CUSTOMER/CLIENT:

Chromalox UK Tecmach L20541

PURCHASE ORDER NUMBER: B51822

DOCUMENT TITLE:

4239-23453 s/n 0315033

DESCRIPTION: ip42,400v,3/50,584kw,842a,2ckts
PROJECT NUMBER:
PROJECT NAME:
CUSTOMER/CLIENT REFERENCE NO. (IF ANY):

CUSTOMER REPRESENTATIVE'S SIGNATURE:

DATE:
RELEASE TO SHIP AUTHORIZED BY:
DATE:
COMMENTS:

Insp. By: ____Richard Follmer_______________

Signature: ___________________
Insp. Stamp:_____N/A____________
Date Cleared: ___03/18/15_____

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A-57902-02.xls

STANDARD TEST PROCEDURE

INSPECTION
CHECK BOXES

N Y S
1. DOCUMENTATION & COMPONENT CHECKS
a.

b.

Check with project engineering that all documents including drawings, parts lists &
ITP (Quality Plans) are at correct issue status. No amendments, customer
comments or approvals outstanding.
Check components comply against parts lists ie.identification numbers and codes

X
X

2. VISUAL INSPECTION
a.
b.
c.
d.

e.

f.
g.
h.
i.
j.
k.
l.
m.
n.

All equipment and components to be securely mounted.

All wiring terminations to be secure, and all terminal clamps to be checked
for tightness.
All terminals must be numbered, or otherwise identified, and correct to
approved drawings.
Identification wire numbers, on all control wiring, to be fitted and visible at each
wire end. Check that all numbering conforms to that shown on the appropriate
schematic diagram.
All panel mounted equipment, instruments and components are to have identification
labels, that conform to the Schematic diagram reference, fitted adjacent to the item,
secure and visible.
All components, fuse links etc must be checked for correct rating and type, against
approved drawings, data and parts list.
Panel mounted instruments must be properly earthed, with continuity maintained even
if an instrument is temporarily removed.
The control system assembly and wiring must conform completely to the Manufacturing
Data Instruction, approved drawings and good practice.
Ensure that wiring /wiring looms are not routed over sharp edges, if unavoidable ensure
protection is provided.
If fitted, check that the main isolator door interlock mechanism correctly and smoothly
engages with the operating shaft of the isolator body. Adjust if necessary.
Check that the Eltron rating plate is correctly marked and fitted securely.
Check general appearance of the control panel.
Ensure that all door mounted instruments and adjacent labels are level, and that the
exterior paint work is blemish free and clean.
Touch-up paint work where necessary with matching colour.

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X

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A-57902-02.xls

STANDARD TEST PROCEDURE

INSPECTION
CHECK BOXES

N Y S
3. MEGGER TESTING - INSULATION RESISTANCE
For CE panels or If required by customer specification as noted on RTP
a. Remove all primary fuse links and neutral links. Close isolator.
b. Apply a 500V dc megger test at terminals as follows:Main power input terminals, phase to phase and phases to earth (frame).
Volt free status repeat contact terminals, between and then each to earth (frame).
c. Log all data onto Test Record sheet.
d. Record test equipment plant numbers.

X
X
X
X
X

500Mohms
500Mohms

Inspection Check Key : N = Incomplete, Y = Accepted, S = Signature

4. FLASH TESTING - DIELECTRIC STRENGTH
For CE panels or If required by customer specification as noted on RTP
a. As 3.a above.
b. Apply a 2500V ac flash test at main power input terminals, phase to phase and
phases to earth (frame).
c. Apply a 1500V ac flash test at all volt free status repeat contact terminals,
between and then each to earth (frame).
d. Each of the above flash tests must be sustained for one-minute duration.
e. Log data onto Test Record sheet.
f. Record test equipment plant numbers.
5. MEGGER TESTING - RECHECK
For CE panels or If required by customer specification as noted on RTP
a. After flash tests, repeat the megger tests described in section 3 above.
b. Log all data onto Test Record sheet.
c. Record test equipment plant numbers.
d. Replace all fuse links and neutral links removed in 3.a above.
Check for correct ratings.
e. Open main isolator.

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X

1.27MA

X
X
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X

.64MA

X
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X

500Mohms
500Mohms

A-57902-02.xls

STANDARD TEST PROCEDURE

INSPECTION
CHECK BOXES

N Y S
6. FUNCTIONAL CHECKS - INITIAL SETTING-UP
a.
b.
c.

d.
e.
f.
g.
h.

Connect a main test supply at input terminals. Compensate for 60Hz if necessary
Connect a suitable test load at output terminals. Observe correct configurations.
Simulate the following input signals at the appropriate terminals:Remote switching.
Remote Temperature controller demand signal.
Temperature sensors from remote heater.
Any other external interlock signals.
Connect test lamps, with suitable supply, at all volt free status repeat
contact terminals.
Set any timers to the appropriate delay period. See schematic diagrams
for this information.
Set panel thermostats as appropriate (see schematic diagram).
Set all instrumentation to simulate normal running conditions.
Set the Thyristor Driver power demand potentiometer to 100%
and its mode switch to " AUTO ".

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X
X
X
NA

X
X
NA

X
X
X

7. FUNCTIONAL CHECKS - INITIAL ENERGISATION

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.

Energise the main test supply and close the panel main isolator.
This action should cause the controls supply to energise.
Check panel indicator lamps/annunciator for correct initial status.
Check also that the test lamps at volt free contact terminals indicate
their correct status.
Reset any trip conditions, and energise the test load by operating the necessary
"HEATER ON" switching.
The test load should now be drawing power in response to the demand signal
produced by the Temperature Controlling device.
Check that the power output to the test load can be adjusted and controlled by
varying the demand signal through the range 4-20mA.
Check that Thyristor output phase rotation is identical to that of the mains
input terminals. Should be anti clockwise.
Check that the Thyristor Driver power demand potentiometer can be used to limit
the average power output 0% to 100%.
Select " MANUAL " at the Driver mode switch. Check that the power output to the
test load can be adjusted and controlled from 0% to 100% by using the power
demand potentiometer, irrespective of the demand signal from the Temperature
controlling device.

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X
X
X
X
X
X
X
NA

A-57902-02.xls

STANDARD TEST PROCEDURE

INSPECTION
CHECK BOXES

N Y S
8. FUNCTIONAL CHECKS - SHUTDOWN AND TRIP FUNCTIONS
Check that the test load can be isolated by simulating shutdown conditions
as follows:a.

b.
c.
d.
e.

f.
g.
h.

i.

Operate normal panel mounted " HEATER OFF " switching. Ensure that the power
output to the test load is de-energised and that the appropriate panel indicator lamps
and volt free status repeat contacts are correct for this situation.
Check each Over temperature Cut-out unit for tripping by simulating an
over temperature condition at the remote sensors.
If fitted, check the Earth Leakage Trip unit for correct tripping and sensitivity,
by inducing a 0-1 amp test current through the FELT toroid.
Sensitivity must be set point +0% -50% mA.
As necessary, check panel tripping facilities for correct operation, sequence
and indication, both at the panel indicator/annunciator lamps and at the volt free
status repeat contact terminals, as follows:
Panel Air over temperature trip.
Thyristor Heat sink Over Temperature trip.
Thyristor Fuse Failure trip.
Cooling Fan Trip/Changeover.
Product Flow trip.
Etc., (list any additional panel tripping facilities)
Check the function of the panel anti-condensation heater. Check primary and
control switching.
If fitted, check panel Ammeters for correct operation by inducing a test current
through the appropriate toroid.
Check panel Voltmeter, in conjunction with its selector switch, for correct supply
voltage indication.
As this procedure has been prepared in general terms and is appropriate for all
standard thyristor control panels, please check for any non-standard design nuance or
addition, and inspect/test thoroughly as necessary.
List any additions etc.
Test engineer to complete the " INSPECTION/TESTING CHECK LIST ".

X
X
X
X

NA

X
NA
NA
NA
NA

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X

X
X
X

9. END OF TESTING
a.
b.
c.
d.
e.
f.
g.
h.

Remove all test supplies and test load.

Remove all test lamps, test switches and other test gear.
Replace any covers and screening removed during tests.
Check that they are fixed securely and that necessary warning labels are in place.
Remove all building rubbish, particularly copper wire strands, swarf and ash.
Ensure that the fuse directory and document pockets are fitted.
Mark up schematic diagrams with any as built changes for revision
by the drawing office.
Check that any ordered spare parts are available, complete and ready
for simultaneous packing and dispatch.

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X
X
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A-57902-02.xls

STANDARD TEST PROCEDURE

INSPECTION
CHECK BOXES

N Y S

Following test is optional not perfomed unless specified at additional cost

TEMPERATURE RISE TEST PROCEDURE FOR ELECTRIC HEATER THYRISTOR
CONTROL PANELS
If required by customer specification as noted on RTP
1. PROCEDURE
I.

Set up the control panel for a full load current temperature rise test
(reduced voltage if necessary).
ii. Full load current to be applied at each phase using the appropriate load banks.
iii. Arrange four temperature sensors, positioned as follows:Panel interior - adjacent to the thyristor driver unit.
Panel interior - mounted onto the top fin of the thyristor heat sink.
Panel exterior - Right hand side suspended in free air.
Panel exterior - Left hand side suspended in free air.
iv. Record all temperatures with a multi-point chart recorder.
Set chart speed at 50mm per hour.
v. Run test for a minimum of four hours after stabilising.
vi. Prepare test report.
viii. Record test equipment plant numbers.

X
X
X
X
X
X
X
X
X
X

Following test is optional not perfomed unless specified at additional cost

WAVE FORM ANALYSIS TEST PROCEDURE FOR ELECTRIC HEATER THYRISTOR
CONTROL PANELS
If required by customer specification as noted on RTP
1. PROCEDURE
i.
ii.

Set up the control panel for normal running, into a suitable test load.
Using a dual beam oscilloscope, monitor the output current and voltage waveforms,
at red phase only, in relation to varying levels of input demand signal.
iii. Check:
4mA to produce first power output pulse.
8mA to produce 25% output power.
12mA to produce 50% output power.
16mA to produce 75% output power.
20mA to produce 100% output power.
iv. Prepare test report and print-outs.
v. Record test equipment plant numbers.

2. LOAD CONTROL PLOT (IF REQUIRED)

If required by customer specification as noted on RTP
i. From the results obtained above, prepare a load control plot to indicate demand signal
to power output linearity.

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NA

A-57902-02.xls

STANDARD TEST PROCEDURE

INSPECTION
CHECK BOXES

N Y S
Following test is optional not perfomed unless specified at additional cost
RADIO FREQUENCY INTERFERENCE TEST PROCEDURE FOR ELECTRIC HEATER
THYRISTOR CONTROL PANELS
If required by customer specification as noted on RTP
1. PANEL RADIATED RADIO FREQUENCY
i.

Assess and plot the radio frequency interference that may be radiated form the
control panel using a spectrum analyser, amplifier, computer and close field probes
to cover 0 to 500 MHz.
ii. With the control panel set up for normal running, into a suitable test load and test
for radio frequency interference.
iii. Repeat these sweeps three times, with the panel output current varied as follows:0% output.
50% output (worst case).
100% output.
iv. Prepare test report and print-outs.
v. Record test equipment plant numbers.
Following test is optional not perfomed unless specified at additional cost
2. ELECTROMAGNETIC INTERFERENCE
If required by customer specification as noted on RTP
i.
Assess the effect of possible electromagnetic interference to instrumentation,
temperature control devices, and any other sensitive control equipment mounted on
or within the control panel.
ii. The tests should be carried out with the control panel operating normally, i.e. with
the doors closed and the output applied to a suitable test load.
iii. Use one watt RMS hand held transmitters, in the ranges 150 to 175 MHz and
440 to 470 MHz. These being the most common frequencies used.
iv. Operate the transmitter, with its aerial midpoint no more than 300mm from any
sensitive instrumentation and control equipment.
v. The tests should demonstrate that no part of the control system is impaired
or degraded during normal running.
vi. Prepare test report if these tests have not been witnessed by the client or
his nominated inspection representative.
vii. Record test equipment plant numbers.

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NA
NA
NA
NA
NA
NA
NA

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NA
NA
NA
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NA

A-57902-02.xls

Panel Part Number: 4239-23453

Panel Serial: 0315033
Test type
Megger Hi Voltage Test
Megger Low Voltage Test

Test Record Sheet

Voltage
400v
400v

Dielectric Hi voltage Test 600 vac

Dielectric Low voltage Test 120
Dielectric Hi voltage Test 400/480vac
Dielectric Low voltage Test 120

400v
120v

Dielectric Hi voltage Test 240 vac

Dielectric Low voltage Test 120
Megger Hi Voltage Test
Megger Low Voltage Test

400v
400v

Voltage to apply
500 vdc
500 vdc

Reading
> 10 Mohms
> 10 Mohms

2200vac
1250 vac

< 5ma
< 5ma

2000vac
1250 vac

< 5ma
< 5ma

1500vac
1250 vac

< 5ma
< 5ma

500 vdc
500 vdc

> 10 Mohms
> 10 Mohms

Reading Taken Test Sign.

500 Mohms
500 Mohms

Date
3/18/2015
3/18/2015

1.27ma
.64ma

3/18/2015
3/18/2015

500 Mohms
500 Mohms

3/18/2015
3/18/2015