EnergyLine Systems Automatic Switch Control

Utility Control Products Qualification Test Report Summary

Utility Control Products

Automatic Switch Control

Model 5800 Series Product
Qualification Test Report
Summary

Revision A
Aug 1999

EnergyLine Systems, Inc.

Alameda, CA, USA

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EnergyLine Systems Automatic Switch Control
Utility Control Products Qualification Test Report Summary

Proprietary Notice

This document contains information which is proprietary to EnergyLine Systems and is provided under
the terms and conditions of a Purchase Order Terms and Conditions Agreement between EnergyLine and
each of its customers. Disclosure of information contained in this document to third parties without prior
written permission from EnergyLine Systems is strictly forbidden.
Information in this manual is subject to change without notice and does not represent a commitment on
the part of the vendor.
Copyright  1998 EnergyLine Systems, Inc.
All Rights Reserved. Printed in the USA.
EnergyLine and the EnergyLine logo are registered trademarks of EnergyLine Systems, Inc.
All other trademarks are the property of their respective holders.
EnergyLine Systems, 1135 Atlantic Ave, Alameda, CA, USA
Tel (510) 864-9300/ FAX (510) 864-6860

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Utility Control Products Qualification Test Report Summary

Contents

Testing Certification:______________________________________________________4
Introduction_____________________________________________________________5
General Test Set-Up ______________________________________________________6
Test Points______________________________________________________________7
Definition of Correctly Operating Unit ________________________________________8
Qualification Test Matrix __________________________________________________9

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Utility Control Products Qualification Test Report Summary

Introduction
This document summarizes the product qualification tests that were performed on the
Model 5801-SC Automatic Switch Control. The units tested were regular production
Switch Control's, without any special modifications. Each unit had a Metricom radio
installed in them.
Two units went through each test.

Document Conventions
The following conventions are used in this document:
BOLD UPPER CASE Labels on faceplates and assemblies; switch positions.
Italic Names of manuals, manual sections, and software
screens.
“Quotes” Names of software setpoints.

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General Test Set-Up

The test samples are either mounted on a wooden pole or placed on a tabletop. The
Switch Control is grounded using #6 AWG stranded copper wire. Line and neutral is
used to power the DUT using a standard wall outlet. A signal generator is used to
generate voltage and current sensor inputs if required by a specific test. A jumper is
installed on the PS/IO board, J1, across pins 1 and 3 to make the switch believe it is in the
closed position.
The initial state of the Switch Control’s is with the OVERCURRENT FAULT LED on,
the switch in the closed position, REMOTE/LOCAL switch in the REMOTE position,
and the AUTOMATIC OPERATION switch in the ENABLED position.
Before testing, the test samples are energized for a minimum period of 2 hours at room
temperature. Functional tests are performed before and after a type test. During a
transition from one test to another, the post functional test of one type test may be used as
a pre functional test of a succeeding type test.
The Switch Control’s go through each test separately.
Any variations in the above set-up are specified in the individual test.

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Test Points
The following test points were used in the type tests, unless otherwise noted in the test
description.
1. Line
2. External inputs
§ FIC-3 (24V-RET)
§ FIC-6 (24V-RET)
§ FIC-7 (SW-CLOSED STATUS)
§ FIC-8 (SW-OPEN STATUS)
§ FIC-9 (IA+)
§ FIC-10 (IB+)
§ FIC-11 (IC+)
§ FIC-13 (VA+)
§ FIC-14 (VB+)
§ FIC-15 (VC+)
§ FIC-21 (VISUAL DISCONNECT)
3. External inputs
§ FIC-1 (SW-OPEN)
§ FIC-2 (SW-CLOSE)
§ FIC-4 (+24V)

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Definition of Correctly Operating Unit

The Switch Control successfully passes a type test if the LCD operation is normal, the
data on the set-up software screens is normal and the Switch Control passes a functional
test after the type test.
To examine the set-up software screens, a PC is connected to the Switch Control. Once
communication is established with the controller, the following screens are observed:
1. SETUP: Miscellaneous - Time/Date section.
2. SETUP: Site-Related - voltage, current, and phase angles for all three phases and
neutral in the Real-Time Data section.
3. SETUP: Battery System - Cabinet Temperature.
4. TROUBLESHOOTING: Event Status - status of all errors logged (first display).
5. TROUBLESHOOTING: Event Status - status of all errors logged (second display).
6. TROUBLESHOOTING: Control & Switch Information - last entry in the Control
Power-Fail History log.
7. TROUBLESHOOTING: Switch Operations - last entry in the log.
8. OVERCURRENT FAULT: Fault Events - last entry in the log.
9. OVERCURRENT FAULT: AC Power Outages – last entry in the log.

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Qualification Test Matrix

The ELC-5801 (S/N 4976-03 and 4976-05) passed the qualification tests presented in the matrix below:
Test Specification Description Purpose Details
No.
1 EnergyLine Burn-in Test Verify no early life Tests units were burned in with the same
failures 24 hour profile as the temperature test.
2 EnergyLine Insulation Verify 2500V RMS The following test signals were used:
Withstand Test isolation between
2.5 kV RMS, 60 Hz, between any line
current-carrying power
voltage/neutral circuits and chassis
input conductors and
ground, for 1 minute with less than 1 mA
chassis ground.
leakage.
Verify 1500V RMS
between system
input/output conductors
and chassis ground.
3 IEEE C37.90.1- Surge Verify immunity to Two waveforms were used: oscillatory
1989 Withstand noise transients and fast transient. The waveform
Capability Test generated by protective characteristics are defined in sections 2.2
relays and relay and 2.3 of ANSI/IEEE C37.90.1-1989.
systems. Both waveforms were applied to each test
point.

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Test Specification Description Purpose Details

No.
4 EnergyLine - ESD Test Verify a minimum The following test signals were used:
derived from IEC acceptable tolerance to
Air discharge of +/-10 kV, one discharge
1000-4-2 1995 expected ESD events
per test point, 100 pF, 1500 ohm
and IEC 255-22-2 during use.
network.
1996
Direct discharge of +/-6kV, five
discharges per test point, 150 pF, 330
ohm network.
5 ANSI C62.41 – Power Line Verify adequate surge The test was conducted in accordance
1991 Section 9.1 Surge withstand capability to with the latest revision of ANSI
and ANSI Withstand surges simulating C37.90A, using the unipolar and ring
C37.90A Voltage and lightning strikes and waveforms. The test was performed using
Current Test other switching-type line-to-ground combinations.
transients on the main
A series of tests were performed with the
power lines.
phase angles shifted in increments of 15
degrees each.
Total number of surges was 504.
6 EN55022B and Electromagnetic Verify radiated The test was set up according to ANSI
ANSI C63.4 Radiation Test emissions are within C63.4. The limits were defined in
specified limits. EN55022B (CISPR22). The frequency
(accepted by
range was 30 MHz to 1 GHz. Manually
FCC for Part 15,
swept. Distance to antennae was 10 m.
Class B testing)

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Test Specification Description Purpose Details

No.
7 EnergyLine – Electromagnetic Verify immunity to The following test signals were used:
derived from IEC Susceptibility radiated emissions. 14 kHz - 512 kHz field strength = 10
255-22-1 and
V/m.
SAMA PMC 33.1
512.01 kHz - 22.99 MHz field strength =
5 V/m.
23 MHz - 1 GHz field strength = 10 V/m
1.01 GHz - 10 GHz field strength = 5
V/m

Keying Test:
14 kHz - 10 GHz field strength = 5 V/m
8 EnergyLine Line Voltage Verify operation over Checked operation at the following
Variation Test worst case line voltage voltages: 96 and 144 VAC.
conditions.

9 EnergyLine Momentary Verify resistance to line Twelve tests were conducted, beginning
Power Loss voltage interruptions with a simulated power loss of 0.5 cycle.
and verify safe This power loss was successively
operation when lengthened by 0.5 cycles, up to 6 cycles.
interruptions occur. The start of each successive test was
delayed by 1-minute minimum.

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Test Specification Description Purpose Details

No.
10 EnergyLine Power On/Off Verify that power 1. With Line voltage = 138 VAC.
Transition on/off transitions do not Rapidly toggled the line voltage off
create unwanted and on 8 times. Verified correct
operations. operation.
2. Repeated step 1 for line voltages of
120, 108, and 60 VAC.
11 EnergyLine Power Failure Verify correct Line power was disconnected when the
Back-up Test operation of the battery battery was fully charged and duration of
back-up system operation w/o primary power was
verified.
12 EnergyLine Brown-out and Verify correct Lowered the line voltage from 120 to
Single-phase operation of the battery 96V AC for six hours – verified correct
Test back-up system under operation. Lowered the line voltage to 60
brown-out conditions. V AC for six hours – verified correct
operation.
13 EnergyLine Temperature Verify operation under 1. Started at +20°C.
Cycle Test normal temperature 2. Ramped to +70°C in 2.5 hours.
variations.
3. Soaked at +70°C for 10.75 hours.
4. Ramped down to -40°C in 5.5 hours
5. Soaked at -40°C for 2.25 hours.
6. Ramped up to +20°C in 3 hours.
7. Repeated steps 1-6 seven times.
The last high temperature cycle was
ramped up to 85 degrees C.

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Test Specification Description Purpose Details

No.
14 ISTA Procedure Shipping Test Verify unit will survive A vibration and drop test was completed
1A, Method B normal shipping according to the specification.
environment.
15 EnergyLine Temperature Verify operation over 1. Started at +20°C.
and Humidity the specified 2. Ramped to +55°C in 2.5 hours.
Test temperature and
3. Soaked at +55°C at RH of 95% for 19
humidity range.
hours.
4. Ramped down to +20°C at RH of 75%
in 2.5 hours.
16 EnergyLine Failed Switch Verify the unit can Performed at 24 VDC. Fuse replacement
Rotor and Short survive a locked rotor was performed on test units.
Circuit Test. condition or short
circuits that may exist
in a switch.
17 NEMA-3R Enclosure Tests Verify that the The supplier of the Switch Control
enclosure meets the enclosure has provided certification for
enumerated the NEMA-3R rating.
specifications.

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