EPS/FMT/STORES/04-APC-REV-00

ELMAS POWER SYSTEMS

208/9, Phase-II, IDA Cherlapally, Hyderabad-500 051
TRACEABILITY REPORT

Customer: pace p Kit Qty: Kit No.:

Rating: 15kva Date: Batch No.:
Sl.No STAGE WISE PROCESS EQUIPMENT/DESCRIPTION OPERATOR
1 Verification of Mandrill Sizes As per the Mandrill Sizes.
2 Bobbin Assembling From the cut pieces Corner Profile 6.5X6.5X160mm
3 Insulation on Bobbin ( 2+3+2 ) 4 corners with cut pieces 7mill Nomex
4 Primary Winding-1st layer 6.7x3.7 mm Copper Strip-Manual Machine
5 After 1st layer insulation 5mil volta flex Paper (145*160*0.16)1 layers
6 Primary Winding-2nd layer 6.7x3.7 mm Copper Strip-Manual Machine
7 After 2nd layer insulation 10*8*160mm Duct Picese&Volta Flux
8 Primary Winding-3rd layer 5x2.75 mm Copper Strip-Manual Machine
9 After 3rd layer insulation (on out side) 5mil Nomex Paper( 1 layers)voltaflex fleces
10 Between Pri and Sec Insulation 10x12x160 ducts all side
11 Secondary Winding-1st layer 5x2x2 copper strip-Manul machine
8x10x160mm (4no"s)Duct Piceses& Volta flux
12 After sec 1st layer insulation paper (2cut pieces)

13 Secondary Winding-2nd layer 5x2x2 copper strip-Manul machine

14 in sulation on sec 2nd layer winding 5mil Nomex Paper 1 layers
15 Secondary Winding-3rd layer 5x2x2 copper strip-Manul machine
Lamination Stacking/Assembling Must be stack with out over laphs manually
8x10x160mm dog bone and 50x195x1mm
backelite piece
Body to coil Insulation 8x10x56 mm 6 Pices or Bakelite
Clamps Assembling Isolate Clamps with 1mm Epoxy
Clamp to Core Small Shield Piece 1no
1 Tai Roads Isolate Tai Roads with 8mm FG Sleaves" F" Cal
Must use GE strip and Hammer
2 Finishing of the Transformer Hammer dots should be take care
31 Inprocess Inspection: Should Follow As per Spec
32 H.v.Test GW Instek BDV Meter
33 No Load Current With Veriac Dimmer and Power Meter
34 No Load Losses With Veriac Dimmer and Power Meter
35 Secondary No load Voltages Measure With Accuracy Multi Meter
36 Painting on Core Use only Rust proof paint
37 Varnishing Isonel 31J Pure Varnish
38 Varnish Curing 110°C 4 Hours
39 Primary Termination G.E.Board with Engraving
40 Secondary Termination G.E.Board with Engraving
Control Winding With Connector G.E.Board with Engraving
 41 Final Inspection: Should Follow As per Spec
42 H.v.Test GW Instek BDV Meter
43 No Load Current With Veriac Dimmer and Power Meter
44 No Load Losses With Veriac Dimmer and Power Meter
45 Secondary No load Voltages Measure With Accuracy Multi Meter
46 Transformer Fixing on the Palletts As per the drawing(Fixing Dimensions)
47 Covering on Transformers Cover with Polythin Carguated Sheet

Verified By:
 EPS-F/PACE-P12.5KVA-TRC/00

ELMAS POWER SYSTEMS

#208/9, Phase-II, IDA Cherlapally, Hyderabad-500 051
TRACEABILITY REPORT

Customer : Pace Power Systems Kit Qty: Kit No.:

Rating: 12.5KVA P Date: Batch No.:
SL. NO STAGE WISE PROCESS EQUIPMENT/DESCRIPTION OPERATOR
Winding stage:
1. Primary winding
1 Verification of Mandrill Sizes As per the Mandrill Sizes.
2 Corner profile assembling Corner Profile 8X8X134 mm
3 Insulation on corner profile 4 corners 2mill Adhesive tap
4 Primary Winding-1st layer 4x2.5 mm Copper Strip
2 pieces 5mil Volta flex fleece
5 Insulation after 1st layer (0.16TX134W)
Ducts at out side - 4 Nos 8X10X134mm
6 Primary Winding-2nd layer 4x2.5 mm Copper Strip
2 pieces 5mil Volta flex fleece
7 Insulation after 2nd layer (0.16TX134W)
Ducts at out side - 4 Nos 8X10X134mm
4x2.5 mm Copper Strip 20Turns 11SWG
Primary Winding-3rd layer 16 Turns
8
5mil Volta flex fleece - 1 Layer
Insulation (0.16TX134W)
9 Primary Winding-4th layer 11SWG copper
2. Secondary winding
10 Between Pri & Sec insulation 10x12x134mm ducts - 8 Nos
11 Sec. first layer 11SWG copper
2 pieces 5mil Volta flex fleece
12 Insulation on sec. first layer (0.16TX134W)
Ducts at out side - 4 Nos 8x10x134mm
13 Sec. second layer 11SWG copper
FG Adhesive tap 2 Layers at bottom and
14 Insulation on sec. second layer top of the coil
Lamination Assembling stage:
15 Corner profile setting 8X8X134mm
16 Inserting lamination EI 309, Must be stack without overlaps
17 Tighing of the lamination With mallet
18 Inserting ducts between core to coil 8x10x134mm ducts - 2 Nos
19 clamp fixing with tie rod and hylem sheet Isolated tie rod with 8mm to be use
Must use GE strip and hammer
20 Finishing of the transformer Hammer dots should not be visible
 Inserting ducts between core to coil at
21 bottom 8x10x47mm ducts - 4 Nos

In-process Testing:
22 Should follows as per spec
23 HV Test Agronic BDV Meter
24 No load current With variac dimmer and power meter
25 No load watt loss With variac dimmer and power meter
26 Sec. no load voltages Measure with accuracy multimeter
Varnishing stage:
27 Painting on core Use only rust proof paint
28 Varnish dipping Isonel 31J pure varnish
29 Varnish curing 110°C for four hours
Termination stage:
GE board with engraving -
30 Fixing of terminal board 30x12x309mm
FG testing:
31 HV Test Agronic BDV Meter
32 No load current With variac dimmer and VAW meter
33 No load watt loss With variac dimmer and VAW meter
34 Sec. no load voltages Measure with accuracy multimeter
Final stage:
35 QC inspection As per the sampling plan
36 Transformer Fixing on the Palletts As per the work instruction
37 Covering on transformer Cover with wrapper

Prepared By: Verified By:

 SE/QA/F-00

Senatla EV products Pvt Ltd

Address: Plot No: 26, Phase III, IOCL, Cherlapalli,
TRACEABILITY REPORT
Customer Name: Kit Qty: Kit /JO No.:
Model/Rating: Date: BOM No/Date.:
Sl.No STAGE WISE PROCESS EQUIPMENT/DESCRIPTION
SMT SECTION :
1 PCB No version AS Per BOM -
1 Paste & Printing machine AS Per WI & BOM - SE/PPDN/WI/01

Pick & Place machine _1 Feeders

2 AS Per WI & BOM - SE/PPDN/WI/01
components (Fuji)

Pick & Place machine _2 Feeders

3 AS Per WI & BOM - SE/PPDN/WI/01
components
Pick & Place _2 Feeders
4 AS Per WI & BOM - SE/PPDN/WI/01
components (JUKI)

5 Reflow machine AS Per WI & BOM - SE/PPDN/WI/01

6 Visual inspection AS Per WI & BOM - SE/PPDN/WI/01

7 Rework details AS Per WI & BOM - SE/PPDN/WI/01

Through hole section :PTH :

Heat sinks fixing (Mylar sheet)
8 AS Per WI & BOM - SE/PPDN/WI/01
with electrical torque

9 Mosfets Q1,Q2 fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/02

10 Diode fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/04

11 Thermal switch fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/03

12 Top plate fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/05

13 Masking tape pasting AS Per WI & BOM - SE/PPDN/WI/06

:

14 Components pre foming stage as per bom AS Per WI & BOM - SE/PPDN/WI/00

15 Components stuffing stage 1 as per bom AS Per WI & BOM - SE/PPDN/WI/07

16 Components stuffing stage 2 as per bom AS Per WI & BOM - SE/PPDN/WI/08

17 Components stuffing stage 3 as per bom AS Per WI & BOM - SE/PPDN/WI/09

18 Components stuffing stage 4 as per bom AS Per WI & BOM - SE/PPDN/WI/10

19 Components stuffing stage 5 as per bom AS Per WI & BOM - SE/PPDN/WI/11

20 Components stuffing stage 6 as per bom AS Per WI & BOM - SE/PPDN/WI/12

Inprocess Testing Stage:
21 In process Inspection Should Follow As per Spec
22 H.V. Test BreakDown Tester

23 No Load Current With Veriac Dimmer and Power Meter

24 No Load Losses With Veriac Dimmer and Power Meter

25 Pri&Secondary No load Voltages Measure With Accuracy Multi Meter

Varnishing Stage:
26 Painting on Core Use only Rust proof paint
27 Varnishing Isonel 31J Pure Varnish
27 Viscocity of the Varnish Viscosity in Sec(50-75)
28 Paint Black
28 Varnish Curing 110°C 5 Hours
Termination Stage:
29 Terminal Board 430x30x12mm
30 Ring lugs 50 SQ mm with M8 hole
31 bolts MS M8x40 mm,5.3Grade, Black
M8 MS plain washers, OD:16MM,
32 Plain Washers
Thickness 1mm,black
33 Nuts M8x40 mm,5.3Grade, Black
34 spring washers M8 MS spring washers
35 Bolts M6X15mm 5.3Grade black
36 Bolts m6X5.3 Grade

37 plain washers M6 MS plain washers

38 Nuts M6 5.3Grade, MS nuts Black

39 HeatShrinkableTube Red(Pri) 12mm size

40 HeatShrinkableTube Black(Sec) 12mm size

41 Screen Printing Ink White(S)

FG Testing:
42 Final Inspection Should Follow As per Spec
43 H.V. Test ITLBreakDown Tester

44 No Load Current With Veriac Dimmer and Power Meter

45 No Load Losses With Veriac Dimmer and Power Meter

46 Secondary No load Voltages Measure With Accuracy Multi Meter

Final Stage:
47 QC inspection As per the sampling plan

48 Transformer Fixing on the Wooden Pallet As per the work instruction

49 Covering on transformer Cover with wrapper

Prepared By: Verified By:

 SE/QA/F-00

Observation
 SE/QA/F-00

Senatla EV products Pvt Ltd

Address: Plot No: 26, Phase III, IOCL, Cherlapalli,

PCB SECTION PROCESS AUDIT

Customer Name: Kit Qty: Kit /JO No.:
Model/Rating: Date: BOM No/Date.:
Sl.No STAGE WISE PROCESS EQUIPMENT/DESCRIPTION Observation

SMT SECTION :

1 PCB No version AS Per BOM -

1 Paste & Printing machine AS Per WI & BOM - SE/PPDN/WI/01

Pick & Place machine _1 Feeders

2 AS Per WI & BOM - SE/PPDN/WI/01
components (Fuji)

Pick & Place machine _2 Feeders

3 AS Per WI & BOM - SE/PPDN/WI/01
components
Pick & Place _2 Feeders
4 AS Per WI & BOM - SE/PPDN/WI/01
components (JUKI)

5 Reflow machine AS Per WI & BOM - SE/PPDN/WI/01

6 Visual inspection AS Per WI & BOM - SE/PPDN/WI/01

7 Rework details AS Per WI & BOM - SE/PPDN/WI/01

Through hole section :PTH :

Heat sinks fixing (Mylar sheet)
8 AS Per WI & BOM - SE/PPDN/WI/01
with electrical torque

9 Mosfets Q1,Q2 fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/02

10 Diode fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/04

11 Thermal switch fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/03

12 Top plate fixing with electrical torque AS Per WI & BOM - SE/PPDN/WI/05

13 Masking tape pasting AS Per WI & BOM - SE/PPDN/WI/06

14 Components pre foming stage as per bom AS Per WI & BOM - SE/PPDN/WI/00

Stuffing Stage :
15 Components stuffing stage 1 as per bom AS Per WI & BOM - SE/PPDN/WI/07

16 Components stuffing stage 2 as per bom AS Per WI & BOM - SE/PPDN/WI/08

17 Components stuffing stage 3 as per bom AS Per WI & BOM - SE/PPDN/WI/09

18 Components stuffing stage 4 as per bom AS Per WI & BOM - SE/PPDN/WI/10

19 Components stuffing stage 5 as per bom AS Per WI & BOM - SE/PPDN/WI/11

20 Components stuffing stage 6 as per bom AS Per WI & BOM - SE/PPDN/WI/12

21 Components stuffing stage 7 as per bom AS Per WI & BOM - SE/PPDN/WI/12

 22 Components stuffing stage 8 as per bom AS Per WI & BOM - SE/PPDN/WI/13

23 Components stuffing stage 9 as per bom AS Per WI & BOM - SE/PPDN/WI/14

24 Components stuffing stage 10 as per bom AS Per WI & BOM - SE/PPDN/WI/15

25 Components stuffing stage 11 as per bom AS Per WI & BOM - SE/PPDN/WI/16

26 Components stuffing stage 12 as per bom AS Per WI & BOM - SE/PPDN/WI/16

27 Components stuffing stage 13 as per bom AS Per WI & BOM - SE/PPDN/WI/17
28 Components stuffing stage 14 as per bom AS Per WI & BOM - SE/PPDN/WI/18
Before wave Visual inspection 15
29 AS Per WI & BOM - SE/PPDN/WI/19

30 Wave soldering AS Per WI - SE/PPDN/WI/20

After wave VQC FQC Stage:
31 After wave Visual inspection 16 AS Per WI & BOM - SE/PPDN/WI/20
32 Excess leads cuting AS Per WI & BOM - SE/PPDN/WI/21
33 Thermal switch 2 leads soldering AS Per WI & BOM - SE/PPDN/WI/22

34 Torriod & Main transformer cable tiening AS Per WI & BOM - SE/PPDN/WI/23

35 PCB Cleaning AS Per WI & BOM - SE/PPDN/WI/24

36 After Cleaning Visual inspection 16 AS Per WI & BOM - SE/PPDN/WI/25
37 Final Visual inspection 17 AS Per WI & BOM - SE/PPDN/WI/26
38 Finshed product packing 18 AS Per WI & BOM - SE/PPDN/WI/27
QA Final Stage:
AS PER IS 2500: - GENERAL
39 QA Final inspection INSPECTION LEVEL - 1 AQL. 0.40
&0.65
Rea inspection PPDN. rea offered to
40 IN Case Rejection came in inspected LOT QA and again QA final inspection,
then clear the lot

Prepared By: Verified By: