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Testing procedure new generator

THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 1 of 20

TESTING OF GENERATOR
1. Visually inspect the machine for proper connection of Busbars; tightening
of all the nuts & bolts, right connection of Busbars, coils.

2. Check that there is no leakage from industrial water circuit.

3. Check Phase Synchronization at output of main MCCB, switch off DM water
MPCB, use dual channel oscilloscope for checking of phase synchronization

NOTE:
Ground lead of one probe preferably channel 1 should be grounded DO NOT
Ground both the probes leads.

Range Setting of Scope.


Voltage

200V/Div

Frequency

5ms/div

4. To confirm ‘R, S, T’ position check Busbar or wires from MCCB going to H.V.
Bridge Fuses.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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Page 2 of 20

R

A

T

S

A'

B'

B

C


C'

Wires going to fuses which are connected to.

A A”

is

‘R’ Phase

B B’

is

‘S’ Phase

C C’

is

‘T’ Phase

Now connect channel ‘A’ to ‘S’ Phase & note the position of waveform.
Keep channel ‘A’ connected and connect channel ‘B’ probe to ‘R’ Phase.
Note the waveforms.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
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Channel 'B'

Channel 'A'

R

'S'

Fig 1.

If you get waveform as fig 1; then R.S.T are in Phase. And;

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 4 of 20

Channel 'A'

Channel B
'R'

'S'

Fig 2.
If you get waveform as fig ‘2’ then R.S.T. sequence is not OK. Interchange
one wire from MCCB input side.
Once correcting the phases (R.S.T) reconfirm it as.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 5 of 20

'R'



60°

'S'

'T'

'R'

'S'

'T'

120° 180° 240° 300° 360°

5. After confirming ‘R, S, T’ sequence start the mains switch. The same
sequence to be confirmed at PCB Phase ‘R

R96, Phase ‘S’

R98 & Phase ‘T’ R-100.
To confirm the same R.S.T sequence at PCB
Set oscilloscope channel ‘A’ & channel ‘B’ as,
Channel A; and of probe must be earthed.
Voltage

200V/Div

Frequency

5ms /Div

Channel B
Voltage

10V /Div

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 6 of 20

Now connect at once channel ‘A’ to ‘R’ of mains & channel ‘B’ to
R – 96 ie. ‘R’ of PCB and observe the waveform they should be
In phase as shown.

Channel 'A'
Channel 'B'

Similarly you will get the waveform at ‘S’ of mains & R-98, & ‘T’ of
Mains and R-100.

6. Check proper functioning of emergency circuit.

7. Fill D.M. Tank with De-ionized water start MPCB of DM pump and check
its direction of rotation & correct it if required. Check very carefully that
there should not be any leakage from DM circuit. Check each & very
connections inlet & outlet, inverter bridge copper coolers, H.V. Bridge

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 7 of 20

copper coolers; if any leakage is found stop the machine and correct it.

8. Check alarm circuit by forcing the alarms. Adjust industrial water pressure
switch and DM water pressure switch. Such that if pressure is less than ‘1’
bar alarm should be actual.

9. Reconfirm wiring of H.V. Bridge Trigger cards at PCB as well at Trigger
card. PCB and inverter card. Start circuit card, 6 L.V. card. Check that
wires of IUMF. TAMF & TA line are connected properly at right connector.
Also confirm wiring of voltage regulator.

10. Remove Busbar from output of filter choke.

11. Remove connector of Inv. bridge from Driver board 1077A.

12. Remove connector of H.V. Bridge from Driver Board 1077A.

13. Check Damped Oscillation.

Connect the oscilloscope to the A.C. Busbar at Inverter Bridge as shown.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 8 of 20

+VE
y-1

x-1
x-2
y'-1

A

B

A.C
BUSBAR

y'-2

y-2
x'-1
x'-2
-VE

TVMF PRI MARY

Setting of oscilloscope to check damped oscillation.
Voltage

200V/Div.

Frequency.: 200µSec.

If you have facility of Trigger ON. In scope use for the testing of
Damped oscillation.

Connect live probe of scope to cathode of x-2 & ground lead to
Cathode of y-2. Press start push button switch.
Damped oscillation will be produced.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
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Note frequency of damped oscillation.
If damped oscillation is not produced then check.

a) Charge at start capacitor.
b) Firing pulses of start trg. card
c) After pressing start P.B. Switch start capacitor should discharge.

14. Once damped oscillation is achieved, check gate pulses with damped
Oscillation to be sure the firing sequence of inverter is correct. Remove
L.V.Trigger cards input wire. Connectors of inverter bridge which was
removed from 1077A should now be connected.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 10 of 20

Use both the channels of oscilloscope. Connect channel ‘A’ live to
Cathode of X – 2 and earth to cathode of Y – 2.
Connect channel ‘B’ only live probe to gate of Y – 2. Adjust voltage of
Channel ‘B’ to 5 Volt / div.
Be sure earth of channel ‘ B ‘ probe is removed.
Now press start push Button.

Not correct.
Interchange wire of Sec.of TVMF

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 11 of 20

Pri

Pri

Sec

Sec

Red Black

Black Red

After changing the wires reconfirm the wave forms.

OK.
15. Now connect input wire of L.V.Trigger card and start the m/c.
From now onwards only one channel will be used.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
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Channel ‘A’

Voltage Range

Frequency Range

100V/div.

100µSec.

Connect Channel ‘A’ Probe across inverter thyristor X – 1.

Live probe to Anode and ground probe to cathode of X - 1.
Start P.B. Switch ; waveform at Oscilloscope should be as.

VFl

Tc Tn Tf

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
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Note frequency; Tc, Tn, Tf, VFl.
For all the thyristors X, X’, Y & Y’.
Tc

Time conduction.

Tn

Time Natural off

Tf

Time off force

Vlf

Force off voltage level.

Wave form across each inverter thyristor should be noted very precisely
and should be same for every thyristor.
If waveform across 1 thyristor is.

OR

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 14 of 20

OR

Other thyristor also should have same waveform.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 15 of 20

16. Check L.V. Gate Pluses.
Connect oscilloscope probe at gate of L.V. module. When start P.B. is
pressed.
L.V. gate pluses appear as:

F

V

Check frequency of gate pulses and amplitude:
Also check DC voltage with multimeter and D.C. Ripple with Oscilloscope

D.C Voltage of L.V. Bridge should be about Secondary .Voltage of
L.V. Transformer X 1.35, for checking DC ripple increase voltage
setting of oscilloscope to 50V/div or 100v/div and remove Trig. keep it at free run.
Probe live to be connected at +ve and gnd. of probe at –ve.
When start P.B. is pressed, waveform of L.V. DC ripple will be

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 16 of 20

'0'

17. After checking L.V. gate pulses, check gate pulses of Inverter thyristors.

They should be same. Note conduction time of each thyristors.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 17 of 20

CONDUCTI ON TI ME

18. With multimeter check Vmf at busbar & check that it matches with the Vmf
displayed on the display board.
After completion of Inverter testing in low voltage. Connectors at 1077A for
High voltage to be fixed (which was removed earlier).

19. Checking of H.V. Ripple
Connect Oscilloscope probe to H.V. Bridge. Live of probe to be connected at
+ve bar & gnd. to –ve busbar.
Start the machine, after 2-3 seconds D.C. will develop & go to full value.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 18 of 20

OK

Note the voltage D.C. & also frequency of Ripple.

If waveform of H.V. D.C. is,

OR

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 19 of 20

Then H.V. thyristors are not firing properly. Check gate pulses of H.V.
thyristors. While checking gate pulses at H.V. thyristor, be careful since A.C.
is present at the thyristors. So every time you connect or disconnect the
OCR probe put-off the Main MCCB.
Once high voltage is O.K. all the ripples are coming then stop the machine.
Put off MCCB, connect D.C. busbar which was removed from filter choke and
restart the machine.
Keep Potentiometer (for Vmf.) at min. level & start the machine. Machine first
works in low voltage & after 2-3 secs. It jumps to high voltage. Jump in Vmf.
from LV to HV should be atleast 100V. also monitor L.V. current, as soon as
machine jumps to HV, LV current drops to ‘zero’.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com


THE INDUCTION HEATING TECHNOLOGY

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ELIND INDUCTION FURNACES Pvt. Ltd
Page 20 of 20

Recheck Inverter thyristors in H.V. slowly increase the Vmf. & check the
Inverter thyristors once again.
Adjust current balancing of R, S, T, phase through trimmer P-19, P-20 & P-21.

ELIND INDUCTION FURNACES PVT. LTD.
Factory: B-1, 2 & 14, Jay Vijay Indl. Estate, Waliv Phata, Vasai (E), Dist. Palghar, Maharashtra, India.
Telefax: +91 9890718723/9022398015/9022998015; E-mail: info@elindinduction.com



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