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OMKAR SYSTEMS

“People will remember what you achieve- not what you promised to achieve.”

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OMKAR SYSTEMS ESD Protective Measures Doc. No.: OS/WI/ASM/001 Date: Version:

Since the damage is far reaching and not easily traceable, it is essential to take precautionary measures to protect panels from damages.

2.Definitions: Nil 3.References: Nil 4.Description:

We have initiated 4 point program i.e. Earthing of panels, wearing fully-buttoned cotton Aprons/ Uniforms, ESD Protective Wrist-straps and ESD Shoes to avoid damages.

It is also important to protect ESD sensitive components/assemblies from dust, plastic and other static-charge generating items.

We can Avoid This!! ….By being ESD sensitive.

Our 4- Point Program for ESD Protection

1. Earthing Panels & ESD Floor Mats

2. Wearing Cotton Aprons/ Uniforms

3. Wearing ESD Shoes

4. Using Wrist-Strap

ATTENTION OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

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OMKAR SYSTEMS ESD Protective Measures Doc. No.: OS/WI/ASM/001 Date: Version:

1. Purpose: Electrostatic Discharge Sensitive devices (ESDS) are discrete devices/ IC’s/ assemblies that may be damaged by electrostatic discharge during handling, testing or transit.

Since the damages is far reaching and not easily traceable, it is essential to take precautionary measures to protect panels from damages. 2.Definations: Nil 3.References: Nil 4.Description: We have initiated 4 point program i.e. Earthing of panels, wearing fully-buttoned cotton Aprons/ Uniforms, ESD Protective Wrist-straps and ESD Shoes to avoid damages. It is also important to protect ESD sensitive components/assemblies from dust, plastic and other static-charge generating items.

ESD Precaution Compulsory

For

Semiconductors -Diodes -Transistors -Thyristors etc.

MOS Structures - FET, IC, Capacitors etc.

PCB’s Drives

Metallisation Structures & Film Resistors

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

Scene 4 (1m 27s)

OMKAR SYSTEMS ESD Protective Measures Doc. No.: OS/WI/ASM/001 Date: Version:

1. Purpose: Electrostatic Discharge Sensitive devices (ESDS) are discrete devices/ IC’s/ assemblies that may be damaged by electrostatic discharge during handling, testing or transit.

Since the damages is far reaching and not easily traceable, it is essential to take precautionary measures to protect panels from damages. 2.Definations: Nil 3.References: Nil 4.Description: We have initiated 4 point program i.e. Earthing of panels, wearing fully-buttoned cotton Aprons/ Uniforms, ESD Protective Wrist-straps and ESD Shoes to avoid damages. It is also important to protect ESD sensitive components/assemblies from dust, plastic and other static-charge generating items.

Do’s Don’ts

D n &necte

st- t

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

1 Panel Earthing Panels & Floor Mats Earthed Earth Drop not connected

2 ESD Shoes

3 Wrist Straps Wrist-Strap Earthed Wrist-Strap not connected

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OMKAR SYSTEMS ESD Protective Measures Doc. No.: OS/WI/ASM/001 Date: Version:

1. Purpose: Electrostatic Discharge Sensitive devices (ESDS) are discrete devices/ IC’s/ assemblies that may be damaged by electrostatic discharge during handling, testing or transit. Since the damages is far reaching and not easily traceable, it is essential to take precautionary measures to protect panels from damages.

2.Definations: Nil

3.References: Nil

4.Description:

We have initiated 4 point program i.e. Earthing of panels, wearing fully-buttoned cotton Aprons/ Uniforms, ESD Protective Wrist-straps and ESD Shoes to avoid damages. It is also important to protect ESD sensitive components/assemblies from dust, plastic and other static-charge generating items.

Have I?

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

1. Earthed Panels & floor Mats 2. Earthed Wrist-Strap

3. Worn Cotton Aprons 4. Worn ESD Shoes

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1. Issue of Cable lug crimping process (for control cable) for better understanding. 2. Definitions: Nil 3. References: Nil

Some special notes of the crimping process: Crimping is a kind of tight connection between a lug and a wire. The process of crimping is called a special process because the result cannot be understood without a

destructive test. Of course, it is not possible to know whether the crimped joint is correct or not.

 That is why there are three things to look for in quality crimping Man, Tools (Machine), Material (Lug & Wire)

 Tools, Lug and Wire to be procured from Approved Supplier Only.

 All Wireman’s should be skilled and validated.

 Carefully remove the insulation on the wire as suggested.

 The wire stripping tool "Stripper" needs to be in good condition so that the conductor is not cut or dented.

 Make sure the crimping tool is good and calibrated. Make sure that its die, ratchet, spring, type is correct.

 With regular care, your tools will last longer and increase their efficiency.

 Wire, lug and crimping tools should be used as suggested.

 It is necessary to keep the crimp height as suggested.

Different types of lugs required in electrical panels

Non-lnsulated Rin Lu

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Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/002

(For Control Cables) Date: Version:

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Crimping process: For control wire

Pressing the handle of the crimping tool completely opens the ratchet and the jaws of the crimping tool. Put a lug in it and press a handle. Make sure that the lug does not change shape. Carefully remove the insulation on the wire and place it in the lug and press the handle of the crimping tool until the ratchet is removed. Remove the crimp joint from the tool. This crimp joint is ready to use.

Removing the insulation on the wire:

Pictures of properly and incorrectly insulated are shown below:

Correct

Incorrect:

3. Conductor uncut, without dent and Without distorting the twisted structure, well insulated.

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/002

(For Control Cables) Date: Version:

Dent on Conductor Conductor Truncated Slanted

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Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/002

(For Control Cables) Date: Version:

If the stripper used is stale / dull or if the distance between them is wide, it will not be cut properly and it will crack.

Pieces of insulation are left on the conductor by a stale / dull stripper.

If the distance between the strippers is short, the conductor gets dented or the conductor is cut.

If the distance between the strippers is short and the insulation is not removed properly, the conductors are pulled and the individual wires are straightened by pulling.

Excessive twisting of individual wires does not result in uniform structure in the crimp shell.

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Things that can be easily examined by the eyes:

it

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/002

(For Control Cables) Date: Version:

Well crimped example: Common Crimping Mistakes: Crimping on the opposite side

Crimp in the wrong place without being in the middle

Removing insulation less than the specified length, the crimp does not fit and the wire pulls away

Uncrimped Conductor

The strands of the conductor are stuck in the insulation holder

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Length of insulation removal = length of the crimp shell + 1mm (for wire size up to 1mm²)

Length of insulation removal = length of the crimp shell + 2mm (for wire size up to

10mm²)

properly covered, it Will withstand a great deal of adverse conditions Clear- looking Belmouth Both wire and Insulation are covered Conductor slightly ahead of the crimp shell (Imm: forwjre Size upto Imm2 2mm: for the wire Size up to 10mm2) length of crimp shell Length of insulation removal

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/002

(For Control Cables) Date: Version:

Scene 11 (4m 42s)

Some Bad Examples of Crimping:

Use the Correct length of lugv

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/002

(For Control Cables) Date: Version:

Conductors appearing next to the crimp shell more

than necessary

Do not cut the lug.

Use the Correct length of lug.

Material Cracked Lug Conductor Cracked/ Truncated

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Version:

1. Purpose: To ensure proper power wire crimping in Electrical Panels.

2. Definations: Nil

3. References: DIN 46235

4. Description of Activities:

1. Select the size of wire, based on drawing or current rating chart and equipments to be mounted.

2. Based on layout of components in panel, measure, mark & cut wires to required lengths.

Recommended Tools:

 Weidmueller make KT45R (Range: Up to 300 sqmm)

 Klauke Cutter

K102 (for cable up to 95sqmm)

Weidrnueller KT45R Wire Size Upto 300Sq m

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/003

(For Power Cables) Date:

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Version:

3.Use recommended Stripping tool. Ensure cutting edges of tool is in good condition to have clean cut and save on time and

effort. Ensure straight cut.

Recommended Tools:

 Weidmueller make KT8 (Up to 16sqmm, can also cut PCP cables)

 Weidmueller make AM25 (to be used only for PVC cable size 6 to 25mm

Diameter) And AM35 (to be used only for PVC cables size 26 to 35mm Diameter)

4.4 It is important to use proper cable-lug-tool combination.

Select and insert recommended lug in stripped cable.

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/003

(For Power Cables) Date:

Scene 14 (5m 32s)

Version:

4.5 All wires of 10sqmm and above are to be crimped using NOVOPRESS Hydraulic crimpers only. Use HP95 for cables with cross section 10sqmm to 70sqmm Use HP300 for cables with cross section 95sqmm to 300sqmm

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/003

(For Power Cables) Date:

CABLE LUG CRIMPING TOOL REMARKS

95sqmm Rolliflex/ APAR/Other Indian cable

120sqmm M10 & M12 (Make as applicable)

NOVOPRESS HP300  Cable strands flare on

insulation removal, hence higher size lug to be used.

 Lugs are with longer

barrel length

 2-stroke crimping to be

done.

120sqmm Rolliflex/ APAR/Other Indian cable

150sqmm M10 & M12 (Make as applicable)

NOVOPRESS HP300

95sqmm imported cables H+S/Lapp/Other

95sqmm M10 & M12 (Make as applicable)

NOVOPRESS HP300 Single stroke crimping to be done.

120sqmm imported cables H+S/Lapp/Other

120sqmm M10 & M12 (Make as applicable)

NOVOPRESS HP300 2-Stroke crimping to be done.

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Version:

6. Process for 2-Stroke crimping

First crimping:

 Stripped portion of cable is to be placed in lug in such a way that conductor is visible through

‘viewing window’.

 First crimping should be at rear end of tubular lug, keeping a minimum distance of 2mm from lug end and enough space towards the front for second crimping.

Second crimping:

 Second crimping take place in the front region of tubular lug.

 Lug is placed in crimping tool in such a way that second crimp does not overlap the first crimp and at the same time, crimping takes place in tubular portion of lug at the front end.

 Both crimping impression should have same depth.

7. Hold cable lug against upper crimping insert of crimping tool. Brazed seam of lug should face the

lower crimping insert.

8. Start crimping operation by actuating foot switch (Option of operating by hand also available). After

Crimping, the pressure piston drops back to its starting position. Remove crimped joint from tool.

Black operation of NOVOPRESS crimping tool (Operating without placing lug) and bending anything other than crimping lug can hamper tool-die.

9. While using NOVOPRESS crimpers, the crimping process should not be interrupted before automatic

shut-off or else crimping depth will be insufficient.

is lush at end the cable Collor from of lug to the first crimpelg is greater than 2mm Both do Mt ov«lap with each other. Crimpög at the end_ Insulaton is visible through hole.

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/003

(For Power Cables) Date:

Scene 16 (6m 53s)

Version:

10. Re-crimping at same location is forbidden as this would lead to deterioration of crimping and cause

reduction in cross section.

11. It is essential that earthing connection is retained to prevent possibility of electric shock. 12. NOVOPRESS crimper gives ‘V’ indent crimping; with mark specifying the crimping tool used i.e. ’10- 95’and ’50-

300’ for HP95 and HP300 respectively.

13. Tightening/Torque application (Electrical Values) to be done as per work instruction no……………………

14. Quality of crimp joint in power wires is done by visual check as well as cross-section analysis.

Example of crimped joint analysis using cross section method Arrangement of conductor in a cross-section of crimped sample is studied using special machine and based on the observed air gaps, crimp joint certified. e.g.

15 0 C.OS+hfC

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/003

(For Power Cables) Date:

Scene 17 (7m 25s)

Version:

4.15 Tips for good power wire crimping:  Only trained and validated wireman to be assigned crimping tools and jobs.  Wireman should be conversant with tool-cable-lug combination.  Precaution to be taken for personal & equipment safety.  ESD Protective requirements to be complied.  Tools to be regularly maintained and calibrated.  Tools, Lugs, Cables etc. to be procured from recommended source only.  Cable bunching to be done without stress formation & with proper bending radius.  Saddles for cable-tie, stickers and cable markers to be used as per guidelines.

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

OMKAR SYSTEMS Cable Lug Crimping Process Doc. No.: OS/WI/ASM/003

(For Power Cables) Date:

Scene 18 (7m 53s)

OMKAR SYSTEMS Affixing Stickers In Electrical Panel Doc. No.: OS/WI/ASM/004 Date:

Version:

1. Purpose: Stickers helps in addressing components in Electrical panel. It is essential to take below mentioned precautions

to ensure retention of stickers in designated locations. 2.Definations: Nil 3.References: Nil 4. Description of Activities:

4.1 Clean & Dry surface using damp cloth (dipped in mild soap solution) where sticker is to be fixed.

4.2 Clean Hands.

4.3 Ensure Stickers are from Approved supplier and within expiry date.

ASE3816249

CAUTION ! DO NOT TOUCH THE ELECTRICAL INSTALLATIONS

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Approved By: Mr. Shinde Nilesh

(Process Owner)

Scene 19 (8m 18s)

OMKAR SYSTEMS Affixing Stickers In Electrical Panel Doc. No.: OS/WI/ASM/004 Date:

Version:

4.3 Peel off sticker paper-base, align & place sticker on surface and neatly smoothen over contact surface. Ensure

sides are not left unstuck.

Special care while affixing stickers:

 Dust-free contact surface.

 Clean Hands.

 Correct positioning of stickers.

 Good visibility.

ooc

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

Poor Visibility due to improper placement

Better Visibility Incorrect Positioning Correct Positioning

Scene 20 (8m 36s)

OMKAR SYSTEMS Care for Proper Saddle Fixing Doc.No.: OS/WI/ASM/005 Date:

Version:

1.Purpose: Saddles helps in holding cable bunch in Electrical panel. 2.Definations: Nil 3.References: Nil 4.Description of Activities:

 Clean Surface prior to saddle fixing

Use damp cloth (dipped in mild soap solution) for surface cleaning. Ensure Surface is dry before fixing Saddle.

 Ensure Saddles are from Approved supplier and within expiry date.

 Apply Adhesive after checking expiry date.

 Use saddle of size suitable to hold the cable bunch easily.

 Use saddles that are undamaged and in good condition.

Good Practice:

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Saddle Unstuck Saddle Unstuck Saddle Damaged Improper Position

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OMKAR SYSTEMS Care for Proper Saddle Fixing Doc.No.: OS/WI/ASM/005 Date: Version:

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

Saddle Mapping and Fixing

Cable bunch routine and proper

positioning

Proper Sizing

Scene 22 (9m 23s)

OMKAR SYSTEMS Take Care to some Visual Points Doc. No.: OS/WI/ASM/006 Date:

Version:

If any component gets damaged during manufacturing, it should bring to supervisors notice immediately. Submit all the remaining/Excess material if any.

Remove all scrap i.e. cut pieces of cables, cable ties, wrong ferrules, rubber bands, carton box etc.

& remaining fasteners like washer, nut, bolt & screw etc.

 Ensure proper tightening of Fasteners.

 Tighten cable ties and cut excess tags.

 Remove all the rubber bands from cable duct after cable bunch ties with cable tie/ bunching belt.

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Scene 23 (9m 48s)

OMKAR SYSTEMS Take Care to some Visual Points Doc. No.: OS/WI/ASM/006 Date:

Version:

 Ensure all the earthing stickers and warning stickers are in place.

 Ensure all the Drawings are in respective place.

DANGER nov AC

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Scene 24 (10m 0s)

OMKAR SYSTEMS Take Care to some Visual Points Doc. No.: OS/WI/ASM/006 Date: Version:

Wire Laying:

“S” type cable laying ensures smooth door movement. OR cable conduit with accessories to be used.

 Ensure wire bunch is properly laid in PVC channel.

 Cut the end petal to accommodate wire bunch properly.

 Do not lay cables over sharp edges as cables could get cut.

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Approved By: Mr. Shinde Nilesh

(Process Owner)

Scene 25 (10m 21s)

OMKAR SYSTEMS Affixing Designation Metal/Traffolyte Doc. No.: OS/WI/ASM/007

Name plates In Electrical Panel

Date:

Version:

1.Purpose & Scope: On Special request by customer, Metal/ Traffolyte Name plates are to be used to designate components in panels. This work instruction is made to ensure proper fixing of such designation name plates, enhancing its adhesion, legibility and aesthetics. 2.Definations: Nil 3.References: Nil 4. Description of Activities:

Designation metal plates are to be affixed, for identification, on individual components and on G.I. plate (adjacent to component.)

Designation plates stuck on the component as well as on G.I. Sheet

4.1 Required data to be printed on nameplates is to be collected from relevant drawings.

2. This required data has to be sent to assigned vendor for getting nameplates. 3. On receipt of nameplates, it is essential to store them order wise, ensuring that they are clutter-free and not prone

to damages.

Care to be taken while affixing nameplates:

4. Fixing surface should be clean, dry and grease-free before applying adhesive.  Clean area where nameplate is to be affixed with moist cloth.

 Maintaining clean hands is necessary.

XBOI

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Scene 26 (11m 3s)

OMKAR SYSTEMS Affixing Designation Metal/Traffolyte Doc. No.: OS/WI/ASM/007

Name plates In Electrical Panel

Date:

Version:

5. Mark location for fixing nameplates. While fixing on G.I. sheet, it is essential to maintain line & length. 6. Some components, like contactors are provided with white C-Plate (specific area for designation). Nameplates must

be pasted only at this location.

7. Wherever, there is no specific provision for nameplates, care should be taken to ensure that the name

plate does not block any printed matter on component.

8. Visibility of nameplate is essential. 9. Use recommended adhesive for affixing nameplate. 10. Check for shelf life of adhesive. 11. To monitor flow & quantity of adhesive, it is essential to have a very small opening on applicator-nozzle tip. 12. While it is difficult to specify exact amount to be applied on each nameplate due to its varying size, care

should be taken to apply adhesive sparingly along the sides of nameplate (on rear side), leaving enough space for it to spread when pressed on G.I. plate or component. Align and place nameplate in position and apply sufficient pressure to ensure adhesive spreads into a thin film. Do not disturb or re -align until curing is achieved, normally in few seconds.

13. Exposure causes glue to set. Close the bottle immediately to avoid glue setting & clogging nozzle-tip. Keep bottle in

upright position.

14. Cutting clogged hole further would increase inner diameter of nozzle-tip, resulting in excess adhesive

getting poured on surface, which would trickle down hampering its alignment and aesthetics. In case excess adhesive is poured accidentally on nameplates, operator should ensure removal of excess amount of prior to affixing nameplate on G.I. sheet. Wiping with dry cloth may hamper aesthetic & some fibers may cling on surface, whereas wet cloth would hasten bonding, hence both are not recommended.

15. In exceptional cases, due to space constraint, one may have to cut & fix nameplates. Care should be taken to ensure

straight cuts and proper alignment while affixing nameplates on components/G.I., such that its longer dimension appears to be optically to be parallel to width of panel.

Undesired examples are illustrated alongside.

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)

Scene 27 (12m 12s)

OMKAR SYSTEMS Affixing Designation Metal/Traffolyte Doc. No.: OS/WI/ASM/007

Name plates In Electrical Panel

Date:

Version:

Wrongly aligned name plates Excess adhesive trickle down

Precaution:

Awareness of precautions mentioned in MSDS of adhesive is suggested. Fumes formed may irritate sensitive membranes in eyes, nose and throat. Adhesive may cause skin bonding. Suggest immerse affected skin in warn, soapy water and contact medical practitioner immediately. Care to be taken: Use adhesive in well ventilated areas. Fix nameplates as quickly as possible minimizing exposure to vapour. Excess adhesive outside bonding area will increase level of vapour. Since application may result in exothermic reaction, avoid use of rubber/cloth gloves. Store adhesive in cool area away from direct sunlight (suggested at or below 23.8°C)

Prepared By: Mr. Bhor Pravin

Approved By: Mr. Shinde Nilesh

(Process Owner)