Main Parts Introduction of SONGYANG Test Benches

Main parts of the test bench

1. List

No Part Name Model Option

1 Reference standard meter (RSM) Single Phase-----SY3803 / SY3804
Three Phase------SY3302 / SY3102 /
SY3102a / SY3102F
2 Signal Source Single Phase-----SY9001
Three Phase------SY9003
3 Amplifier Case SY9013
4 Switching Case SY9051
5 Insulation Current Transformer (ICT) SY9103
6 Multi Secondary Voltage Transformer SY9101
(MSVT)
7 Error Processor SY9030
8 Scanner Head HD101
9 Serial Ports Server NC916 / NC932 / HTC8048

2. Structure frame of the test bench.

a) Power source cabinet:

Page -1-
Main Parts Introduction of SONGYANG Test Benches

b) Front panel of mounting rack

Tower Warning Lamp

Scanner Head Port Error Display Unit (SY9030) P/F RST

FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
Error Display Unit (SY9030) P/F RST
FL
RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232

Error Processor
RS232 Port
O O O O O O O O O O
1 1 1 1 1 1 1 1 1 1
CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2 CT-POWER
2
3 3 3 3 3 3 3 3 3 3
4 4 4 4 4 4 4 4 4 4
5 5 5 5 5 5 5 5 5 5
CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6 CT-ALARM
6
7 7 7 7 7 7 7 7 7 7
8 8 8 8 8 8 8 8 8 8
RUN

Running Lamp
9 9 9 9 9 9 9 9 9 9
10 10 10 10 10 10 10 10 10 10
11 11 11 11 11 11 11 11 11 11
12 12 12 12 12 12 12 12 12 12
13 13 13 13 13 13 13 13 13 13
14 14 14 14 14 14 14 14 14 14
15 15 15 15 15 15 15 15 15 15
16 16 16 16 16 16 16 16 16 16
Alarm 17 17 17 17 17 17 17 17 17 17

Alarm Lamp
18 18 18 18 18 18 18 18 18 18

Neutral Cutting
19 19 19 19 19 19 19 19 19 19
20 20 20 20 20 20 20 20 20 20

FH, FL for Calibration

Neutral Current

Open-Link/Close Link
Scanner Movement

Emergency Button Emergency Button

Quick Connector

UA UA UA UA UA UA UA UA UA UA

UB UB UB UB UB UB UB UB UB UB

Voltage Terminals
UC UC UC UC UC UC UC UC UC UC

UN UN UN UN UN UN UN UN UN UN

c) Rear panel of mounting rack

ON ON ON ON ON ON ON ON ON ON

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

FL FL FL FL FL FL FL FL FL FL
RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232 RS-232

CT-POWER CT-POWER CT-POWER CT-POWER CT-POWER CT-POWER CT-POWER CT-POWER CT-POWER CT-POWER

CT-ALARM CT-ALARM CT-ALARM CT-ALARM CT-ALARM CT-ALARM CT-ALARM CT-ALARM CT-ALARM CT-ALARM
G
0V1
232Z10P1706 RUN
MT5 MT4 MT3 MT2 MT1
G 5V G 5V

MT10 MT9 MT8 MT7 MT6

PC10 PC9 PC8 PC7 PC6

PC5 PC4 PC3 PC2 PC1

R
0V2
Alarm

S2 S1 SW3SW2SW1SW4 CZ1

SJDQ1705

0V
IB/IN Link 24V
24V
0V
UAUB

UA

UJDQ1705
UN
UA/UB

UNSW1705
UN

BYP1705
Ncut

24V 0V
R 0V2
UNSW1705 UNSW1705 UNSW1705 UNSW1705 UNSW1705 UNSW1705 UNSW1705 UNSW1705 G 0V1
BYP1705 BYP1705 BYP1705 BYP1705 BYP1705 BYP1705 BYP1705 BYP1705 BYP1705 P-24V Er-Led1705

UA UA UA UA UA UA UA UA UA UA

UB UB UB UB UB UB UB UB UB UB

UC UC UC UC UC UC UC UC UC UC

UN UN UN UN UN UN UN UN UN UN

WJ302-A WJ302-A WJ302-A WJ302-A WJ302-A WJ302-A WJ302-A WJ302-A WJ302-A WJ302-A

WJ302-B WJ302-B WJ302-B WJ302-B WJ302-B WJ302-B WJ302-B WJ302-B WJ302-B WJ302-B

WJ302-C WJ302-C WJ302-C WJ302-C WJ302-C WJ302-C WJ302-C WJ302-C WJ302-C WJ302-C

ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) --- ICT ( SY9103 ) ---
10# 9# 8# 7# 6# 5# 4# 3# 2# 1#

Page -2-
Main Parts Introduction of SONGYANG Test Benches

3. Description of main parts

a) Reference standard meter

Multifunctional standard meter is the high precision electric power measure meter
using international newest figure electron technique and on the basis of the DSP high
speedy processor.

May test and show systemic voltage (V), current (A), active power (W), reactive power
(VAR), frequency(Hz), power factor (PF), phase angle(θ),apparent power(s), the electricity
quantity and the output energy impulse. The show is using character gather LCD menu,
which is clear, operate easily, function set is convenient, it is the brainpower electric power
test instrument.

Standard meter is the main standard equipment of the facility. Compare all the tested
meters to the standard impulse, account the error of the tested meter. Please consult
installation setting to install the standard meter.

SY3803 SY3804

SY3302 SY3102

SY3102a SY3102F

Page -3-
Main Parts Introduction of SONGYANG Test Benches

b) Signal source
It is controlled by a single chip microcomputer, outputs both small voltage and current

signals, meanwhile, receives orders from any button (or personal computer), perform such

operations as frequency modulation, amplitude modulation, and phase modulation on output

signals, and conducts controls on relays based on current values and orders transmitted and

also on various error calculators of meter hangers. Also, on signal source’s front board there

exist one keyboard and one LED display which are the windows for man-machine dialogue, and

it is this keyboard through which we send out orders to let the equipment work. LED’s function is

to display signals, information on watt-hour meter to be calibrated, and calibration status.

Moreover, on signal source’s panel there exist one DIP switches and six small red lights; DIP

switch is to configure keyboard operation/computer connection and small red lights are to

display power amplifiers’ protection status (if any signal fails, the corresponding small red light

will give out light, accompanied by a buzz sound). The following figures are signal source’s

schematic diagrams of its front and rear views.

Page -4-
SY8330 Service Manual

c) Power amplifier
Power amplifier uses the most advanced technology of Pulse Width Modulating power

operation amplifier. It has designed a perfect protection system for overloading voltage short

circuit and overloading current open circuit. It has speedy limit current protection system and

keeps the power amplifier in steady working.

Three-phase power source contains voltage-current-power amplifier, current amplifier,

voltage amplifier. Input signals include voltage signals, current signals.

Page -5-
SY8330 Service Manual

d) Voltage and current switch case

Inside switch case, there are feedback CT, feedback PT, and voltage-current measurement
range switch, voltage-current measurement range switching signals, auxiliary power supply,
24V switch power and so on; output signals include 0 ~ 120A current signals, 0~300V voltage
signal, etc.

There are 11 internal current ranges: 0.01A, 0.1A, 0.25A, 0.5A, 1A, 2.5A, 5A, 10A, 25A,
50A, 100A respectively.

Current measurement range switchboard is phase sequence dependent and can not be
changed arbitrarily. If switchboard is replaced, jumper setting (EN) must be identical with actual
situation.

Because three phase meter has many voltage standards, we divide the voltage into
four(57.7/100/220/380), so we should switch when meter in different voltage, signal source
sends the switch signal, control the relay board in the switch case to achieve the circuit of the
switch rising depressor. The voltage to each meter and to the standard meter is the same
voltage.

Page -6-
SY8330 Service Manual

e) Isolation Current Transformer (ICT)

 MAIN CHARACTERISTIC
 Wide electric current working range: 1mA… 120A
 Maximum transmission power: Max. 60VA
 Adopt the electronic error to compensate, guarantee accuracy
 Overload indication

 RANGE OF APPLICATION
 At multi-position check-up device, measure electric current and
voltage return circuit can separating or electric energy meter
not separated
 Carry on the transformation to the existing check-up device

 ORDINARY INDEX
 Auxiliary voltage: 240V + 15% / 50（60）Hz + 5%/Max. 10VA
 Machine case: The metal case body assembles three and isolates the
transformer of electric current
 Weight: 14.5kg
 Working environment temperature: +10 0C ~ +400C
 Function environment temperature: -100C ~ +500C
 Store temperature: -400C ~ +800C

 TRANSFORMATIONAL INDEX
 Nominal frequency: 50Hz/60Hz + 5%
 Primary current: 1mA ~ 120A
 Secondary current: 1mA ~ 120A

 OUTPUT LOAD
 Output power: Max. 60VA
 Output load:
60VA (4.17mΩ) @ 120A, 50VA (5mΩ) @ 100A, 30VA (8.33mΩ) @ 60A,
25VA (10mΩ) @ 50A, 15VA (16.6mΩ) @ 30A, 5VA (50mΩ) @ 10A

 ERROR

Current
Accuracy 500mA to 120A 50mA to 500mA 10mA to 50mA

Ratio error 0.01% 0.03% 0.1%

Angle error 0.8min 2min 5min

Page -7-
SY8330 Service Manual

f) Multi secondary voltage transformer (MSVT)

Primary voltage: 100V ~ 300A

Secondary voltage: 100V ~ 300A

Voltage Ratio between secondary winding: 1:1

No of secondary outputs: up to 72

Range of secondary burden: 25VA per winding

Error: < + 0.01%, + 0.3 min, when each secondary load is the same

Insulation performance: AC voltage 2kV for 1 minute (between primary and

secondary)

Page -8-
SY8330 Service Manual

g) Error processor
Each position has the error calculator, which is fixed behind the error display window of
the meter mount rack. Connect PC by RS485 and main control SCM.
There are some technical parameters about the SY9030 type error processor.
a Error display range: four bits efficient digits, decimal fraction display error.
b Error range: + 99.99%
c Checkout method: high frequency pulse figure set up in advance
d Photoelectric pulse passage: < 100Hz
e Standard pulse passage: < 500kHz
f Pulse signal electricity plane: TTL or OC(open collector)
g The tested meter’s circles range: 1-99
h Check meter number: 1
i The range of the standard number setting up in advance: 1-9,999,999;
j Exterior communication connection: RS-485 joined connection can communicate
with PC computer, calibrating meter automatically.
k Uncertainty: + 1 theoretics pulse number

SY-8330 equipment calculates comparative error with high frequency pulse setting up
in advance (%). The high frequency pulse of standard electricity energy meter send to the
error calculator, after the tested meter turns one circle , the error calculator numerate the
high frequency number added up as the actual test high frequency pulse number m,
compared with preset high frequency impulse figure m0.According to the formula(1)it
calculate the comparative error of the tested meter γ（%） ：
m  m0
  100%   0 …………………………………. (1)
m0
Among them:
γ 0: When the system error of standard meter or test bench do not need
correctedγ0=0
m: The actual test high frequency pulse figure
m0; Preset high frequency pulse figure that is the standard preset figure.
Calculate standard preset figure in according to formula 2:
C HO  N
m0  ……………………………….. (2)
C L  K I  KU  J N
Among them:
CHO: The high frequency pulse constant of the standard meter (PH/kWh);
N: The low frequency pulse figure of the tested meter, that is checkout circles;
CL: The low frequency pulse constant of the tested meter, (PL/kWh);
KI: The current transformers change and compare, for wide loading standard
meter; KI=1
KU: The isolated proportion of the voltage isolated transformers twice terminal and
standard terminal, for the wide quantity limited standard electric power meter:
KU=1；

Page -9-
SY8330 Service Manual

JN; The connection modulus, single-phase JN=1。

The low frequency pulses of watt-hour meter to be calibrated N, measurement range of

transformer connected to standard meter or the shift of standard meter’s override switch should
be selected properly so that the calculated (or pre-configured) pulses and actually measured
pulses meet the following stipulations.

Accumulated value of different-grade watt-hour meters

Accuracy grade of
Class 0.02 Class 0.05 Class 0.1 Class 0.2
watt-hour meters
Minimum accumulated
50000 20000 10000 5000
value

485OUT 485IN

GND GND
FH FH
B2 B2
A2 A2
B1 B1
A1 A1

ON

1 2 3 4 5 6 7 8

0V 0V
5Vout 5Vin
5V 5V

P1 G
G PA2

G P1out PA2out
PA1 P4
PAO G
3.3V 5V

PAout P4out

Error calculator rear panel

Page -10-