U SE R ’S M AN UAL
Guidelines for IN STALLAT STALLATION ION & M AINTENANCE AINTE NANCE
PACE POWER SYSTEMS PVT. LTD., Plot # V-12, Industrial Estate, Kumbalgodu, Bangalore-Mysore Highway, BANGALORE - 560 074. Tel. : +91-80-28437792 / 28437794. Fax.: +91-80-28437793. E-mail:
[email protected] Website: www.pacepowerindia.com
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PACE POW ER SYSTEMS PVT. LTD., LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., LTD., Bangalore
TABLE OF CONTENTS
S L. N O .
D E S C R I P TI O N
P AG E N O .
1.
LIST O F ABBREVIATIO NS
4
2.
SEC TIO N I
P RO DUCT DESCRIP TIO N
5
3.
SEC TIO N II
SP ECIFICATIO N
7
4.
SEC TIO N III
INSTALLATIO N AND
9
COMMISSIONING PROCEDURE 5.
SECTIO N IV
MA MAINTENANCE
12
6.
SEC TIO N V
INPUT/O UTPUT TERMINATIO N
13
DRAWING INDEX 7.
ALARM TERMINAL DETAILS
29
8.
O TH ER TERMINAL DETAILS
30
9.
NETWO RK MANAG EMENT SYSTEM (G SM)
32
1 0.
NETWO RK MO NITO RING SYSTEM (G P RS)
36
1 1.
PACE P MU CO NTRO LLER DESCRIP TIO N
37
1 2.
TRO UBLE S H O O TING C H ART
46
13.
SECTIO N VIII
47
1 4.
WARRANTY CERTIFIC ATE
48
15.
FEED BACK FO RM
49
SAFETY INSTUC TIO NS
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PACE POW ER SYSTEMS PVT. LTD., LTD., Bangalore
REVISION HISTORY Re visio n No No. Re visio n da da ttee
Brie f d e scrip tio n o f ch a ng nge s
In itia ttee d by by
Ap p ro ve d by by
01
0 9 -0 6 -2 0 0 8
In itia l Issu e
Ra m e sh
Ba n ga r
02
3 0 -0 8 -2 0 0 8
Ad d e d Ala rm d e ta ils
Ra m e sh
B a n ga r
03
1 5 -1 2 -2 0 0 8
Ad d e d Micro Co n tro lle r De ta ils
Ra m e sh
Ba n g a r
ABBREVIATIONS PS U ................................... ................................... POWER SHARI SHARING UNIT UNIT PMU........ PMU ........ ............... ....... ........ ........ .... POWER PO WER MANA ANAGEMENT UNIT UNIT PMS ................................... ................................... POWER MANAGEM NAGEMENT ENT SYSTEM SYSTEM PU ...................................... ...................................... POWER UNIT UNIT MCU .................................. .................................. MAIN CO NTROL NTROL UNIT UNIT BIS ........ ........ ........ ........ ..... BUREA BUREAU U OF INDI INDIA AN STA STANDARDS NDARDS BNC ................................... ................................... BAY BAYONET CO UPLING UPLING AC ....... ........ ........ ........ ....... ALTERNATI TERNATING NG CURRENT A.F. ..................................... ..................................... AUDIO UDIO FREQUENCY FREQUENCY C-DOT ........ ............... ....... ........ ........ ....... . CENTRE FOR DEVEL DEVELOP OPM MENT OF TELEM TELEMA ATICS TICS DG MCB ............... ....... ........ ........ ..... DIESEL DIESEL GENERATOR GENERATOR MCB CMOS ............... ....... ........ ........ ......... ....... .. COMPLIM COMPLIMENTAR ENTARY Y META ETAL OXI OXIDE SEME SEME CONDUCTOR CACT ........ ............... ....... ........ .......... ....... ... CENTRE FOR COMPONENT APPROVA PPROVAL TELECOMM TELECOMM., ., I/P .......... ............... .......... .......... .......... .......... ........ ... INPUT NPUT EB MCB MCB ........ ....... ........ ...... ELECTRI ELECTRICITY CITY BOARD BOARD (MA (MAINS) MCB SVR MCB ....... ... ........ ........ ........ ........ ....... ... STA STATIC TIC VOLT VOLTAGE REGULATER REGULATER MCB C/O .......... ............... .......... .......... .......... .......... ....... CHANGE CHANGE OVER OVER CFR........ CFR ........ ........ ........ ........ .... CARBON CARBON FILM FILM RESISTOR RESISTOR CO .......... ............... .......... .......... .......... .......... ....... .. CO-OP ERATE ERATE CO RP. RP. ................................ ................................ CO RPO RATION RATION DC ..................................... ..................................... DIRECT DIRECT CURRE CURRENT NT EQUI. ................................. ................................. EQUIVAL EQUIVALENT ENT DPST ................................. ................................. DOUBLE DOUBLE POLE SINGLE SINGLE THROW DO E ................................... ................................... DEPA DEPARTM RTMENT OF ELECTR ELECTRONI ONICS CS DO T ........ ........ ........ ....... .... DEPARTM DEPARTMENT ENT OF TELECOMM TELECOMMUNICA UNICATI TION ON IMD. ................................... ................................... IMPO IMPO RTED EXCH EXCH .......... ............... .......... .......... .......... ....... .. EXCHANGE EXCHANGE AMF AMF CONTRO LLER ....... ... ...... .. AUTO AUTO MAI MAINS NS FAI FAIL LURE CONTROLLER CO NTROLLER IMP. .................................... .................................... IMPO IMPO RTANT RTANT INST. NST. .................................. .................................. INSTRUM INSTRUMENT ENT INV. .................................... .................................... INVERTER INVERTER O/P .......... ............... .......... .......... .......... .......... ....... OUT PUT PUT
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PACE POW ER SYSTEMS PVT. LTD., LTD., Bangalore
S ECTIO N -1
PRO DUCT DESCRIPTION Reliab le Telecom Power S olution The Product is a fully automatic, high-availability telecom power solution, an d is ideal for po wering critical applications such as BTS sites of GSM, CDMA, a nd 3G networks, a s well as Optical repeater networks.
The Prod uct is a high-availability power source designed to enable valuable Telecom equipments to work with maximum reliability and availability in ha rsh AC mains environmen ts.
The Product integrates, in a single cabinet, all the elements necessary to deliver uninterrup tible, reliable power to any Telecom equipment. Thanks to its high level of integration, it reduces floor and wall space in the Telecom site. The Pro duct also eliminates the complex interconn ection wiring fou nd in conve ntional Telecom site po wer solutions making the Produ ct easy to deploy and ma intain.
It is a complete and in t egra t ed s o l u t i o n which
re-
places the current, conventional practice in telecom site power of dep loying numerous, disparate comp onents such as servo stabilizers, isolation transformers, relay-based AMF p an els, Diesel generator control units and counters, ACDB, fire alarm control mod ules, aviation warning lamp timer etc.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
The Product integrates the following features :
1.
Automatic Mains Failure (AMF) functions
2.
ACDB
3.
Sta tic Vo lta ge Re gu la to r
4
Au to ma tic Be st P ha se Se le cto r.
5
Fault Alarms with potential-free Contact.
6
Ma in s a n d DG pa ra m ete r Mo nito rin g
7
Fire Alarm Module
8
Avia tion La mp Control
9
Real time clock and event recording.
10
Monitoring & Control through GSM Network
11
Monitoring through GPRS Network
There is also provision for the fitting of op tional modu les; Air Con ditioner Controller an d SMPS / Commun ication Equipment. Con figurations or
The Produ cts are a vailable in the following
can be mo dified on Customer’s Specifications.
1)
1 P h as e to 1 Ph as e (R at in g : 5 t o 1 0 KVA )
1)
3 P h as e to 1 Ph as e (R at in g : 5 t o 5 0 KVA )
2)
3 P h as e to 2 Ph as e (R at in g : 5 t o 5 0 KVA )
3)
3 P h as e to 3 Ph as e (R at in g : 5 t o 5 0 KVA )
KEY FEATURES High-availability power protection by mea ns of integral Isolation Transformer, Lightning an d Surge protection devices.
Battery voltage and shelter internal tempe rature mo nitoring feature to switch on the DG set – fuel saving
Completely integrated, high-availability power solution
DG Battery voltage and supervision
Automa tic an d Manua l Mode s of opera tion with key switch
Built-in circuit provided to monitor DG / PCM circuitry
Minimum Diesel Generator utilization (gives fuel savings, less DG wear and tear, lower pollution)
MTTR as low as 15 m inutes (reduced down time)
Automatic switching from grid power to backup generator Simplified Enginee ring, Installation Maintenance
battery voltage
Performa nce, fau lt da ta storage fea tures provided for easy maintenance
an d
Compact & Modular design – easy replaceme nt o f sub-mod ules at site
Dedicated controller with True RMS display of voltage, current, frequency, scrolling display, LED indica tors a nd Ala rm extension fea tures
High MTBF thanks to careful design, the selection of quality comp one nts and use of non-moving parts
Con tinuou sly mo nitoring fau lt records/ data’s up to 500 events on the controller display through key o peration.
Significant saving of space an d installation materials, giving savings in
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
SECTION -II GENERAL SPECIFICATIONS AVAILABLE CONFIGURATIONS Input Power Supply Capacity (for Standard Models) Customization can be be done based on needs.
Single Phase 5KVA to 10 KVA
Two Phase 5 KVA to 50 KVA
Three Phase 5 KVA to 50 KVA
1 4 0 V-2 8 0 V o r
24 0 V-4 8 0 V o r
2 4 0V-4 8 0 V o r
9 0 V-2 70 V
155V - 465V
155V - 465V
Line to Neutral
Line to Line
Line to Line
Input Current
Total Capacity/ Input Voltage
Total Capacity/ Input Voltage
Total Capacity/ Input Voltage
Frequency
47 - 53 Hz
47 - 53 Hz
47 - 53 Hz
Rated output voltage
220V ± 10% or 220V + 13% Line to Neutral
220V ± 10% or 220V + 13% Line to Neutral
220V ± 10% or 220V + 13% Line to Neutral
Output Current
Total Capacity / Output Voltage
Total Capacity / Output Voltage
Total Capacity / Output Voltage
System Efficiency
> 94%
> 94%
> 94%
Circuit breaker type
DIN Class C type
DIN Class C type
DIN Class C type
EB Input
As per Requirement
As per Requirement
As per Requirement
DG Input
As per Requirement
As per Requirement
As per Requirement
INPUT Input voltage range
OUTPUT
AC DS ITIRBUTION (ACDB)
Load Distribution: Site load details and circuit breaker current ratings are con figured as per requirement. Power Plant (SMPS)
32AMPS SP for SMPS – 1No.
32/63AMPS SP for SMPS – 3Nos.
32/63AMPS SP for SMPS - 3Nos.
Air Conditioner
NA
32 Amp SP for Air co nd itio ne r 1 &2 – 2Nos.
32 Amp TP for Air co nd itio ne r 1 &2 – 4Nos.
Battery Charger
6 Amp (SP) – 1No.
6 Amp (SP) – 1No.
6 Amp (SP) – 1No.
Lighting
6 Amp (SP) – 1 No.
6 Amp (SP) – 1 No.
6 Amp (SP) – 1 No.
Power point
16 Amp(SP) – 1 No.
16 Amp(SP) – 1 No.
16 Amp(SP) – 1 No.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
MAIN CONTROLLER •
Micro Processor based con troller, working voltage 11 volts to 16 volts DC with battery back-up a nd Auto changeo ver facility provided.
•
AMF functions are incorporated.
•
Display parameter (LED and LCD) : 55 parameters
•
Monitoring and metering : 28 parameters
•
Digital output (Relay Out) : 16 parameters
•
Digital Fault inputs : 16 parameters
•
Programmable parameters through Laptop / PC : upto 50
•
Event recording: 500 events, which can converted to MS Excel for diagnosis. o Parameter list with date and time stamp ing. o Fau lt events with date an d time stamping. o DG start and stop event log with date and time stamping.
•
RS 232 / RS 485 port provided for any change in setting though laptop or for monitoring through GSM / GPRS.
SVR & ISOLATION TRANSFORMER • Micro processor ba sed controller • Static stab iliser with wide ra nge o f Inp ut. • Built-in Isolation tran sforme r • IGBT ba sed static Voltage Regulator • Dynamic response 400V/1s • Built-in high voltage an d low voltage protection a t input a nd o utput with response time < 10ms • Modu lar de sign for easy replacement o f SVR control module.
ENVIRONMENTAL Noise level Operating Temperature Storage Temperature Humidity
< 65 Db -5° to + 55° C -20° to + 80° C RH 95%
< 65 Db -5° to + 55° C -20° to + 80° C RH 95%
< 65 dB -5° to + 55° C -20° to + 80° C RH 95%
Construction
Sheet metal fabricated cabinet of 1.6mm thick sheets for covers and 2 mm thick for hinged doo r.
Ea rth in g /G ro un din g
A co mm on ea rth bu sb ar p ro vid ed in sid e to p o f th e UNIT a nd a ll th e in te rn al e arth wires are terminated to the common earth busbar. Provision is made to connect externa l ea rth cab les to the green / Yellow TB an d com mon busb ar.
Cable entry
Cable entry provision is made at the top of UNIT and cable entry holes are provided with rubber grommets or plastic cable gland.
Founda tion h oles
The UNIT grouting holes 4 nos. of 14 mm dia provided at bottom
Equipment color/ shade
As per customer requirement
Packing
Wooden or Cardboard packing with cushion
STANDARDS Conducted Emission Ra dia ted Emissio n Electrical Fast Transient (EFT) Electro Static Discharge(ESD)
Me ets Cla ss A G ro up II lim its o f CISP R 1 1 Meets Cla ss A Group II limits of CISPR 11 IEC 61000-4-4:2001 IEC 61000-4-2:2001
Surge Immunity R.F. Conducted Immunity Environment MTBF
IEC 61000-4-5:2001 IEC 61000-4-6:2001 TEC QM 333 B2 Product material & workmanship shall be of professional quality and meet the MTBF requ irement. The MTBF of the Prod uct is more than 7 000 0 hrs. IEC 60950
Safety
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
SECTION - III INS TALLATIO N AND
CO MMISS IO NING PR O CE DURE
SAFETY PRECAUTION 1. Read and understand the safety instructions before operating / maintenance / trouble shooting of the product.
PRE 1. 2. 3. 4. 5. 6. 7.
INSTALLATION CHECKS Ensure that shelter is ready / installed. Ensure Equipment layout drawing is available. E B Power supply is available at the site. Check that AC Cables are laid from Meter Box to UNIT. Check that Battery Bank is installed and cables are laid from Battery Bank to UNIT. Ensure that DG Installed and commissioned cables laid from DG to UNIT. Check that Grounding cable is routed from Grounding bus bar to Unit.
INSTALLATION The flowing steps are to be followed sequentially during installation at the site. Make sure the Accessories and the tool kits are available for the usage at the Installation site. ACCESSORIES: •
Multimeter with Probes.
•
Lap top with the Communication cable (I/F) - Optional
•
M10x50 Coach Screw for shelter mtg. shelter)
(use Anchor bolts for RCC
•
Hex HD Bolt Steel M6 x 30 – 2 Nos.
(For battery charger mtg.)
•
Plain Washer M6 – 4 Nos.
(For battery charger mtg.)
•
Spring Washer M6 – 2 Nos.
(For battery charger mtg.)
•
Hex Nut M6 – 4 Nos. (With Lock Nut)
(For battery charger mtg.)
•
Water sealant – A/R
•
Alarm Cable – As per spec
(part of Unit shipment)
•
Ala rm Ca ble fo r BTS gro un d ca ble a s p er sp ec
(p art o f P SU sh ip me nt)
•
Mecha nica l Tool Kit
•
Wire cu ttin g & Crim pin g to ol
•
Ferrules A/R
•
Wire Gra y co lo r 1 .5 mm sq ua re – A/R
•
Drilling m/c with bits to take up to 15 mm
•
Po we r ch ord s & exte nsio n box.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
1.0 RECEIPT OF ITEMS / MATERIALS 1.1 RECEIPT OF PRODUCT WITH PACKING . • En su re th at th e p ackin g is n ot da ma ge d. • Refer the SL No. / Box No. and record. • Open the packing and observe for the physical damages if any. • Check the components, cords, plug-in relays, auxiliary transformers & all other items for any loose fittings or dismantled during transportation. • Press all the connector on the PCB’s and other sub-assembles for proper mating of the connectors. • Check the manual operations of the keys on front panel door inside. • Use the field wiring diagram and terminate the cables 1.2 •
Unpack the transformer packing and observe for any damages . Check for the moment of terminations and terminal block and make sure these are tight enough so that there are no shorts with each other.
1.3
DG BATTERY CHARGER BOX / DG CONTROLLER
•
Unpack the box and check for the components, terminations & PCB for damages.
•
Note: If there is any damages found in the all three unpacking sequence above, components must be replaced before installation con tinue s.
2.0 2.1 • • • • •
IN S TALLATI O N P R O C E DU RE Li ft a n d p l a c e t h e P ro d u c t c a b i n e t o n t he r e q u ir e d lo c a t i on i n t h e s h el t e r. Mark the mounting location clearly and take out the cabinet. Drill all the four holes for mounting with M10x50 coach screw. Place the Unit to match with the drilled holes and align for the proper mounting. Use the standard coach fasteners listed under the accessories and mount rigidly Make sure the coach screws are tightened properly.
2.2 •
TR AN S F O R ME R I N S TALLATI O N . Install the transformer in the Product using its own fasteners. Make sure the terminal block of the transformer are facing front of the cabinet. Use metal ‘U’ channel (Ref. Page No. ) on front bottom frame to avoid scratch while loading transformers.
2.3
B ATTE RY C H AR G E R BO X / DG C O N TR O LLE R
•
Identify the battery charger box mounting location in the DG canopy and Drill dia 8.0mm hole, two places on cano py side wa ll (or on the stand provided b y the customer)
•
Use the M6 fasteners listed under the accessories and mount the battery charger box on to cano py side wall or (on to the vertical stan d p rovided by the customer). Ensure that bo lt hea d and plain washer is on the side the canopy. Apply water sealant a round the bo lt / washer o n the canop y out side wa ll to protect the water leakages.
3.0 3.1
C AB LE / WI RI NG T E RMI NATI O N S G E NE RAL TE RMIN ATIO N :
•
Connect the cables from Unit to the DG Battery charger Box / DG Controller Relay Board connector.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
•
Connect the Alarm cable on to the Relay board or from the terminals provided and the other end has to be taken through the BTS end connection. Customer to identify the location for connection.
•
Connect the customer supplied wire from Unit TB located at left hand top side of the cabinet to the Do or Switch, Smoke de tector and PCM. The lengths of the wires ha ve to be decided a t site ba sed on location of these compo nen ts.
•
Customer Supplied DC Cables routed from Power Plant Batteries to be terminated on to the
•
UNIT MCB on top end of the cabinet . Connect the AC supply coming from DG to DG MCB with proper polarity (L&N)
•
Connect the AC supply coming from Mains/ EB to the EB Mains MCB with proper polarity
(RYBN). 3.2 Transformer to SVR Box term ination: • Identify the termination wires coming from SVR terminal block, the wire no 0 to 5 are to be terminated on to the Transforme r terminal block. 3.3 Ground Cable Termination: • Use earthling cables provided by customer at site & connect from shelter / site earthling bus bar to the Unit earth bus bar. Make sure the proper rating of the wire has been used and tightened p roperly at both e nds. 1. Functional Procedure • Ensure that before switching on Unit all components are fixed / terminated properly. • Make a continuity check between Phase to Ground, Neutral to ground and Ground to chassis as a safety requireme nt. • Switch on the Mains MCB on AC Distribution unit. • Check the voltage at Input terminals and record. • Keep AUTO MANUAL switch in AUTO mode. • Switch on the AC supply from the EB switch. • Switch ON EB, DG a nd SVR MCB’S. • After certain time delay SVR ON lamp will glow. • PSU Controller will sense EB supply presence and after certain time delay it will switch on EB contactor. • At this time, Mains AC supply will be available for load. • If MAINS fails, DG will not starts immediately. System Battery will give the load for telecom battery for some time. The controller senses the EB supply presence, roo m tem p. H igh (preset) and system battery low (pre-set) & then Controller gives command to start the DG by considering the a bove three conditions. • IF MAINS restores in normal range, controller gives the command to change over the load to MAINS and put OFF the DG. • DG will run for about 5 minutes without load for cooling. • The controller senses the DG faults and stops the load on DG immediately. • If controller is not working then keep AUTO MANUAL switch in manual mode and put the loa d on DG ma nua lly. • The controller displays O/P voltage, current and frequency simultaneously all other messages will be d isplayed on LCD display. • Conduct the load test for at least one hour. • Note the installation, manufacturing and transportation damages in the feedback form send it back to factory. • Ensure that after installation, installation report and customer feed back duly signed by the customer to be sent to Bangalore office.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
SECTION -IV 2. MAINTENANCE
This system is conservatively designed. It is completely static with all advanced digital circuits. This system will provide troub le free service with minimu m maintena nce. However a regular p eriodic maintenan ce program should be followed. Table given below provides the schedule of maintenance procedure in detail.
5.1 TABLE OF PERIODIC INSPECTION AND MAINTENANCE ITEMS
INSPECTION PERIOD
PROCEDURE
Ventila tio n a nd Openings
Da ily
Check tha t inta ke a nd exha ust a ir o penings a re not obstru cted
Cabinet Assemblies
Weekly
Remove dust and foreign particles within the Chassis using comp ressed air or blower. Check mou nting bolts an d terminals looseness. Tighten them
Cabinet
3 Months Quarterly
Inspect transformers for evidence of over heating, damaged insulation or loose mo unting screws Correct any ma lfunction ing before operating the unit. Tighten any loose screws or nuts. Clean electrical contacts with a cloth dampened carbon tetrachloride. Do no t use clean ing solvents on e lectrical conta cts. Replace if found defective
Controls & Indications 3 Months
Internal components
Check all LEDs
6 Months Half-yearly
Check all controls for operability. or malfunctioning is observed.
Replace if any dama ge
12 Months
Check the cable for input and output power and internal wiring to compo nen ts. Check for cracks or broken insulation. Replace as indicated.
12 Months Yearly
Inspect the general conditions of PCB. Check the components for evidence of over hea ting cracks or peeling. Repair or replace board if necessary
12 Months
Inspect Diodes, Silicon Controlled Rectifiers (SCRs) & MOSFETS and their hea t dissipaters for loose mou nting or defective electrical conn ections. Tighten screws an d nuts.
12 Months
Inspect PCB, Sockets for loose electrical connections, Tighten the mounting screws and replace defective sockets, if any.
12 Months
Inspect electric wiring for broken solder connections, eviden ce of peeled insulation a nd gen eral deterioration, Repa ir or replace damaged wiring.
CAUTION ONLY AUTHO RISED PERS ON TO H ANDLE MAINTENANCE
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
4.2 MAINTENANCE TIPS : When replacing the com ponent s, obs erve th e following
1.
When replacing the compon ents switch off the respective supply.
2.
Note down the terminal numbers/wire numbers before removing the wires.
3.
Utmost care shall be taken while re-connecting the cables back.
4.
Do not drop any type of hardware and tools inside the chassis.
5.
Do not damage leads of other components by pushing or pulling them aside.
6.
Maintain a log of all repairs and adjustments. Comprehensive notes and an accurate log, make it possible to reverse the procedure or to facilitate the communications regarding repair procedure.
7.
When detaching wires from components, mark the wire with tape to ensure correct rewiring.
8.
Always place the component in the exact position occupied by the original.
9.
Whenever one or more components have been replaced, testing and readjustment of appropriate circuit is necessary.
SECTION - V INPUT/OUTPUT TERMINATION DRAWINGS
1
Block Diagrams
2
Sin gle lin e dia gra ms
3
SVR Co nn ectio n Dia gra ms
4.
Control Wiring Diagrams
5.
Term in al De ta ils
6.
Ala rm Details
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
R V S 1 ) G D H P 1 & S N I A M H P 1 3 ( M A R G A I D K C O L B
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
R V S 2 ) G D H P 3 & S N I A M H P 1 H P 3 ( M A R G A I D K C O L B
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
NEUTRAL BUS BAR
EARTH BUS BAR
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
STATIC VOLTAGE REGULATOR (PRIMARY CONTROL)
P/S TX
1
SVR CONTROLLER
2
0
1
2
3
4
5
0
1
2
3
4
5
TWO - PH INPUT - R&Y or Single - PH INPUT - L & N
L L N OUTPUT 220 V
N
POWER TRANSFORMER NAME DRAWN
RAMESH
CHECKED
BANGAR
APPRVD.
SIGNATURE
DATE
DIAG. NOT TO SCALE REV. -01
PACE
VENUGOPAL
POWER SYSTEMS PVT. LTD.,
MFG.
OK
STATIC VOLTAGE REGULATOR
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
STATIC VOLTAGE REGULATOR (SECONDARY CONTROL)
P/S TX
L
SVR CONTROLLER
N
0
1
2
3
4
5
0
1
2
3
4
5
L N OUTPUT 220 V
TWO - PH INPUT - R&Y or Single - PH INPUT - L & N
1
2
POWER TRANSFORMER NAME DRAWN CHECKED APPRVD.
SIGNATURE
DATE
DIAG. NOT TO SCALE REV. -01
RAMESH BANGAR
PACE
VENUGOPAL
POWER SYSTEMS PVT. LTD.,
MFG.
OK
STATIC VOLTAGE REGULATOR
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
WIRING DRAWING RED +ve
+
32
BLACK
MODEM
BLUE
-
31
- ve
SMOKE SENSOR
NO
GREEN
COMMON
TO BTS
BTS ALARMS RELAY BOARD
RELAY BOARD
FROM MCU K1 K3 K5 C3 C2
A2
E6 E7 A2 E4
C12 C13 C14 C15
DG BATT. CHARGER
VMR -1PH
VMR -3PH
E L
N1
K1 (+ve)
A10 A9
A10 A9
L N1 E
J1
DC - DC CONVERTER
DC - DC CONVERTER
A1
81
32
K2 (-ve)
SYS. BATT. CHARGER
J1 A1 81 51
+ve
7 AH BATTERY
31 51
NAME DRAWN
RAMESH
CHKD
BANGAR
APPRVD
VENUGOPAL
-ve
SIGNATURE
DATE
DO NOT SCALE DIAGRAM
REV-01
PACE POWER SYSTEMS PVT. LTD.
MFG
WIRING DIAGRAM
QA
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
DG AUTOMATION DRAWING WITH PMU (For Individual DG Controller) DG TERMINALS DG BATT. +ve (4 Sq.)
1
DG BATT -ve (4 Sq.)
2
DG START (4 Sq.)
3
DG STOP (4 Sq.)
4
1
DG BATT +ve (4 Sq.)
LLOP (1.5 Sq.)
5
2
DG BATT -ve (4 Sq.)
HCT (1.5 Sq.)
6
3
V-BELT (1.5 Sq.)
HALF FUEL (1.5 Sq.)
7
4
LOW FUEL (1.5 Sq.)
LOW FUEL (1.5 Sq.)
9
5
DG START (1.5 Sq.)
V- BELT (1.5 Sq.)
10
6
DG STOP (1.5 Sq.)
7
LLOP (1.5 Sq.)
8
HCT (1.5 Sq.)
9
HALF FUEL (1.5 Sq.)
PMU TERMINALS
10 DG BATT. +ve (4 Sq.)
NOTE : The cable from PMU to DG will be of 4 sq. mm. 2-core and 1.5 sq. mm. 8-core Armoured. DG STOP FROM PMU (1.5 Sq.) DG START FROM PMU (1.5 Sq.) DG BATT -ve (1.5 Sq.) DG BATT +ve (1.5 Sq.)
DG CONTROLLER
NAME DRAWN
RAMESH
CHECKED
BANGAR
APPRVD.
VENUGOPAL
SIGNATURE
DATE
DIAG. NOT TO SCALE REV. -01
PACE POWER SYSTEMS PVT. LTD.,
MFG.
OK
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DG AUTOMATION DRAWING
PACE POW ER SYSTEMS PVT. LTD., Bangalore
ALAR M DETAI LS 1 2 3 4 5 6
DG CONTROLLER
SVR FAIL ) . q S 4 ( T R A T S G D
MAINS FAIL SMOKE /FIRE
7 8 9
DOOR OPEN ) . q S 4 ( e v + T T A B G D
HIGH ROOM TEMP
10 11 12 13 14 15 16 17 18
CONTACTOR FAULT BTS BATT. LOW
) . q S 4 ( P O T S G D
R E L L O R T N O C G D
LOAD ON DG DG BATT. LOW
19 20 21 22 23 24 25 26 27 28 29
DG FAULT
N E P O
) . q S 4 ( e v + T T A B G D
) N O S K C A J ( . q S 4 P O T S G D
. q S 1 - ) N O S K C A J ( U M P m o r f P O T S G D
OVER LOAD LOW FUEL LLOP FAULT
- - - - -
HCT / HWT
) . q S 1 ( U M P m o r f P O T S G D ) . q S 1 ( U M P m o r f T R A T S G D
FAIL TO STOP
) . q S 1 ( e v - . T T A B G D
30
) . q S 1 ( e v + . T T A B G D
31 32
FAIL TO START
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
FIELD WIR ING DIAGRAM T N I P O M P 3 A R L E S . W 3 I - P V O C M A P A S
T H G I L 2 M S O 2 - P O C M R A S
2 1 1 +ve 1
K1
}-ve HOOTER
K2 K3
0 1 +ve 9
BTS BATT. }-ve INPUT L O R T N O C M O O R O T
FAN -ve
8
PCM +ve
7
DOOR SWITCH SMOKE SENSOR
T U P N I S N I A M
. G H 1 C . T 1 S T - P A C M B A S
K4 K5 K6 K7
6
K8
5
K9
4
C1
COMN. 3
C2
} ‘NO’
C3
-ve 2
SMOKE SENSOR
}
KC
1
T U P N I G D
+ve DG BATTERY
2
-ve DG BATTERY
3
DG START
4
V-BELT
5
DG STOP
6
LLOP
7
HWT/HCT
8
HALF FUEL
9
LOW FUEL
1 0
FAULT
1 1
RESET
1 2
CANOPY FAN
1 3
T O D G B A T T . C H G . & D G C O N T R O L L E R U N I T
DG COMMN.
+ve 1
TERMINAL BLOCK DETAILS (FOR INBUILT BATT. CHARGER & SEPERATE DG CONTROLLER) TO DG CONTROLLER Y R E T T A B G D e v +
Y R E T T A B G D e v -
T R A T S G D
1
2
3
T L E B V
P O T S G D
4
5
P O L L
L T E C U F H / F T L W A H H
e . e v - ) N v s G m O r L M f o D r a E M e r l U O v o A s e F C + m r v G W a + r l O G D ( o L D A f
6
7
9
8
1 2 3 4 5 6 7 8 9 K K K K K K K K K
30
10 C K
PACE POW ER SYSTEMS PVT. LTD., Bangalore
TERMINAL BLOCK DETAILS (FOR INDIVIDUAL BATT. CHARGER & DG CONTROLLER) 1
+ve
2
-ve
3 4 5 6 7 8 9
}
SMOKE
K1
SENSOR
K2
COMN. ‘NO’
}
K3 SMOKE SENSOR T
DOOR SWITCH +ve PCM -ve FAN +ve
K4
O
K5
R O O M C O N T R O L
K6 K7 K8 K9 C1
}
1 0
BTS BATT. -ve INPUT
1 1
+ve
1 2
-ve
C2 C3
} HOOTER
KC
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3
+ve DG BATTERY -ve DG BATTERY DG START V-BELT DG STOP LLOP HWT/HCT HALF FUEL LOW FUEL FAULT RESET CANOPY FAN DG COMMN. (+ve Normal DG) (-ve Jackson DG)
T O D G B A T T . C H G . & D G C O N T R O L L E R U N I T
BATTERY CHARGER TB DETAILS
TO DG CONTROL
FROM UNIT TB DETAILS 1. 2. 3. 4. 5. 6. 7. 8. 9 10. 11. 12. 13. 14. 15. 16. 17.
+ve DG BATTERY -ve DG BATTERY START (Normal & Jackson) V - BELT STOP (Normal), START (Jackson ) STOP (Jackson) LLOP HCT / HWT HALF FUEL LOW FUEL DG FAULT RESET CANOPY FAN DG COMMON (+ve Normal DG) (-ve Jackson DG) PH 230V AC N FROM UNIT E
1.
+ve DG BATTERY
2.
-ve DG BATTERY
3.
START (Normal & Jackson)
4.
V - BELT
5.
STOP (Normal), START (Jackson )
6.
STOP (Jackson)
7.
LLOP
8.
HCT / HWT
9.
HALF FUEL
10.
LOW FUEL
11.
DG COMMON (+ve Normal DG) (-ve Jackson DG)
}
31
12.
CANOPY FAN DRY O/P
13.
CANOPY FAN DRY O/P
14
CANOPY LIGHT LINE
15.
CANOPY LINE NEUTRAL
PACE POW ER SYSTEMS PVT. LTD., Bangalore
NETWORK MANAGEMENT SYSTEM (GSM - OPTIONAL) 1.
The Product is having 2 way communication facility with the central console.
2.
The communication protocol and format are as per standard format.
3.
The error broadcast facility is available for 6 mobile numbers.
4.
Status, program values and meter readings are retrievable any time from mobile or central console through specific SMS command.
5.
Control functions through mobile or Start DG, Stop DG, Reset System by typing message in capital like START, STOP, RESET.
MESSAGE FORMAT :
a)
Status - Status of a remote site can be sought from a designated mobile phones or central console as per below format. FORMAT :
Sent message
: STATS (for Maintenance Staff )
Response from Site :
TXT MSG, MODE = Text, DG = XXX.X V, EB = XXX.X V, TEMP = XX.XC, BATT = XX.XXV, SYSBAT = XX.XXV, FUEL LVL = XX.XX, SITE ID TEXT.
The Example for the above format is :
LOAD ON DG, MODE = AUTO, DG = 230V, EB = 0V, TEMP = 28.9C, BATT = 28.20V, SYSBATT = 13.06, FUEL LVL = 17.5, ID : BANGALORE. Sent Message
:
Response from Site :
CSTAT (For Central Console) S/SITE ID / MAINS V / DG 1V / DG2V/BTY1V / BTY 2V / BTY 3V / TEMP / FUEL LEVEL / DG RT / EB RT / BT RT / DATE / TIME / ERROR LAST.
Date format
:
- DD - MM - YY
Time Format
:
HH : MM : SS (24 Hours format)
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
b)
ERROR / ALARM : Site Master Control will broadcoast error message to designated maintainance personnel and Central console as per following format. Error Code / Site ID / Date / Time / Text Message explaining the error. For Example : E 20 / BANGALORE / 09-06-08 / 09 : 22 : 30 / DG FAULT.
c)
Som e m ore Com m ands :
a)
Adding the Site Identification name / Tower ID COMMAND MESSAGE : ADDSN
b)
Console reporting time : Once in 24 hours. COMMAND MESSAGE : ADDUT < TIMING HH : MM FORMAT>
c)
Storing the mobiles of Site Engineers at remote site for alarm broadcoast COMMAND MESSAGE :
ADD1C ADD2C ADD3C ADD4C ADD5C ADD6C
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
GENERAL PACKET RADIO SERVICE (GPRS - OPTIONAL) The General Packet Radio Service (GPRS) is a new nonvoice value added service that allows information to be sent and received across a mobile telephone network. It supplements today’s Circuit Switched Data and Short Message Service. GPRS is NOT related to GPS (the Global Positioning System), a similar acronym that is often used in mobile contexts.
KEY USER FEATURES OF GPRS Theoretical maximum speeds of up to 171.2 kilobits per second (kbps) are achievable with GPRS using all eight timeslots at the same time. This is about three times as fast as the data transmission speeds possible over today’s fixed telecommunications networks and ten times as fast as current Circuit Switched Data services on GSM networks. By allowing information to be transmitted more quickly, immediately and efficiently across the mobile network, GPRS may well be a relatively less costly mobile data service compared to SMS and Circuit Switched Data. GPRS facilitates instant connections whereby information can be sent or received immediately as the need arises, subject to radio coverage. No dial-up modem connection is necessary. This is why GPRS users are sometimes referred to be as being “always connected”. Immediacy is one of the advantages of GPRS (and SMS) when compared to Circuit Switched Data. High immediacy is a very important feature for time critical applications such as remote credit card authorization where it would be unacceptable to keep the customer waiting for even thirty extra seconds. GPRS facilitates several new applications that have not previously been available over GSM networks due to the limitations in speed of Circuit Switched Data (9.6 kbps) and message length of the Short Message Service (160 characters). GPRS will fully enable the Internet applications you are used to on your desktop from web browsing to chat over the mobile network. Other new applications for GPRS, profiled later, include file transfer and home automation - the ability to remotely access and control in-house appliances and machines.
TO USE GPRS, USERS SPECIFICALLY NEED: § § § §
§
§
a mobile phone or terminal that supports GPRS (existing GSM phones do NOT support GPRS); a subscription to a mobile telephone network that supports GPRS; use of GPRS must be enabled for that user. Automatic access to the GPRS may be allowed by some mobile network operators, others will require a specific opt-in; knowledge of how to send and/or receive GPRS information using their specific model of mobile phone, including software and hardware configuration (this creates a customer service requirement); a destination to send or receive information through GPRS. Whereas with SMS this was often another mobile phone, in the case of GPRS, it is likely to be an Internet address, since GPRS is designed to make the Internet fully available to mobile users for the first time. From day one, GPRS users can access any web page or other Internet applicationsproviding an immediate critical mass of uses; Having looked at the key user features of GPRS, lets look at the key features from a network operator perspective.
KEY NETWORK FEATURES OF GPRS GPRS involves overlaying a packet based air interface on the existing circuit switched GSM network. This gives the user an option to use a packet-based data service. To supplement a circuit switched
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
network architecture with packet switching is quite a major upgrade. However, as we shall see later, the GPRS standard is delivered in a very elegant manner - with network operators needing only to add a couple of new infrastructure nodes and making a software upgrade to some existing network elements. With GPRS, the information is split into separate but related “packets” before being transmitted and reassembled at the receiving end. Packet switching is similar to a jigsaw puzzle - the image that the puzzle represents is divided into pieces at the manufacturing factory and put into a plastic bag. During transportation of the now boxed jigsaw from the factory to the end user, the pieces get jumbled up. When the recipient empties the bag with all the pieces, they are reassembled to form the original image. All the pieces are all related and fit together, but the way they are transported and assembled varies. The Internet itself is another example of a packet data network, the most famous of many such network types.
Packet switching means that GPRS radio resources are used only when users are actually sending or receiving data. Rather than dedicating a radio channel to a mobile data user for a fixed period of time, the available radio resource can be concurrently shared between several users. This efficient use of scarce radio resources means that large numbers of GPRS users can potentially share the same bandwidth and be served from a single cell. The actual number of users supported depends on the application being used and how much data is being transferred. Because of the spectrum efficiency of GPRS, there is less need to build in idle capacity that is only used in peak hours. GPRS therefore lets network operators maximize the use of their network resources in a dynamic and flexible way, along with user access to resources and revenues. GPRS should improve the peak time capacity of a GSM network since it simultaneously: § allocates scarce radio resources more efficiently by supporting virtual connectivity; § migrates traffic that was previously sent using Circuit Switched Data to GPRS instead; § reduces SMS Center and signalling channel loading by migrating some traffic that previously was sent using SMS to GPRS instead using the GPRS/SMS interconnect that is supported by the GPRS standards. For the first time, GPRS fully enables Mobile Internet functionality by allowing interworking between the existing Internet and the new GPRS network. Any service that is used over the fixed Internet today - File Transfer Protocol (FTP), web browsing, chat, email, telnet - will be as available over the mobile network because of GPRS. In fact, many network operators are considering the opportunity to use GPRS to help become wireless Internet Service Providers in their own right. The World Wide Web is becoming the primary communications interface - people access the Internet for entertainment and information collection, the intranet for accessing company information and connecting with colleagues and the extranet for accessing customers and suppliers. These are all derivatives of the World Wide Web aimed at connecting different communities of interest. There is a trend away from storing information locally in specific software packages on PCs to remotely on the Internet. When you want to check your schedule or contacts, instead of using something like “Act!”, you go onto the Internet site such as a portal. Hence, web browsing is a very important application for GPRS. Because it uses the same protocols, the GPRS network can be viewed as a sub-network of the Internet with GPRS capable mobile phones being viewed as mobile hosts. This means that each GPRS terminal can potentially have its own IP address and will be addressable as such. It should be noted right that the General Packet Radio Service is not only a service designed to be deployed on mobile networks that are based on the GSM digital mobile phone standard. The IS-136 Time Division Multiple Access (TDMA) standard, popular in North and South America, will also support GPRS. This follows an agreement to follow the same evolution path towards third generation mobile phone networks concluded in early 1999 by the industry associations that support these two network types.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
MONITORING PARAMETER DETAILS USING GPRS DESCRIPTION
DISPLAY TYPE
MAINS VOLTAGE LCU1 VOLTAGE LCU2 VOLTAGE MAINS FREQUENCY DG R-PHASE VOLTAGE DG Y –PHASE VOLTAGE DG B-PHASE VOLTAGE DG FREQUENCY LOAD CURRENT R-PHASE LOAD CURRENT Y-PHASE LOAD CURRENT B-PHASE DG BATTERY VOLTAGE BTS BATTERY VOLTAGE SYS BATTERY VOLTAGE ROOM TEMPEARTURE MAINS RUN HOURS DG RUN HOURS BATTERY RUN HOURS MAINS ENERGY DG ENERGY AC1 RUN HOURS AC2 RUN HOURS FREE COOL RUN HOURS DATE MONTH YEAR HOUR MINUTE MAINS OK ALARM DG OK ALARM DG BATTERY LOW ALARM BTS BATTERY LOW ALARM AC1 ON ALARM AC2 ON ALARM AVATION LAMP ON ALARM LOW FUEL ALARM HALF FUEL ALARM OVERSPEED ALARM HIGH ENG TEMP ALARM LLOP FAULT ALARM OVER LOAD ALARM FAIL TO START ALARM FAIL TO STOP ALARM MANUAL MODE DG ALT. FAULT ALARM EB CONTRACTOR FAIL DG CONTRACTOR FAIL DOOR OPEN FAULT DG DOOR OPEN FAULT MAINS FAIL HIGH ROOM TEMP SMOKE FIRE LCU FAIL DG COMMON FAULT SYS BATTERY LOW
XXX XXX XXX XX.X XXX XXX XXX XX.X XX.X XX.X XX.X XX.X XX.X XX.X XX.X XXXX.X XXXX.X XXXX.X XXXXXX.X XXXXXX.X XXXX.X XXXX.X XXXX.X XX XX 20XX XX XX LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED LED
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
PACE PMU MICRO CONTROLLER INTRODUCTION: PACE PMU MICROCONTROLLER is an integrated multifunction high speed micro controller based on highly reliable technology. Its having the capacity of handling single phase / two phase /three phase mains and DG with Automatic /manual modes of operations. The module includes protections for mains and DG (as per standards).The microcontroller module includes total three battery monitoring and room temperature monitoring facility. And the same can be enabled or disabled as per requirements. There are two options for DG start depends on battery mode operation (Fuel saver mode). One is, If battery mode operation is ON , mains and LCU voltages are not healthy then controller will keep the site running on BTS battery by monitoring continuously battery voltage and room temperature. If the battery voltage goes below set limit or temperature goes high above the set limit then controller will generate the start command to the generator. Microcontroller keep generator on load for set run hours. Again after finishing set run hour’s controller will release the stop command to the generator and keep generator in off mode till to get the condition of battery voltage and room temperature. Second is , If battery mode operation is OFF , controller will run the generator for set run hours , then it will stop the generator and keep in off mode still to finish the set rest hours. After finish of set rest hours controller will start the generator. Again this will save the diesel and DG running hours. The microcontroller is having the facilities of interfacing the new generation devices like GSM module & GPRS module for monitoring the data online.
Specification (Features) A) Monitoring of mains parameters. B) Monitoring of DG parameters. C) Monitoring of Analog and Digital parameter. D) Programmable parameters (almost fifty programmable parameters). E) Calibration (on site calibration facility for all analog parameter). F) AMF functions & control. G) DG Fuel & Run time saver. H) Aviation lamp controller. I)
Smoke/Fire controller.
J) One/Two DG controller. K) Fault alarms with free of potential. L) Real time and events recording. M) High MTBF N) Compact and modular design. O) NMS (Network management system).
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
DESCRIPTION MONITORING PARAMETERS 1. ANALOG PARAMETERS a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r)
Mains Input voltage. SVR input voltage. SVR output voltage. Three or single Phase DG voltage. Three or single phase output load. BTS battery voltage. DG battery voltage. System battery voltage. Room Temperature. Mains frequency. DG frequency. Mains Run hours. DG Run hours. BTS Battery Run hours. Mains Energy. DG Energy. Free cooling run hours. Air conditioner run hours.
2. DIGITAL PARAMETERS a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r)
Mains Fail. DG Fail to START. DG Fail to STOP. DG LLOP. DG HALF FUEL. DG LOW FUEL. High engine temperature. V-belt cut High room temperature. SVR fail. Contactor fails. Smoke Fire. Door open. Overload. DG over speed. BTS battery low DG battery low. System battery low.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
PROGRAMMABLE PARAMETERS The programmable parameters provided in microcontroller module are as follows.
S.NO
Parameter Name
Max Value
Min Value
Default Value
1
Mains High Cut off
500
240
485 Volt
2
Mains Low Cut off
350
70
240 Volt
3
Mains High Cut in
500
220
470 Volt
4
Mains Low Cut in
380
70
265 Volt
5
DG High Cut off
300
240
260 Volt
6
DG Low Cut off
210
150
180 Volt
7
DG RPM High
3300
1550
1600 RPM
8
DG RPM Low
2500
1000
1350 RPM
9
DG Rest Time
600
5
30 Minute
10
Room Temperature High alarm
60
20
40 °C
11
Overload
99
0
35 Amp
12
BTS Battery Low
60
20
47 Volt
13
DG battery Low
24
7
10 Volt
14
DG Auto Run Time
9
1
1 Hour
15
Crank Active Time
99
1
2 Seconds
16
Crank Retries
5
0
2
17
Stop Hold Time
90
10
20 Seconds
18
Stop Retries
5
0
2
19
DG Warm UP time
90
5
20 Seconds
20
Mains Restore Time
300
5
30 Seconds
21
DG Cool Down Time
900
5
30 Seconds
22
DG Long Lock Time
60
10
20 Minutes
23
Low Fuel Shut down Time
240
1
2Seconds
24
Aviation On Time (Hours)
23
0
18
25
Aviation On Time (Minutes)
59
0
0
26
Aviation Off Time (Hours)
23
0
7
27
Aviation Off Time (Minutes)
59
0
0
28
Console Report Time (Hours)
23
0
13
29
Console Report Time (Minutes)
59
0
0
30
Battery Mode Operation
ON
OFF
ON
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
S.NO
Parameter Name
31
LLOP Delay Time
32
Max Value
Min Value
Default Value
99
2
10 Seconds
DG Start Interval
240
1
40 Seconds
33
Current Ratio
125
25
125
34
LCU High Cut off
300
240
260
35
LCU Low Cut off
210
150
190
36
LLOP enable/disable
Enable
Disable
Enable
37
Max Mobile Number
6
0
6
38
Site ID (Character)
13
0
13
39
System Name (Character)
3
0
3
40
1st Mobile Number (Digits)
10
0
10
41
2nd Mobile Number (Digits)
10
0
10
42
3rd Mobile Number (Digits)
10
0
10
43
4th Mobile Number (Digits)
10
0
10
44
5th Mobile Number (Digits)
10
0
10
45
6th Mobile Number (Digits)
10
0
10
46
Date
31
1
47
Month
12
1
48
Year
99
0
49
Hour
23
0
50
Minute
59
0
8
CALIBRATION PARAMETERS: The calibration parameters are as follows. S.No
Parameter name
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Mains Voltages LCU1 Voltage LCU2 Voltage LCU3 Voltage DG R-Phase DG Y-Phase DG B-Phase Load current R-Phase Load current Y-Phase Load current B-Phase BTS Battery voltage DG Battery voltage INT Battery voltage Room Temperature
Actual value
Measured value
XXX XXX XXX XXX XXX XXX XXX XX.X XX.X XX.X XX.X XX.X XX.X XX.X
XXX XXX XXX XXX XXX XXX XXX XX.X XX.X XX.X XX.X XX.X XX.X XX.X
Actual value – Means to set whatever is coming on the terminal by standard meter Measured value – Means whatever controller is measuring the value. 40
PACE POW ER SYSTEMS PVT. LTD., Bangalore
SMS MODULE (OPTIONAL) SMS feature of Pace controller is having two-way communication facility and the details are as below. 1) If any alarm is generated at the site , controller will send SMS to SIX different mobile numbers on specified format. ( The alarm details ) 2) If User Send Some command like START, STOP, RESET, CSTAT, STAT to the site , then controller gives response according to specified format. ( The site status ) 3) User can do the configuration of some parameters via SMS like Site name, console report time, all mobile numbers. 4) User can START DG , STOP DG & RESET the fault via SMS. GPRS MODULE (OPTIONAL) User can monitor the site and all parameters via GPRS network.
Operation Details The operational details of pace microcontroller are as below. 1) Key function 2) Calibrations 3) Configurations 4) System operations 5) Aviation Lamp control 6) SMS Feature 7) Events logging 8) Smoke/fire control 9) Emergency Shutdown Key Function There are five push buttons on the front panel of Microcontroller to operate and monitor the controller & site details.
SW1
# # # # #
SW1 SW2 SW3 SW4 SW5
for for for for for
SW2
SW3
SW4
SW5
Increment and Reset Decrement and Scrolling Enter and Events Configuration (Menu setting & Calibration) Escape from inside program to main menu
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
#SW1 This switch can be used for two purposes one for increment the value and other for system reset. Normally this switch will act as system reset. When you go for configuration that time this switch will act as a increment the value. #SW2 This switch can be used for two purposes one for decrement the value and other for verifying the various parameter values. Normally this switch will act as a scroll function. When you go for configuration that time this switch will function as a decrement the value. #SW3 This switch can be used for two purposes one for Enter and other for verifying the various events. Normally this switch is working for events log display. When you go for configuration that time this switch will work as enter button. #SW4 This switch can be used for two purposes one for going backward during menu setting and calibration , other for entering in menu setting and calibration mode. Normally this switch will work to enter in configuration mode. #SW5 This switch can be used for escape only. setting mode to the default display mode.
Purpose of this switch is to come out of the
CALIBRATION: For any analog parameter calibration follow the following steps. 1. 2. 3. 4. 5. 6. 7.
Press menu button. Enter password by increment, decrement & enter push buttons. Enter into calibration mode. Check the values by multimeter and calibrate the same. Press enter button to go forward. Press menu button to go backward. Press escape button to come out.
Configuration For any programmable parameter configuration (setting) follow the following steps 1. 2. 3. 4. 5. 6. 7.
Press menu button. Enter password by increment, decrement & enter push buttons. Enter into menu setting mode. Set the parameters as per requirement. Press enter button to go forward. Press menu button to go backward. Press escape button to come out. 42
PACE POW ER SYSTEMS PVT. LTD., Bangalore
SYSTEM OPERATION The operation of pace controller in two way on is AUTO mode and other is MANNUAL mode. In auto mode controller control the DG function automatically and check the DG alarm status but in manual mode no control the DG operation. ALARM CHECKING 1)
Fail to stop While running the DG in auto mode , create any DG fault and don’t stop the DG, then controller will generate the fail to stop alarm.
2)
Fail to start While running the controller in auto mode , create DG start condition and don’t start the generator , after three cranks trial controller will generate the fail to start alarm.
3)
LLOP Fault While running DG in auto mode , create LLOP fault ( short battery –ve and LLOP ) , then controller will generate the LLOP fault.
4)
LOW FUEL While running DG in auto mode , create LOW FUEL fault ( short battery –ve and low fuel ) , then controller will generate low fuel fault.
5)
Half FUEL While running DG in auto mode , create half fuel fault ( short battery –ve and half fuel ) , then controller will generate the low fuel fault and display the half fuel in LCD.
6)
HCT/HWT Fault While running DG in auto mode , create HCT fault ( short battery –ve and HCT) then controller will generate the HCT fault.
7)
OVERLOAD While running DG in auto mode on load , create overload or short battery –ve and overload , then controller will generate the overload fault.
8)
Over speed While running DG in auto mode , if speed of the generator goes beyond the limits , then controller will generate the overspeed fault.
10)
Alternate Fault While running DG in auto mode , switch off the DG MCB , then controller will generate the alternator fault.
11)
V-belt Fault While running DG in auto mode , create V-belt fault ( short battery –ve and V-belt) then controller will generate the V-belt fault.
12)
Smoke Fire alarm While running the system in auto mode on mains or DG , create smoke / fire alarm , then controller will shuts off the power and generate the smoke / fire alarm.
13)
Emergency stop While running the system in auto mode on mains or DG , press EM stop button, then controller will generate the emergency alarm.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
14)
Contactor Fail After giving command of contactor on by the controller , if contactor is not getting on , then controller will generate the contactor fail alarm.
15)
BTS battery Low If battery voltage goes below set limit then controller will generate the BTS battery low alarm.
16)
DG battery Low If battery voltage goes below set limit then controller will generate the DG battery low alarm.
17)
High room temperature If room temperature goes above set limit then controller will generate the high room temperature alarm.
18)
Door open If controller gets the sensing as open from door switch then controller will generate the door open alarm.
All above alarms are displayed in LCD display 3 rd line continuous scrolling type and by LED’s .
Aviation Lamp function : While running the system , if real time matches the lamp on time then controller will switch on the lamp . if real time matches the lamp off time then controller will switch off the lamp.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
STANDAR D SETTIN GS FOR DIFFERENT RANGES NO
PARAMETER
STANDARD SETTING 240 - 480 V
155 - 465 V
UNIT
200-495V
1
MAINS HIGH CUT OFF
485
465
495
VOLT
2
MAINS LOW CUT OFF
240
155
200
VOLT
3
MAINS HIGH CUT IN
470
450
485
VOLT
4
MAINS LOW CUT IN
265
180
225
VOLT
5
DG HIGH CUT OFF
260
260
260
VOLT
6
DG LOW CUT OFF
180
180
180
VOLT
7
DG RPM HIGH
1650
1650
1650
RPM
8
DG RPM LOW
1350
1350
1350
RPM
9
DG REST TIME
60
60
60
MINUTS
10
ROOM TEMP.HIGH
35
35
35
DEGREE
11
OVERLOAD
45
45
45
AMP
12
BTS BATT.LOW LIMIT
47
47
47
VOLT
13
DG BATT.LOW LIMIT
10
10
10
VOLT
14
DG AUTO RUN TIME
6
6
6
HOURS
15
CRANK ACTIVE TIME
3
3
3
SECONDS
16
CRANK RETRIES
2
2
2
TIMES
17
STOP HOLD TIME
25
25
25
18
STOP RETRIES
2
2
2
TIMES
19
DG WARM UP TIME
5
5
5
SECONDS
20
MAINS RESTORE TIME
5
5
5
SECONDS
21
DG COOL DOWN TIME
30
30
30
SECONDS
22
DG LONG LOCK TIME
10
10
10
MINUTS
23
LOW FUEL SHUT DN. TIME
1
1
1
24
AVIATION ON TIME
18
18
18
HOURS
25
AVIATION OFF TIME
6
6
6
HOURS
26
CONSOLE REPORT TIME
10
10
10
HOURS
27
BATT. MODE OPERATION
ON
ON
ON
28
LLOP DELAY TIME
2
2
2
SECONDS
29
DG START INTERVAL
40
40
40
SECONDS
30
CT RATIO
75
75
75
FUNCTION
31
LCU HIGH CUT OFF
260
260
260
VOLT
32
LCU LOW CUT OFF
180
180
180
VOLT
33
LLOP ENABLE / DISABLE
ENABLE
ENABLE
ENABLE
FUNCTION
34
MAX MOBILE NUMBER
6
6
6
FUNCTION
35
SITE ID
1234
1234
NUMBER
36
SYSTEM NAME
NAME
NAME
NAME
NAME
37
SITE NAME
NAME
NAME
NAME
NAME
38
SET 1ST MOBILE NUMBER
NUMBER
NUMBER
NUMBER
NUMBER
39
SET 2ND MOBILE NUMBER
NUMBER
NUMBER
NUMBER
NUMBER
40
SET 3RD MOBILE NUMBER
NUMBER
NUMBER
NUMBER
NUMBER
41
SET 4TH MOBILE NUMBER
NUMBER
NUMBER
NUMBER
NUMBER
42
SET 5TH MOBILE NUMBER
NUMBER
NUMBER
NUMBER
NUMBER
43
SET 6TH MOBILE NUMBER
NUMBER
NUMBER
NUMBER
NUMBER
44
SET DATE
PRESENT
PRESENT
DATE
NUMBER
45
SET MONTH
PRESENT
PRESENT
MONTH
NUMBER
46
SET YEAR
PRESENT
PRESENT
YEAR
NUMBER
47
SET HOUR
PRESENT
PRESENT
HOURS
NUMBER
48
SET MINUTE
PRESENT
PRESENT
MINUTS
NUMBER
45
SECONDS
SECONDS
FUNCTION
NUMBER
PACE POW ER SYSTEMS PV T. LTD., Bangalore
SECTION - VI TROUBLE SHOOTING CHART In case there is any fault in the system, it is preferable that the unit is tested step by step. It is further desirable that the basic principle of operation of each section is clear in mind before trouble shooting. However, brief guidelines are provided through the following chart for expediting the fault tracing. S .No.
1
S YS TEM FAULT
DG fail to start
PRO BABLE CAUS E
REMEDY
a) DG battery voltage low.
a) Check battery voltage and charge battery. b) Tighten all connections.
b) Loose contact at DG start relay, start soleno id. 2
DG fails to stop.
a) Battery is discharged b) Loose contact at DG stop relay, stop soleno id.
a) Keep the battery in charged condition b) Tighten the connections.
3
OVER LOAD Indication comes on while the load is switched on
a) Load surge.
a) Switch on the load one by one or overload setting.
4
Alternator fault
a) DG is on but voltage not coming at o/p o f DG.
Check alternator of DG.
5
Room temperature high
a) Temperature sensor not working. b) Sensor wire open. c) False indications due to d efective setting of temp. in controller.
a) Check temperature sensor. b) Connect the wire. c) Check the setting and correct it
6
Smoke / Fire
a) Smoke sensor not working or sensor wire open.
a) Check sensor or connect the wire.
7
LLOP(Lo w lu be oil pressure)
a ) LLOP switch fa ulty or o il pressures less.
a ) Ch eck the LLOP switch or fill the oil.
8
DG fuel low
a) Fuel sensor faulty or fuel less
a) Check the sensor or fill the fuel.
9
En gin e te mp era tu re high
a ) Se nso r fa ult, wire o pe n o r engine running for more time.
a ) Ch eck th e se nso r, co nn ect the wire or stop the DG for some time.
10
DG battery low
a) Battery discharged charge the battery.
a) Check battery charger,
11
System battery low
a) SMPS supply off
a) Check SMPS switch.
12
PSU ba ttery low
a ) Ba ttery ch arger n ot wo rking a ) Check ba ttery cha rger.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
SECTION - VII 1. LIST OF CRITICAL SPARES Sl. N o.
I tem Description
Qty for 1 00 installation
01
5 Nos
02
SVR Module M CU
03 04
SVR Transformer AC contactor’s
3 Nos 10 Nos
05
Mcb’s all types
5 Nos
5 Nos
SECTION -VIII
1. SAFETY INSTUCTION S 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11
8.12
Use electrical safety hand gloves while working on the live Product. Ensure that ground cables are terminated to the product as well as protective grounding system. Use insulated tools while working on live product. Check the site wiring to the product as per the drawing before power-ON the product. Before power-ON the product check the supply by using test lamp / tester Ensure that there is NO continuity between product body and Phase terminal. Ensure the all the terminations are firmly tightened. While working on product, follow the tag out and lock out process at incoming supply source. While working on the Printed Circuit Boards, and controller, use wrist band, which should be properly grounded. Panel door key shall be kept in a secured place. Only authorized personnel shall open the door and operate the product. Electrical Safety ground symbol is provided below.
Read and understand the safety instructions before operating / maintenance / trouble shooting of the product
! WARNING DO NOT ATTEMPT TO OP ERATE THE PRODUCT UNTIL THE IN STRUCTIONS GIVEN IN THE USER’S MAN UAL ARE READ AND UNDERSTOOD. BE SURE THAT ALL SWITCHES ARE IN OFF POSITI ON AND THAT THE INPU T SUPPLY VOLTAGE IS AS SPECIFI ED IN THE USER’S MANAUL. HAZARDOUS OPETATI NG VOLTAGE IS PRESENT IN THE PRODUCT. HENCE EXTREME CARE SHOULD BE TAKEN WHEN PERFORMING M AINTENANCE TASK OR TROUBLE SHOOTING THE PR ODUCT, TO PREVENT ACCIDENTA L ELECTRIC SHOCK.
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
SERIAL NUMBER
SYSTEM DESCRIPTION
RATING
:
:
:
KVA
THE EQUIPMENT REFERED ABOVE IS GUARANTEED AGAINST ALL MANUFACTURING DEFECTS AND WORKMANSHIP PROBLEMS, IF ANY FOR A PERIOD OF 18 M ONTHS FROM THE DATE OF DESPATCH.
THIS GUARANTEE IS VALID ONLY WHEN THE EQUIPMENT HAS BEEN USED WITHIN ITS ELECTRICAL, ELECTRONICS, MECHANICAL AND THE ENVIRONMENTAL SPECIFICATIONS.
For PACE P OWER SY STEMS P VT. LTD, BAN GALORE.
AUTHORISED SIGNATORY
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PACE POW ER SYSTEMS PVT. LTD., Bangalore
