a z 1 o n e ( r e g o l a b t l e s u i p a n n e l l o a n t e r i o r e ) " A 0 2 3 1 4 T I M E D M U L T I F U N C T I O N , M U L T I - V O L T A G E O R S I N G L E - V O L T A G E R E L A Y - 1 D I N w i t h b a c k l i t d i s p l a y C E E N G L I S H 1 - T e c h n i c a l s p e c i f i c a t i o n s M o d e ! S u p p l y M u l t 1 v o l t a g e D C 2 3 0 V -~--~--~"-- - - - - 1 1 0 V 4 8 V : C ) ' · / I Y ' _ : _ , ( ) ' I T 2 4 V C ' ' 1 2 V H~:ll t:;~lc:;l:cJl:Jt- - , - m e Sf;t·t~:'] ' c J : ' C l t ? l v 1 a • J , J i U r J e S t : c l o : ' ' i l M : r w n L 1 r n r : : l _ . l s e c L : r 3 : t o n H e c o · / P I ) ~trne V o l t a g e f o r m s u : a t t o n t e s t O~crat:r:c; turn~:cr::.l.u'~ l n 1 1 1 s rul~; T y p e o f o u t 0 u t u . ! s - - ~YJ r 1 s~ltrt · m m ) 2 . S ' l l i T l ' : J C I ' T 1 S - s · o o · n s 2 ~ K \ J l ' 1 = i 5 0 F I " J f . ' " " ? . r - N t : l B ' , M a x 1 m u m p o w e r A C D C D e s c r i p t i o n , f r o n t v i e w a n d d i s p l a y F n o T / T - 1 1 ! : ' ' X 3 ~/-~· ' f l O n n 1 0 U 0 0 ' " • ' X 1 D O , o u 1 2 ± f f i . . . . . v n n . n n . ~,-, , - , . , - , , - , 1 . - : - - - ! h _ r n _ _ s . d _ X 1 0 Q J . _ : . f s C c c . r - c : : ; ' . i r 1 · r '.~r r-~~ 0 i r r . : : J e r e c t r . c d l C;Jnr·,ec~rc,ns o · r n u s : : J e p e r + c r T r ( Y _ : 8 · 1 q u a . f r e d o r ; r c ; c ; r l ' ' f : > · r : - · cor··c~rmrl·/ ' " · ' " ' f 8 Q ' . : I . : = t t · C I I S T h ; : r n r l r - , L . J a c u r e · dO~"S .~ot O S S t Y l r ! ? F l ' l j ' ~eSp0nS3:JI'It~. t r s e : : ; f t h + : : . . _ ; r o c u c t s w r 1 C i ' m u s t c : c w f o r m 1 0 p a r t · c t r l a r 8 1 1 \ J C ' r n e r 1 : o 1 : = J ' l r h : Y s L 1 r 1 d a c l s 2 - E L E C T R I C A L C O N N E C T I O N S s , . , , r t c r ma:·~s su~'P::r' c o n n e c t t h e ( : ; o w e r s u p p l y , d e p e n d , n g o r 1 t h e m o d e l , t o t e r ; n p a l s a a n d b c o : , r · . e c l i l l e r r t e · l u u e c \ " J 8 v • r : 8 I C ' · 8 r . r w : a l s 1 2 3 1 - ~Jorm3,1y q : : c r 1 c : c r n a C 2 C o n H n c r l 3 Norrn;_~,!·/ cor11cc~ S T A R T w · c J R E S E T bt.·tior~s c a n h e c o n n e c t e d t c t e r r T l l , . . . , , l l s R , X , S l l l ; ) L J : " J O T E : . n t h e s e r n s t r u c t 1 o n s t h e f o l l O W i n g c o n v e n t t o n I S u s e d ' n t r n n ~·'""''". 1 ' ~r , , r , , r h r ~-a_ b _ 1 _ 2 _ J _ _ _ R _ _ ! _ s _ : } ,-,ul 1 ~r , , r r 1 J t ' N - t t c . ' l l y c d • e u c > e n " " ' " ' ' w-~n S T A R T n n p e r m a n e n t l y 0 0 a l 1 g h t 3 - P R O G R A M M I N G F U N C T I O N S E L E C T I O N F 0 1 · T 1 ' ~J B 1 ' 1 ' " " ' , c M O D E k e - , • : n g ( ; J . : _ ; t : I • J r n n + 'F"o§T.~~ ' I ~ I P t = ' 3 E T • I n n u u , ! ~-'--j b l i n k 1 n g L + J I I ' : 1 .J'o~ ' ' . , r o g r . ' 1 : I I , ~ i ' ~~~ii-n.nn.! · • u u · u U i i l l j h ~, I A E S E ' : • + : i --~=~\ , , , : I f 1 l 2 T , ' I 1 1 9 T T , : T I M E S C A L E O n c P s e l e . - - ; h l n · s · T l a , l e ; - : : c ; r ; L r n • v v · , ! h O K i c . t ' l : ! : F 0 9 T , I · ! 1 . . . . . . . . . . ' ' ; ! 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I _ !L. ~? -~ ---~ _!J_ ~-~~ ~ -;~-r· =~~~ : :: I : :j 11 60 31 I 10 I 11 ! - - - ~ - - t - - - , -- , ~-? _ 6~ ~~ -+ -7 ~ 11 _ j 6i ) . 34 I 1, J n l 35 ·- ;t. m R >t O ut lin e dr aw in g a · _ _ £_ 1 C• n 0 1: . A _ _ (f -~ r _ _ l __ _ lf -- ·- f~ J~ f! i~ H - - - - - ~ " - - - Q RCT-35 Q RCT-58 Q . . RCT-90 RCTltO S T ir n R C T S er ie s. "'~ lil i :c l); - ~ . . ,.. ···~·-- ···-·· .... ~ .@I • Hu ke 92 B/9 6B /99 B/1 05 B Sc op e M ete r 0/ 1- M ar -1 99 6 © 19 96 F lu ke C or po ra tio n. A ll rig ht s re se rv e d. P rin te d in th e N et he rla nd s. Al l p ro du ct n a m e s a re tr ad em ar ks o f t he ir re sp ec tiv e co m pa ni es . ! A . ' j I ' I I ' ' Elt~ t.'f /t.. ?t11 ( / (1 /ks lu :;, C rJ ;() /z/ ; l ... · ;c l Us ers M an ua l F L U K E ® /o , v /;· . 9 7 :u ·· 1 ' ' 18 ' 111 11 ' .' l< l1i fli7 trJ IIIl O II 111 111 111 111 111 1 I lll t.! SI .• III .J II U! bl lll ill l.f UI III IIl ill it " 'lil lfi. l l fL !ili tiU IIIR IJI (IItf ltt! Pm lii!R IJJ la.u 11 111 11 / \ ~ltage L e v e l S e n s o r P a g e 1 o f 2 R o s s E N G I N E E R I N G ( o R P O R A T C o m p a n y \ / O L T A G E L E V E L S E N S O R U p : : : : t a n d a r d i \ 1 1 o d e l [ 1 e l u x e ~~·,10 d e l , l i t b V f J i t a g a A C lli~lt • ~ . . . ' · . ' •~1 - , i j i • -~·~.-.\ ? ! l - . . . ' ' " l i ~... -·~' 1 - U I V R I U U U V R M I 1 - l R I I V R M I ~"'~~•~-~- ~'"l I n t e r n a t i o n a l 8 - 1 0 V O L T A G E L E V E L S E N S O R / I N T E R L O C K U s e f u l f o r P o w e r S u p p l y V o l t a g e L i m i t e r , C a p a c i t o r C h a r g e L e v e l a n d , u n d e r o r o v e r V o l t a g e C o n t r o l , o r I n d i c a t i n g . R o s s E n g i n e e r i n g C o r p o r a t i o n w i l l c u s t o m b u i l d y o u v o l t a g e l e v e l s e n s o r I i n d i c a t o r I i n t e r l o c k f r o m o u r b b u i l d i n g b l o c k s . 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S o m e o f t h e m a n y o p t i o n s a v a i l a b l e a r e : • H i g h a c c u r a c y a d j u s t a b l e t r i p p o i n t . • H i g h s e n s o r i n p u t i m p e d a n c e f o r i n t e r n a l l i n e o r e x t e r n a l s e n s i f i g . . . • E x t r e m e l y f a s t r e s p o n s e o r a d j u s t a b l e d e l a y . • V o l t a g e l e v e l s e n s o r c a n b e p o w e r e d f r o m y o u r A C l i n e o r D C s o u r c e , 5 t o 1 5 0 V D C ( I f D C s o u r c e v o l t a g e b e i n g s e n s e d i t m u s t h a v e a c o m m o n c o n n e c t i o n ) , a c t u a t e f r o m v o l t a g e w h o s e l e v e l i s b e i n g s e n s e d ( r e q u i r e s a t 0 . 0 1 a m p e r e f o r t r i p ) . C a n h a v e i s o l a t e d t r i p i n p u t . • V o l t a g e l e v e l s e n s o r c a n h a v e t r a n s i e n t p r o t e c t i o n i n s t a l l e d . • A C o r p o s i t i v e , z e r o o r n e g a t i v e v o l t a g e l e v e l c a n b e s e n s e d . • V o l t a g e l e v e l s t o ± 7 5 0 v o l t s c a n b e s e n s e d u s i n g r e s i s t o r s m o u n t e d i n t e r n ; : o n p r i n t e d c i r c u i t b o a r d . • V o l t a g e l e v e l s g r e a t e r t h a n ± 7 5 0 v o l t s c a n b e s e n s e d u s i n g e x t e r n a l v o l t a g d i v i d e r s . • V o l t a g e l e v e l s l e s s t h a n ± 1 m i c r o v o l t c a n b e s e n s e d u n d e r o p t i m u m c o n d i t • F i x e d t r i p p o i n t c a n b e b u i l t i n t o v o l t a g e l e v e l s e n s o r . • E x t e r n a l r e s i s t o r , o r a t r i m m e r p o t e n t i o m e t e r , o r a r e m o t e c o n v e n t i o n a l p o t e n t i o m e t e r m a y b e u s e d t o s e t v a r i a b l e t r i p p o i n t . : t l : ' \ \ ' W W . r o s s e n g i n e e r i n g c o r n . c o m / v o l t a g e l e v e l s e n s o r h t m 1 ( ) / 1 ( ; / ) ( ) ( ) g