NAVJEEVAN EDUCATION SOCITYS

POLYTECHNIC
Ganesh Nagar, Ganesh Path, Bhandup (w), Mumbai 400078.

CERTIFICATE OF APPROVAL OF PROJECT WORK

This is to Certify that Mr. / Miss. has satisfactorily carried out the project work entitled ELECTROMIZER PANEL for partial fulfillment of the Diploma in Electrical Engineering. of Maharashtra State Board of Technical Education , Mumbai for the Year 20102011.

PROJECT GUIDE EXTERNAL EXAMINER MEANING OF PROJECT P- Planning before carrying out work R- Raw material required for work

HEAD OF DEPARTMENT PRINCIPAL

O- Organization of work J- Joint effort put together in work E- Estimation of material required for work C-Costing of work T- Techniques of performing work

Index Page
Chap. 1) 2) 3) Description Abstract.. Introduction.. Need Electromizer panel .. Working Principal. List of the component. Function of component. Specification of component. Assembly of panel. Working. Pages

4)

Circuit Description Wiring diagram. Block diagram. Testing Mechanical test Electrical test. Calculation. Effect of induction load on electromizer. Technical note on life of electromizer Advantages Disadvantages Application Estimating & costing. Bibliography..

5)

6) 7) 8) 9) 10) 11)

Chapter 1

ABSTRACT
Electromizer is basically a lossless reactance coil which when introduced in a lighting circuit helps reduce the power consumption in discharge lighting devices like Mercury Vapor Lamps, Sodium Vapor Lamps and Fluorescent Tube Lights. It is a device which applies a reduced voltage to discharge lighting devices which results in a lower current flow through these. It is worthwhile to note here that the technical characteristics of discharge lamps are such that they allow reduction in power input without affecting the lumen output in the same proportion. Therefore the percentage of energy saved is substantially more than the reduction in light output. It has been proven over the past so many years that such reduction in light level (which is very insignificant) is not detectable to the naked eye and does not compromise the comfort level of the user to any appreciable extent. It is also necessary to point out here that the electromizer can be employed as an energy saver since, while resorting to energy saving, the device itself does not consume any significant quantum of energy (thus the term lossless). Generally the electromizer is supplied to the end user in the form of a panel complete with standard switchgear items like MCB at the input, LEDs for phase indication, By-pass Switch and any other switchgear - like Automatic tap selection feature, KW meter (analogue or electronic type), timer, etc... The panel is normally fabricated out of 14 /16 gauge CRCA sheets dually powder coated for long life and corrosion resistance.

Chapter 2

Introduction
In modern days ,electricity is an important part of our life and the requirement of electricity also increases with the lifestyle of the human being. So In order to maintain the electricity various inventions are taken into considerations to conserve and save the electricity for the future purpose. In many places, experiments have been conducted by a number of end users to save lighting energy by reducing the number of lighting point. Although it is quite true that such action will result in lesser energy consumption, it will also directly affect the illumination level (adversely) to a very substantial extent and which may not be acceptable. Typical examples can be cited as under.

Many inventions are done to minimize the total requirement of electricity, many experiment are done such as twin tube light fittings installed in a hall or office room, Removing one tube light from each of these fittings will result in a 50% energy saving but at the same time, will also result in the illumination level dropping by at least 50% (if not more considering other factors like the reflectivity of the walls, light fixtures etc.) Such drop would, in most cases be unacceptable. On highways or streets, experiments have been carried out by some end users to switch off one out of every three lights for some part of early night hours and two out of every three lights for the rest of the late night period. This solution will yield a saving of 33.33 % in the first case and 66.67 % in the second. However, this solution is not recommended for the main reason that dark & bright pockets are created on the road (like zebra crossing spot). This would make driving conditions hazardous due to non-uniform lighting However; installation of electromizer would maintain a uniform lighting level at all points on the road / highway. Although the general lighting level would reduce slightly, the uniformity of such slightly reduced lighting level would not compromise safety requirements appreciably however, such a solution will still yield a saving of between 20-35%. Electromizer is basically a lossless reactance coil which when introduced in a lighting circuit; helps reduce the power consumption in discharge lighting devices like Mercury Vapor Lamps, Sodium Vapor Lamps and Fluorescent Tube Lights. It is a device which applies a reduced voltage to discharge lighting devices which results in a lower current flow through these. It is worthwhile to note here that the technical characteristics of discharge lamps are such that they allow reduction in power input without affecting the lumen output in the same proportion. Therefore the percentage of energy saved is substantially more than the reduction in light output. It has been proven over the past so many years that such reduction in light level (which is very insignificant) is not detectable to the naked eye and does not compromise the comfort level of the user to any appreciable extent.

As explained earlier, the electromizer is basically a device which applies a reduced voltage to the lighting devices. A reduced voltage can also be applied by using conventional equipment like step down transformer, auto transformer, CVT, Voltage Stabilizer etc. However, what is important to note here is that such equipments, while managing to save energy consumption in the lighting devices, will also lose fair amount of energy within themselves. Here therefore, the efficiency of the equipment plays an important role. The electromizer being what we refer to as a lossless, reactance coil boasts an efficiency of better than 99.4% virtually over the entire loading range. We have tested this feature of electromizer coil at Central Power Research Institute (C.P.R.I.), Bhopal. Thus, the losses within the electromizer are well below 0.6%. Obviously, therefore, it consumes negligible amount of power itself and practically delivers almost all the input power to the lighting devise connected to the output but at a reduced voltage. Experiments were also conducted at many customer locations to verify this. Measurements of all electrical parameters like voltage, current, Watts, VA, VAR and PF were made at both the input and the output of the electromizer. The observations showed that the POWER as measured at the output was just about 0.1 0.35% less than that as measured at the input. From these observations it is clear that the efficiency measured up to almost a minimum of 99.65% and a maximum of 99.9%.

Need
The need of the electromizer panel is as follow:-

Efficiency - at least 1% better than apparently similar or comparable devices. A proprietary micro-processor based controller cum monitor (Montroller) for fault less operation & automatic database generation. Much higher efficiency than conventional devices like Ordinary double winding step down transformer, Lighting transformer, CVT, Voltage stabilizer, auto transformer etc. Highly superior engineering inputs in terms of design, layout, workmanship, reliability, ease of routine servicing, durability, quality of components and material used easy availability in the market as the raw material is used from all reputed manufacturers. Excellent level of support system for both pre and after sales In view of full-fledged service set-up at Kiekie to address Kiekie Cant. BOOT project for at least 13 more years where we already have installed app. 100 energy savers. Continuous product improvement ensures addition of latest features.

Flexibility to meet specific customer requirements. Highly competitive product pricing. Low pay-back period with Consistent higher savings Long zero-maintenance life. Increases life of discharge lights. Proven Durability.

Chapter 3

Working principal List of component

 Function of component Specification of component Assembly of panel

Working principal
At the starting condition, the supply is given to the input terminal of the panel thus, when supply is provided to the panel, the MCB connected across the phase wire is switch ON and thus the supply is passed to the KWH Meter and connected to the first terminal of the coil and the neutral from the supply is connected to the second terminal of the reactance coil then the Automatic-TapChanger Switch is connected across the load. On through tap changer switch we can change the mode of the panel and also setting of the panel, and to indicate the mode of saving and Indicating Lamp is used .Thus in short the electromizer panel works by saving the energy. Electromizer is basically a lossless reactance coil which when introduced in a lighting circuit helps reduce the power consumption in discharge lighting devices like Mercury Vapor Lamps, Sodium Vapor Lamps and Fluorescent Tube Lights. It is a device which applies a reduced voltage to discharge lighting devices which results in a lower current flow through these. It is worthwhile to note here that the technical characteristics of discharge lamps are such that they allow reduction in power input without affecting the lumen output in the same proportion. Therefore the percentage of energy saved is substantially more than the reduction in light output. It has been proven over the past so many years that such reduction in light level (which is very insignificant) is not detectable to the to the naked eye and does not compromise the comfort level of the user to any appreciable extent. It is also necessary to point out here that the electromizer can be employed as an energy saver since, while resorting to energy saving, the device itself does not consume any significant quantum of energy (thus the term lossless).

The electromizer delivers a minimum saving of 20% (subject to the load circuit being a segregated discharge lighting feeder and also the input voltage being not less than 240 VAC).

List of component
List of the materials MS-BOX of required size. MCB for the purpose of isolating.

LEDs Lamps, KWH Meter. Manually operated Tap Changer and Bypass switches . Reactance coil. Relay.

Function of component
1)

MS-BOX:-

Prior to taking up the panel for fabrication, a GA drawing showing details of construction and the BOM of switchgear used is sent to the client for approval. Details of dimensions, cable entries, cable glands, terminations, locations of meters, phase indicating LEDs, SFUs, etc have to be Okayed by the end user after considering his specific requirements as well as site conditions. On receipt of the original approved drawing and BOM, the panel is released for fabrication. The panel is fabricated out of CRCA sheet SWG 18 / 16 /14 as specified in the approved GA drawing & depending on various factors like the size of the panel, whether the panel is to be placed indoors or outdoors etc.. At the same time, the

doors and frames are made out of CRCA sheets of suitable SWG size. Prior to the start of activity of fabrication, the steel sheets are inspected for quality and thickness. Subsequently, when the panel is ready for powder coating, the entire structure is checked for surface evenness, dents, sharpness of corners, doors and walls alignment, welding of joints, brazing, etc. At the same time, the panel is checked for dimensional conformance with the approved GA drawing. All panels are treated by Seven-Tank process prior to powder coating. The fabricated panel then is sent for powder coating. Random checks are carried out at the powder coating facility to check conformance of process with specified norms like thickness of coat, temperature of oven, time duration of oven baking, colour shade (e.g. Siemens Grey - 631 etc.). On completion of process, the panel is inspected for evenness of powder coat, thickness (checked randomly at different points on the panel). The panel is then cleared for assembly.

It is made of a CRC sheet grade. It is depth in a 7 tank process. It consists of washing tank, cleaning tank, dry tank. In one tank the oil cleaning taken out from the panel. In second tank the dust is taken out from the panel. For remove corrosion it depth in third tank. In the fourth tank painting is given to the panel. In fifth tank the panel is heated. In sixth tank the panel is allow to cool. In seventh tank the panel is depth in the water for cleaning purpose. It is layer is given to a 50 to 70 micron. Size H W B 125 X 350 X 300 mm.

2) Miniature circuit breaker:MCB:A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once and then has to be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city. Origins:An early form of circuit breaker was described by Thomas Alva Edison in an 1879 patent application, although his commercial power distribution system used fuses.Its purpose was to protect lighting circuit wiring from accidental shortcircuits and overloads.

Operation

Circuit breakers are electrical switching devices for protecting and controlling the electricity supply to respective electrical circuits. Circuit breakers protect electrical circuitry from damage due to an overcurrent condition, such as an overload condition or a relatively high level short circuit or fault condition. Electrical systems in residential, commercial and industrial applications usually include a panelboard for receiving electrical power from a utility source. The electrical power is then delivered from the panelboard to designated branch circuits supplying one or more loads. Typically, various types of circuit interrupters are connected to the branch circuits to reduce the risk of injury, damage or fires. Circuit interrupters include, for example, circuit breakers, contactors, motor starters, motor controllers, other load controllers and receptacles having a trip mechanism. In the event an overcurrent condition occurs, electrical contacts within the circuit breaker will open, stopping the flow of electrical current through the circuit breaker to the equipment. Circuit breakers have an operating mechanism and trip means, such as a thermal trip assembly and/or magnetic trip assembly, which are automatically releasable to effect tripping operations and manually resettable following tripping operations. Overload protection is provided by a thermal element which, when heated by the increased current, will cause the circuit breaker to trip and interrupt the power. Use of circuit breakers is widespread in modern-day residential, commercial and industrial electric systems, and they constitute an indispensable component of such systems toward providing

protection against over-current conditions. Various circuit breaker mechanisms have evolved and have been perfected over time on the basis of applicationspecific factors such as current capacity, response time, and the type of reset (manual or remote) function desired of the breaker. Circuit breakers used in residential and light commercial installations are referred to as miniature circuit breakers (MCBs). Miniature circuit breakers are commonly used in the electrical consumer units of domestic dwellings and small industrial premises to protect and control the electrical supply to respective electrical circuits of the building. Miniature circuit breakers have been in use for many years and their design has been refined to provide an effective, reliable circuit breaker, which can be easily and economically manufactured on a large scale. Miniature circuit breakers often are single pole breakers and are configured to be installed in a cabinet that houses a plurality of such miniature circuit breakers. Miniature circuit breakers typically include an electrical contact mounted on a movable contact carrier which rotates away from a stationary contact in order to interrupt the current path. Such circuit breakers have molded insulative housings of standard dimensions sized to interchangeably plug into or bolt onto the hot stabs in a load center or panel board. Typically, there is a fixed contact attached to the housing and a movable contact coupled to an operating mechanism. The operating mechanism includes a movable handle that extends outside of the housing. The handle has essentially three stable positions: on, off, and tripped. These three positions tell the operator what condition the contacts are in when the handle is viewed. The operating mechanism may be actuated to move the contacts into a second, open position. The trip mechanism is automatically releasable to effect tripping operations and manually resettable following tripping operations. The trip mechanism may include a thermal trip capability, which responds to persistent low level overcurrents, and/or a magnetic trip capability, which responds instantaneously to higher overload currents. The thermal-magnetic device includes a bimetal which heats up and bends in response to persistent overcurrent conditions to unlatch a spring powered operating mechanism which opens the contacts which opens the separable contacts of the circuit breaker to interrupt current flow in the protected power system. For short circuit protection, an armature, which is attracted by the sizable magnetic forces generated in a magnetic core by a short circuit, unlatches, or trips, the operating mechanism. Miniature circuit breakers may be utilized in conjunction with arc fault and/or

ground fault trip mechanisms. Some miniature circuit breakers include a ground fault detection system that is operatively connected with the operating mechanism to open the contacts in the event of a line-to-ground fault or a neutral-to-ground fault. Such circuit breakers typically are referred to as ground fault circuit breakers. A common ground fault circuit used in such applications includes a toroidal coil (current transformer) for differential current sensing. The ground fault detection system of the ground fault circuit breaker typically includes a pair of spaced current transformers and a circuit board. The primaries of the current transformers are conductors that pass the current traveling through the circuit breaker through the central bores of the toroidal current transformers forming the secondary windings. The secondary windings of the current transformers are connected with the circuit board. A ground fault causes an imbalance which generates a signal in the winding of the toroidal current transformer. This signal is processed, typically by circuitry implemented on a printed circuit board, and energizes a solenoid which actuates the trip mechanism. The purpose of the ground fault detector in residential circuit breakers is to protect persons from electrical shocks and the accepted level for tripping is 5 ma of ground fault current. Molded case circuit breakers for light to medium industrial and commercial applications have a case molded from an electrically insulative resin. Such circuit breakers can be single pole or multi-pole. One pole circuit breakers of this type are typically three quarters to an inch thick. Two pole circuit breakers of this type have side-byside compartments for the poles making them proportionally thicker, but still relatively thin. For applications where ground fault protection is desired, the ground fault circuitry is housed in one compartment and the mechanical pole in an adjacent compartment. A load terminal is provided in such a miniature molded case circuit breaker by a rigid conductor which extends from the separable contacts within the housing to a terminal recess molded in the outer surface of the housing. 3) Indicating devices.

Light Emitting Diode It is use for the purpose of monitoring and indicating the mode of saving on the Electromizer. LEDs lamps are use in electromizer panel to indicate mode. In our panel have a five indicator lamps. They are use for indicating the incoming supply, minimum saving and maximum saving, and automatic control.

4) KW Meter:-

 True RMS 4 Digit measurement of KVA, KW & Power Factor. Conviniently accessed DIP Switch at rear for C.T Selection.C.T Selection from range of 30.0/5A to 1500/5A. Auto Scroll Facility Available. Accuracy Class : 1.0 Comact Standard DIN Flush Mounting. Size : 96mm X 96mm X 85mm.

It is use for the purpose of showing the watts consumed by the load and power factor drawn by the panel on the panel. This type of equipment is generally consider under the basic necessity of the panel But for the small panels having small loads an only a KWH Meters is provided

in the panels for calculations.

5) Bypass switch

Bypass switch
A bypass switch is a hardware device that provides a fail-safe access port for an inline monitoring appliance such as an intrusion prevention system (IPS), firewall, WAN optimization device or unified threat management system. In-line monitoring appliances are single points of failure in computer networks because if the appliance loses power, experiences a software failure, or is removed, traffic can no longer flow through the link. The bypass switch removes this point of failure by

automatically shunting traffic around the appliance whenever the appliance is incapable of passing traffic. A bypass switch has four ports. Two network ports create an in-line connection in the network link that is to be monitored. This connection is fully passive; if the bypass switch itself loses power, traffic continues to flow unimpeded through the link. Two monitor ports are used to connect the in-line monitoring appliance. During normal operation, the bypass switch passes all network traffic through the appliance as if it were directly in-line itself. But when the in-line appliance loses power, is disconnected, or otherwise fails, the bypass switch passes traffic directly between its network ports, bypassing the appliance, and ensuring that traffic continues to flow on the network link. In some products, when the bypass switch is shunting traffic around the monitoring appliance, the monitor ports revert to acting like a network tap, mirroring the half-duplex traffic received at the network ports to the monitor ports. In this mode, an attached IPS appliance can be used as an intrusion detection system (IDS) to passively monitor the traffic without affecting it. This mode is useful for analyzing the effectiveness of a signature set before switching to IPS mode and potentially disrupting network traffic. Multi-segment bypass switches provide a number of independent bypass switches in a single chassis, providing higher density in the equipment rack 6) Reactance coils:Generally it is the heart of the coil ,it is a step down type coil, in which a supply voltage is certainly step down at specific point. It works on the tap changer switch. The electromizer is having `series reactance coil with secondary compensation. Essentially it is a `voltage step-down' equipment which applies a reduced voltage to the lighting circuit thereby reducing power consumption in the lighting fixtures. The Inductor coil In its most basic form, an Inductor is simply a coil of wire. For most coils the current, ( i ) flowing through the coil produces a magnetic flux, ( N) that is proportional to this flow of electrical current. In our tutorials about electromagnetism saw that when electrons flow through a conductor a magnetic flux is developed around the conductor producing a relationship between the

direction of this flux around the conductor and the direction of the electrons flowing through the conductor, with this relationship being called, "Fleming's Left Hand Rule". But another important property of a wound coil exists, and that is a voltage is induced into the coil by this magnetic flux as it opposes or resists any changes in the electrical current flowing it. The inductor, also called a choke, is another passive type electrical component designed to take advantage of this relationship by producing a much stronger magnetic field than one that would be produced by a simple coil. Inductors are formed with wire tightly wrapped around a solid central core which can be either a straight cylindrical rod or a continuous loop or ring to concentrate their magnetic flux. The schematic symbol for a inductor is that of a coil of wire so therefore, a coil of wire can also be called an inductor. Inductors are categorized according to the type of inner core with the different core types being distinguished by adding continuous or dotted parallel lines next to the wire coil as shown below. Inductor Symbols

The current, i that flows through an inductor produces a magnetic flux that is proportional to it. But unlike a capacitor which opposes a change of voltage across their plates, an inductor opposes the rate of change of current flowing through it due to the buildup of self-induced energy within its magnetic field. In other words, inductors resist or oppose changes of current but will easily pass a steady state DC current. This ability of an inductor to resist changes in current and which also

relates current, i with its magnetic flux linkage, N as a constant of proportionality is called inductance which is given the symbol L with units of Henry, (H) after Joseph Henry. Because the Henry is a relatively large unit of inductance in its own right, for the smaller inductors sub-units of the Henry are used to denote its value. For example:

Prefix Milli Micro Nano

Symbol m n

Multiplier 1/1,000 1/1,000,000 1/1,000,000,000

Power of Ten 10-3 10-6 10-9

So to display the sub-units of the Henry we would use as an example: 1mH = 1 mille-Henry - which is equal to one thousandths (1/1000) of a Henry. 100uH = 100 micro-Henries - which is equal to 100 millionth's (1/1,000,000) of a Henry. Inductors or c/oils are very common in electrical circuits and there are many factors which determine the inductance of a coil such as the shape of the coil, the number of turns of the insulated wire, the number of layers of wire, the spacing between the turns, the permeability of the core material, the size or cross-sectional area of the core etc, to name a few. An inductor coil has a central core area, (A) with a constant number of turns of wire per unit length, (l). So if a coil of N turns is linked by an amount of magnetic flux, then the coil has a flux linkage of N and any current, ( i ) that flows through the coil will produce an induced magnetic flux in the opposite direction to the flow of current. Then according to Faraday's Law, any change in this magnetic flux linkage produces a self-induced voltage in the single coil of:

Where: N is the number of turns A is the cross-sectional Area in m2 is the amount of flux in Webbers is the Permeability of the core material l is the Length of the coil in meters di/dt is the Currents rate of change in amps/second A time varying magnetic field induces a voltage that is proportional to the rate of change of the current producing it with a positive value indicating an increase in emf and a negative value indicating a decrease in emf. The equation relating this self-induced voltage, current and inductance can be found by substituting the N2A / l with L denoting the constant of proportionality called the Inductance of the coil. The relation between the flux in the inductor and the current flowing through the inductor is given as: = Li. As an inductor consists of a coil of conducting wire, this then reduces the above equation to give the self-induced emf, sometimes called the back emf induced in the coil too: The back emf Generated by an Inductor

Where: L is the self-inductance and di/dt the rate of current change.

Toroidal Cores (Ring Cores)

Toroidal cores and ring cores offered by us have find usage in mains transformers and are wound from cold rolled grain oriented (CRGO) silicon steel strips to provide optimum performance. These toroidal cores and ring cores are wound by automatic core winding machine and are annealed in high vacuum furnace under protection atmosphere or in continuous tunnel furnace, which results in features like compact volume, light, low magnetic leakage and hum & high efficiency.

Toroidal Cores (Ring Cores)

Specifications
Sizes upto 700 mm OD In CRGO grades required by customer, duly wound and annealed in inert atmosphere Guaranteed No load current (AT /Cm) as per B-H Curve of particular grade In house testing facilities and 100% testing done on all Toroidal Cores

at flux densities specified by customers

Core Frame Assemblies

We offer clients high performance transformer cores, core frames, oriented core frame assemblies that find application in meeting the specific application demands of industrial and commercial transformers. These core frame assemblies are also duly assembled and tested for no load losses with dummy turns, which assure clients of their flawless and consistent performance. We have with us cutting-edge technical expertise to meet the specific manufacturing demands of core frame assemblies. These are offered for a wide range of transformers starting from 25 KVA to 5 MVA. Further, the high quality standards followed during the production stage also ensure optimum service life standards for core frame assemblies.

Specifications:
Miltered Lamination core frame assemblies upto 5 MVA with facilities to test no load losses off power analysis of our works.

CRGO Transformer Lamination Core

Premier Core Industries manufactures the following products : We manufacture Transformer Core Laminations for Power and Distrubution Transformer ranging from 10 KVA to 200000 KVA from Cold Rolled Grain Oriented (CRGO) steel in grades M2, M3, M4, M5, M6 and also the Hi-B CRGO grades of ZH, ZDKH, ZDMH, ORSI-H, TCH-O, TCH-1 etc. For more technical details on the various grades of CRGO steel We are able to deliver CRGO Transformer Lamination Cores as leg or sheet packet, according to your packing requirements, inside of wooden box or on the pallets.

7) Relay

Relay
A relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism mechanically, but other operating principles are also used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits),

or where several circuits must be controlled by one signal. The first relays were used in long distance telegraph circuits, repeating the signal coming in from one circuit and re-transmitting it to another. Relays were used extensively in telephone exchanges and early computers to perform logical operations. A type of relay that can handle the high power required to directly drive an electric motor is called a contractor. Solid-state relays control power circuits with no moving parts, instead using a semiconductor device to perform switching. Relays with calibrated operating characteristics and sometimes multiple operating coils are used to protect electrical circuits from overload or faults; in modern electric power systems these functions are performed by digital instruments still called "protective relays".

Basic design and operation

Simple electromechanical relay:A simple electromagnetic relay consists of a coil of wire surrounding a soft iron core, an iron yoke which provides a low reluctance path for magnetic flux, a movable iron armature, and one or more sets of contacts (there are two in the relay pictured). The armature is hinged to the yoke and mechanically linked to one or more sets of moving contacts. It is held in place by a spring so that when the relay is de-energized there is an air gap in the magnetic circuit. In this condition, one of the two sets of contacts in the relay pictured is closed, and the other set is open. Other relays may have more or fewer sets of contacts depending on their function.

The relay in the picture also has a wire connecting the armature to the yoke. This ensures continuity of the circuit between the moving contacts on the armature. When an electric current is passed through the coil it generates a magnetic field that attracts the armature and the consequent movement of the movable contact either makes or breaks (depending upon construction) a connection with a fixed contact. If the set of contacts was closed when the relay was de-energized, then the movement opens the contacts and breaks the connection, and vice versa if the contacts were open. When the current to the coil is switched off, the armature is returned by a force, approximately half as strong as the magnetic force, to its relaxed position. Usually this force is provided by a spring, but gravity is also used commonly in industrial motor starters. Most relays are manufactured to operate quickly. In a low-voltage application this reduces noise; in a high voltage or current application it reduces arcing. When the coil is energized with direct current, a diode is often placed across the coil to dissipate the energy from the collapsing magnetic field at deactivation, which would otherwise generate a voltage spike dangerous to semiconductor circuit components. Some automotive relays include a diode inside the relay case. Alternatively, a contact protection network consisting of a capacitor and resistor in series (snubber circuit) may absorb the surge. If the coil is designed to be energized with alternating current (AC), a small copper "shading ring" can be crimped to the end of the solenoid, creating a small out-of-phase current which increases the minimum pull on the armature during the AC cycle. A solid-state relay uses a thyristor or other solid-state switching device, activated by the control signal, to switch the controlled load, instead of a solenoid. An optocoupler (a light-emitting diode (LED) coupled with a photo transistor) can be used to isolate control and controlled circuits.

Specification of component
Miniature circuit breaker Company :- Indo Asian. Range Voltage Breaking capacity Insulation class ::::0.5 to 63 Amps. 240/415 V. 10 kA. class A.

KWH Meter
Voltage - : 230 V

 Frequency - : 50 HZ City ratio

- : 200/5 A - : 210 298/ 493-05 11 - : 143.75 Kwh

S/N

FS

Torodal core Coil Copper wire super enameled

Voltage

- : 230 V. - : 10 Amp -: 10 SWG

Current Size

Output voltage - : 200V, 205V, 210V Insulation class - : F class

Indicator lamp

Make Type Rating Frequency Unit

- : mine/ vanishing - : LED - : 230 V - : 50 HZ - : 3 Nos. -: 5

Quantity

Assembling of panel
The entire product can be split up in three parts as under: 1. `Electromizer reactance coils. 2. Panel enclosure 3. Switchgear items 1. Reactance coil The reactance coils are manufactured at the plant of company name M/s. Gilbert and Maxwell Pvt Ltd., Nasik. While the main inputs to the coil are enameled copper wire and CRGO core, other items like nuts-bolts, epoxy, insulation paper material, terminals etc are also used. a) Super enameled copper wire Electrolytic grade - meeting IS-13730 is used. The wire meets Class 'F' requirements of insulation (155 degrees C). The design temperature rise of the assembled coils is within Class 'B' requirements. b) Core: Made out of prime imported CRGO (Cold Rolled Grain Oriented) material meeting M4 or better specs. This is tested prior to use in `electromizer for guaranteed B-H curve and other parameters as per test certificate issued by the manufacturer. Tests are carried out to confirm that the B-H curve does not saturate over the entire design range of operation. The basic CRGO material is sourced from Japan or European countries like Spain, Italy or sometimes even USA. To the best of our knowledge, there is no known IS for CRGO material. The CRGO material used in the electromizer

reactance coils has a guaranteed loss of less than 0.9 Watts per Kg. c) Terminals Terminals and other hardware used is made out of extruded Ni plated brass. At the same time, tin plated electrolytic grade copper bus bars are used wherecurrent requirements demand. d) Insulation Insulation material of highest grade and appropriate thermal grade is used The Electromizer coils are rated for continuous operation at 100% load, approx. 6 hours for 110 % load, 30 minutes for 120% load and ALSO indefinitely for up to 115% over voltage. 2. PANEL: Prior to taking up the panel for fabrication, a GA drawing showing details of construction and the BOM of switchgear used is sent to the client for approval. Details of dimensions, cable entries, cable glands, terminations, locations of meters, phase indicating LEDs, SFUs, etc have to be Okayed by the end user after considering his specific requirements as well as site conditions. On receipt of the original approved drawing and BOM, the panel is released for fabrication. The panel is fabricated out of CRCA sheet SWG 18 / 16 /14 as specified in the approved GA drawing & depending on various factors like the size of the panel, whether the panel is to be placed indoors or outdoors etc.. At the same time, the doors and frames are made out of CRCA sheets of suitable SWG size. Prior to the start of activity of fabrication, the steel sheets are inspected for quality and thickness. Subsequently, when the panel is ready for powder coating, the entire structure is checked for surface evenness, dents, sharpness of corners, doors and walls alignment, welding of joints, brazing, etc. At the same time, the panel is checked for dimensional conformance with the approved GA drawing. All panels are treated by Seven-Tank process prior to powder coating. The fabricated panel then is sent for powder coating. Random checks are carried

out at the powder coating facility to check conformance of process with specified norms like thickness of coat, temperature of oven, time duration of oven baking, colour shade (e.g. Siemens Grey - 631 etc.). On completion of process, the panel is inspected for evenness of powder coat, thickness (checked randomly at different points on the panel). The panel is then cleared for assembly.

3. SWITCHGEAR & CABLES / BUSBARS / CONNECTORS: All incoming switchgear and cables / connectors and other hardware is checked for make / manufacturer, model & ratings conformance with order specifications. At the same time, each Contactor, MCB, MCCB, SFU, Timer, Voltage Relay is checked for operational performance. Any faulty material found is recorded and returned to the supplier for replacement. Bus bars & Cables as well as other hardware too are checked for quantity, make and size / specifications. After the incoming check, the ok materials are stored separately for use later.

At the time of assembly, all necessary switchgear materials are issued from the OK lot and tested once again prior to fitting in the panel.

The panels assembly will generally meet all relevant standards as specified in IS as specified for LT applications. This includes gasketing, cabling, ferruling, lugging, channeling, terminating, spacing, shrouding, labeling etc. as specified in the relevant IS.

On completion of assembly, the panel is once again tested for operational correctness as also for insulation resistance (HV and Megger tests). Correctness of input and output voltages is checked and recorded.

Working
The Manual model of Electromizer is a fully manually operated version consisting of the following: 1. Isolators (in the form of MCB) at the input and / or output for Switching load `ON' or `OFF' as also to isolate load as and when required for the purpose of maintenance. 2. Monitoring / indicating devices like Phase Indicating LEDs, KWHMeter.

3. Manually operated Tap Changer and Bypass switches. 4. Terminations and other connections at bus-bars / connectors etc. Generally the electromizer panel is made out of 14 /16 gauge CRCA sheets Duly powder coated for long life and corrosion resistance. The workmanship is of the highest quality with all internal cabling done to meet

Or exceed accepted standards in terms of bunching, gladding, lugging, ferruling, Channeling, insulating and bolting / termination. Similarly, only the best brands Of switchgear / cables like L & T, Siemens, GE-Also, Asian, Switching, Polycab, Finolex, Automatic Electric, Meco, Enercon, etc. are used. Special Attention is also paid to incorporation of safety norms as defined in relevant Standards.

Chapter 4

Wiring Diagram Block Diagram

Chapter 5

Mechanical testing Electrical testing Calculation Effect of induction load on electromizer

Mechanical testing

1) Looks - Neat & Clean 2) Firmness of terminal strips, terminals, holding bolts 3) Connections - Marking & Position 4) Labeling - Rating plate data shall be legible as specified 5) Overall dimension - As per customer's specs or our standard drawings

Electrical testing
01) Megger Test 02) H.V.Test 03) Polarity Test 04) Resistance Test 05) Inter turn Test

06) Ratio Test 07) Accuracy Test 08) OC & SC test 09) Heat run test (By using short circuit method) 10) Inductance 11) Regulation 12) Efficiency

Calculation

A sample calculation is given below:

Case 1.electromizer rated 1.5 KVA single phase. a.) NO LOAD LOSSES:Voltage applied 240 V No load current -19 milliamps = 0.019 amps Power factor - 0.9 No load losses = 240 x 0.019 x 0.9 = 4.10 w b.)COPPER LOSSES: - (BY DIFFERENTIAL CURRENT METHOD) Pass current - 5.33 amps Volts required - 9.7 volts Copper losses = 5.33 x 9.7 = 51.7 VA = say 52 W

Therefore: Output = 7500 VA = 7500 W Input = 7500 + 3 + 52 = 7555 W Therefore, % efficiency = Output = 99.20% /Input X 100

Regulation

REGULATION:
(NLV-FLV) (NLV) X 100

Typical values of regulation for various capacities for electromizer are:

A)

Better than 2%for rating up to 3.0 KVA

B) Better than 1.5% for rating 4.5 TO 7.5 KVA C) Better than 1.2% 9 for rating 0 TO 12.0 KVA & D) Better than 1% for rating above 12.0 KVA

EFFECT ON PERFORMANCE OF ELECTROMIZER ON NON LIGHTING DEVICE.

Generally, one finds, that in newly designed factories, manufacturing units or administrative buildings, the Electrical distribution system is planned in such a way that different types of loads are completely segregated. Thus a lighting subfeeder will have only lighting devices, a separate feeder will cater to Air conditioners and water coolers and yet another will feed computers, printers, fax machines and photocopiers etc. Such segregated distribution system helps during handling of maintenance related problems and also makes monitoring / load analysis of individual utilities easier. Such segregation, although desirable, is not always possible. This is particularly true in the case of old installations where sufficient advance planning has not gone into the design of the distribution system. As a result, over a period of time, practically all the feeders get mixed up and start feeding all sorts of loads. Thus the whole system becomes extremely complicated and therefore difficult to monitor and maintain. The electromizer is an energy saving device which works on a `reduction of voltage' principle. Applied to a lighting feeder, this helps reduce the power consumption in the lighting devices on account of reduction in current. This is possible due to the behavior of lighting devices which, by virtue of their principle of operation, consume lesser current on application of a lower voltage. The same is not true of other loads like motors, compressors and fans. These types of loads consume higher current on application of lower voltage (to enable driving of same load). One can very easily see here therefore that whereas by using voltage reduction devices, the power consumption in lighting devices can be reduced, presence of motors or compressors would result in a reverse effect - that of increased power consumption. The presence of motors or compressors in lighting feeders would therefore have

the following two implications: 1. While on the one hand, power consumption in the lighting devices will reduce, that in air conditioners will increase leading to increased power consumption instead of saving. This statement however needs to be qualified. The extent of damage or otherwise will depend on a number of factors like the percentage constituent of A/Cs, fans or motors out of the total feeder load, the technical characteristics and ratings of these devices, their age, extent of wear and tear etc. There is no known specific formula to calculate this factor. Only a practical trial would indicate the extent of negative effect on the energy saving. One thing is certain however. The energy saving percentage will definitely come down in the case of mixed loads. What remains to be seen is whether this figure comes down to a `less-than-acceptable' level of pay-back period.

Chapter 6

 TECHNICAL NOTE ELECTROMIZER

ON

EXPECTED

LIFE

OF

The electromizer is expected to have a much longer life as compared to other apparently similar devices due to the following reasons: 1. As you are already aware, any transformer would have certain losses. Higher the losses, higher will be the heating effect. The winding insulation deteriorates steadily on account of high temperature ultimately resulting in transformer failure. This is one of the main reasons of limited transformer life span.

The electrometer has a maximum loss of 1.4% in the worst case of unloading. In case of full load, the losses are totally approx. 0.6%. Now, let us consider two

cases when the transformer is: a) Unloaded and b) Fully loaded.

In the unloaded condition, the total current flowing through the transformer is negligible and therefore even though the total losses (core + copper) are comparatively higher at 1.4%, the net effect on the temperature is virtually NIL. Thus the winding remains cool. In the fully loaded condition, the losses themselves being very low i.e. 0.6 %, the copper losses (which form a further smaller part of this 0.6%) are negligible. Therefore in this case too, the temperature rise is not at all significant. In practice, you would notice that even at full load, if you were to touch the electromizer with your bare hands, it would feel as cool as the ambient (i.e. not even warm).Thus the deterioration of the winding insulation on account of heat is almost non-existent in the electromizer.

Chapter 7

Advantages & Benefits

1 2

Reduction in energy consumption in terms of kWh. Increase in the life of lighting equipments and lamps.

3 Reduction in repair and replacement cost.

4 5

Power factor correction. Reduction in the maximum demand and penalties if any.

6 Protection against Voltage Fluctuations. 7 Increase scope for acquiring Certified Emission Reduction. 8 All products are eligible for 80% Accelerated depreciation. 9 Considerable saving in Tax payments.
10

Short payback period.

11 Reduces heat load on air conditioners thereby saving more in ac bills Using an external bypass switch to connect an in-line appliance such as an IPS has several benefits 13 It keeps network traffic flowing when the in-line appliance fail
12

Chapter 8

Disadvantages

1)

Bypass switches add acquisition cost to the monitoring solution, although they may save cost in the long run by increasing network uptime Bypass switches move the single point of failure from the in-line monitoring appliance to the bypass switch itself.

2)

3) This should be a net gain in reliability, because the bypass switch is a simpler device than the monitoring appliance, and because it is designed for fault-tolerance. 4) Nevertheless, reliability is an important criteria when evaluating bypass switch solutions.

Chapter 9

Applications:
The electromizer finds application in energy saving in all types of discharge lamps like - FTLs, CFLs, HPSV, HPMV and MH lamps. Today, all these lamps are widely used in industry as well as office blocks and administrative buildings. Although electromizer can be used for incandescent lamps also, it is not advised due to the substantial illumination drop.

These include: 1. Automatic switching 'on' and 'off' of lighting feeders instead of Manual. This eliminates the possibility of excess power consumption due to lights being switched 'on' earlier than required and also being put 'off' later than necessary due to unpredictable human behavior.

2. Automatic variation in switching 'on' and 'off' of lights strictly on the basis of need depending on the seasonal changes in sunrise and sunset times. 3. Automatic application of optimum voltage depending on unpredictable input supply voltage to get best possible energy savings. 4. Automatic phase cutoff to enable cyclic switching 'off' of one, two or all three phases at user settable times in a sequential manner such that the same phase will not be put off on more than one occasion and at the same time in three nights.

APPLICATIONS Of ELECTROMIZER

Electromizer finds applications in all industry since lighting is an integral part of every activity. Typical areas where electromizer is employed are shop floors, plant lighting, administrative blocks, toilets, lobbies, corridors, storehouses, laboratories, streets, highways and any other locations where discharge lights like sodium vapor lamps, mercury vapor lamps, fluorescent tube lights, and CFLs & Metal Halide lamps are used. The electromizer is not suitable for use with T5 type of FTLs (which generally employ non-dimmable electronic ballasts) and also for use with any type of motive load (Three Phase Motors) In many places, experiments have been conducted by a number of end users to save lighting energy by reducing the number of lights. Although it is quite true that such action will result in lesser energy consumption, it will also directly affect the illumination level (adversely) to a very substantial extent and which may not be acceptable. Typical examples can be cited as under.

Twin tube light fittings installed in a hall or office room : Removing one tube light from each of these fittings will result in a 50% energy saving

BUT at the same time, will also result in the illumination level dropping by atlest50% (if not more considering other factors like the reflectivity of the walls, light fixtures etc.) Such drop would, in most cases be unacceptable. As against this, if electromizer were to be used, one would get energy saving to the tune of about 20-35% at the cost of a lumen drop of about 515% approx.

On highways or streets, experiments have been carried out by some end users to switch OFF one out of every three lights for some part of early night hours and two out of every three lights for the rest of the late night period. This solution will yield a saving of 33.33 % in the first case and 66.67 % in the second. However, this solution is not recommended for the main reason that dark bright pockets are created on the road (zebra effect). This would make driving conditions hazardous due to nonuniform lighting However; installation of electromizer would maintain a uniform lighting level at all points on the road / highway. Although the general lighting level would reduce slightly, the uniformity of such slightly reduced lighting level would not compromise safety requirements appreciably however, such a solution will still yield a saving of between 20-35%.

TECHNICAL APPLICATION Electromizer basically a lossless reactance coil which when introduced in a lighting circuit helps reduce the power consumption in discharge lighting devices like Mercury Vapor Lamps, Sodium Vapor Lamps and Fluorescent Tube Lights. It is a device which applies a reduced voltage to discharge lighting devices which results in a lower current flow through these. It is worthwhile to note here that the technical characteristics of discharge lamps are such that they allow reduction in power input without affecting the lumen output in the same proportion. Therefore the percentage of energy saved is substantially more than the reduction in light output. It has been proven over the past so many years that such reduction in light level (which is very insignificant) is not detectable to the naked eye and does not compromise the comfort level of the user to any appreciable extent.

It is also necessary to point out here that the electromizer can be employed as an energy saver since, while resorting to energy saving, the device itself does not consume any significant quantum of energy (thus the term lossless). The electromizer delivers a minimum saving of 20% (subject to the load circuit being a segregated discharge lighting feeder and also the input voltage being not less than 240 VAC).

Chapter 10

No Estimating of material 1 MS-BOX with powder coated

Quantity 1

Cost 850/-

(350X300X150mm) 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Step-down Torroidal Coil Miniature Circuit Breaker (230 V, 16 A) KW meter (230V, 5A) Indication lamps Tap changer switch Timer Relay Wires and Cables Lug (1.5 sq. mm) Sleeve Cable Tie MCB channel MCB lock Soldering Iron with flux Total Cost 1 1 1 5 1 1 1 10 Mtr 1 Pkg 5 Mtr 1 Pkg 15 Cm 4 Nos 3500/100/3000/350/250/2400/550/150/300/50/40/50/40/15/11645/-

Chapter 11

 Switchgear and protection - S.S.Rao. Power system V.L.Thareja. Principle of electronics S.Chand. www.google.com www.wikipedia.com

A Project Report On Electromizer Power Saving Panel

SUBMITED BY:-

Mr. PRASHNT G. DALVI Mr. PRASAD P. BHOWAR Mr. PRATHAMESH B. BHAVE Mr. AHIJEET DESAI GUIDED BY:PROF.:-

(909) (908) (906) (910)

NAVJEEVAN EDUCATION SOCITEYS BHANDUP (W) MUMBAI: 400078 * YEAR* 2010-2011