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USER’S MANUAL 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 Guidelines for INSTALLATION & MAINTENANCE 1 PACE POWER SYSTEMS PVT. LTD., Bangalore
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Page 1: PACE PMU USER'S GUIDE

USER’S MANUAL

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]: www.pacepowerindia.com

Guidelinesfor

INSTALLATION & MAINTENANCE

1 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 2: PACE PMU USER'S GUIDE

2 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 3: PACE PMU USER'S GUIDE

TABLE OF CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1. LIST OF ABBREVIATIONS 4

2. SECTION I PRODUCT DESCRIPTION 5

3. SECTION II SPECIFICATION 7

4. SECTION III INSTALLATION AND 9

COMMISSIONING PROCEDURE

5. SECTION IV MAINTENANCE 12

6. SECTION V INPUT/OUTPUT TERMINATION 13

DRAWING INDEX

7. ALARM TERMINAL DETAILS 29

8. OTHER TERMINAL DETAILS 30

9. NETWORK MANAGEMENT SYSTEM (GSM) 32

10. NETWORK MONITORING SYSTEM (GPRS) 36

11. PACE PMU CONTROLLER DESCRIPTION 37

12. TROUBLE SHOOTING CHART 46

13. SECTION VIII SAFETY INSTUCTIONS 47

14. WARRANTY CERTIFICATE 48

15. FEED BACK FORM 49

3 PACE POWER SYSTEMS PVT. LTD., Bangalore

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ABBREVIATIONS

PSU ................................... POWER SHARING UNITPMU................................... POWER MANAGEMENT UNITPMS ................................... POWER MANAGEMENT SYSTEMPU ...................................... POWER UNITMCU .................................. MAIN CONTROL UNITBIS ..................................... BUREAU OF INDIAN STANDARDSBNC ................................... BAYONET COUPLINGAC...................................... ALTERNATING CURRENTA.F. ..................................... AUDIO FREQUENCYC-DOT ............................... CENTRE FOR DEVELOPMENT OF TELEMATICSDG MCB ............................ DIESEL GENERATOR MCBCMOS ................................ COMPLIMENTARY METAL OXIDE SEME CONDUCTORCACT ................................. CENTRE FOR COMPONENT APPROVAL TELECOMM.,I/P ...................................... INPUTEB MCB ............................. ELECTRICITY BOARD (MAINS) MCBSVR MCB .......................... STATIC VOLTAGE REGULATER MCBC/O .................................... CHANGE OVERCFR.................................... CARBON FILM RESISTORCO ..................................... CO-OPERATECORP. ................................ CORPORATIONDC ..................................... DIRECT CURRENTEQUI. ................................. EQUIVALENTDPST ................................. DOUBLE POLE SINGLE THROWDOE................................... DEPARTMENT OF ELECTRONICSDOT................................... DEPARTMENT OF TELECOMMUNICATIONIMD. ................................... IMPORTEDEXCH ................................ EXCHANGEAMF CONTROLLER ......... AUTO MAINS FAILURE CONTROLLERIMP. .................................... IMPORTANTINST. .................................. INSTRUMENTINV. .................................... INVERTERO/P .................................... OUT PUT

REVISION HISTORY

Revision No. Revision date Brief description of changes Initiated by Approved by

01 09-06-2008 Initial Issue Ramesh Bangar

02 30-08-2008 Added Alarm details Ramesh Bangar

4 PACE POWER SYSTEMS PVT. LTD., Bangalore

03 15-12-2008 Added Micro Controller Details Ramesh Bangar

Page 5: PACE PMU USER'S GUIDE

PRODUCT DESCRIPTION

Reliable Telecom Power Solution

The Product is a fully automatic, high-availability telecompower solution, and is ideal for powering critical applications suchas BTS sites of GSM, CDMA, and 3G networks, as well as Opticalrepeater networks.

The Product is a high-availability power source designed toenable valuable Telecom equipments to work with maximum reliabilityand availability in harsh AC mains environments.

The Product integrates, in a single cabinet, all the elementsnecessary to deliver uninterruptible, reliable power to any Telecomequipment. Thanks to its high level of integration, it reduces floor andwall space in the Telecom site. The Product also eliminates the complexinterconnection wiring found in conventional Telecom site powersolutions making the Product easy to deploy and maintain.

It is a complete and integrated solution which re-places the current, conventional practice in telecom site power ofdeploying numerous, disparate components such as servo stabilizers,isolation transformers, relay-based AMF panels, Diesel generatorcontrol units and counters, ACDB, fire alarm control modules, aviationwarning lamp timer etc.

SECTION -1

5 PACE POWER SYSTEMS PVT. LTD., Bangalore

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KEY FEATURES

W High-availability power protection by meansof integral Isolation Transformer, Lightningand Surge protection devices.

W Completely integrated, high-availabilitypower solution

W Automatic and Manual Modes of operationwith key switch

W Minimum Diesel Generator utilization (givesfuel savings, less DG wear and tear, lowerpollution)

W Automatic switching from grid power tobackup generator

W Simplified Engineering, Installation andMaintenance

W Dedicated controller with True RMS displayof voltage, current, frequency, scrollingdisplay, LED indicators and Alarmextension features

W Continuously monitoring fault records/data’s up to 500 events on the controllerdisplay through key operation.

W Battery voltage and shelter internaltemperature monitoring feature to switch onthe DG set – fuel saving

W DG Battery voltage and battery voltagesupervision

W Built-in circuit provided to monitor DG /PCM circuitry

W MTTR as low as 15 minutes (reduced downtime)

W Performance, fault data storage featuresprovided for easy maintenance

W Compact & Modular design – easyreplacement of sub-modules at site

W High MTBF thanks to careful design, theselection of quality components and use ofnon-moving parts

W Significant saving of space and installationmaterials, giving savings in

The Product integrates the following features :1. Automatic Mains Failure (AMF) functions2. ACDB3. Static Voltage Regulator4 Automatic Best Phase Selector.5 Fault Alarms with potential-free Contact.6 Mains and DG parameter Monitoring7 Fire Alarm Module8 Aviation Lamp Control9 Real time clock and event recording.10 Monitoring & Control through GSM Network11 Monitoring through GPRS Network

There is also provision for the fitting of optional modules; Air Conditioner Controllerand SMPS / Communication Equipment. The Products are available in the followingConfigurations or can be modified on Customer’s Specifications.1) 1 Phase to 1 Phase (Rating : 5 to 10 KVA)1) 3 Phase to 1 Phase (Rating : 5 to 50 KVA)2) 3 Phase to 2 Phase (Rating : 5 to 50 KVA)3) 3 Phase to 3 Phase (Rating : 5 to 50 KVA)

6 PACE POWER SYSTEMS PVT. LTD., Bangalore

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SECTION -II

GENERAL SPECIFICATIONS

AVAILABLE CONFIGURATIONS

Input Power Supply Single Phase Two Phase Three PhaseCapacity (for Standard Models) 5KVA to 5 KVA to 5 KVA toCustomization can 10 KVA 50 KVA 50 KVAbe be done based on needs.

INPUT

Input voltage range 140V-280V or 240V-480V or 240V-480V or90 V-270V 155V - 465V 155V - 465VLine to Neutral Line to Line Line to Line

Input Current Total Capacity/ Total Capacity/ Total Capacity/Input Voltage Input Voltage Input Voltage

Frequency 47 - 53 Hz 47 - 53 Hz 47 - 53 Hz

OUTPUT

Rated output voltage 220V ±10% 220V ±10% 220V ±10%or 220V + 13% or 220V + 13% or 220V + 13%Line to Neutral Line to Neutral Line to Neutral

Output Current Total Capacity / Total Capacity / Total Capacity /Output Voltage Output Voltage Output Voltage

System Efficiency >94% >94% >94%

AC DSITIRBUTION (ACDB)

Circuit breaker type DIN Class C type DIN Class C type DIN Class C type

EB Input As per As per As perRequirement Requirement Requirement

DG Input As per As per As perRequirement Requirement Requirement

Load Distribution: Site load details and circuit breaker current ratings are configured as per requirement.

Power Plant (SMPS) 32AMPS SP 32/63AMPS SP 32/63AMPS SPfor SMPS – 1No. for SMPS – 3Nos. for SMPS - 3Nos.

Air Conditioner NA 32 Amp SP for Air 32 Amp TP for Airconditioner 1&2– conditioner 1&2–2Nos. 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.

7 PACE POWER SYSTEMS PVT. LTD., Bangalore

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MAIN CONTROLLER

• Micro Processor based controller, working voltage 11 volts to 16 volts DC with batteryback-up and Auto changeover 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 stamping. o Fault events with date and 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 monitoringthrough GSM / GPRS.

SVR & ISOLATION TRANSFORMER• Micro processor based controller

• Static stabiliser with wide range of Input.

• Built-in Isolation transformer

• IGBT based static Voltage Regulator

• Dynamic response 400V/1s

• Built-in high voltage and low voltage protection at input and output with response time < 10ms

• Modular design for easy replacement of SVR control module.

ENVIRONMENTALNoise level < 65 Db < 65 Db < 65 dBOperating Temperature -5° to +55° C -5° to +55° C -5° to +55° CStorage Temperature -20° to +80° C -20° to +80° C -20° to +80° CHumidity RH 95% RH 95% RH 95%

STANDARDS

Conducted Emission Meets Class A Group II limits of CISPR 11Radiated Emission Meets Class A Group II limits of CISPR 11Electrical Fast Transient (EFT) IEC 61000-4-4:2001Electro Static Discharge(ESD) IEC 61000-4-2:2001Surge Immunity IEC 61000-4-5:2001R.F. Conducted Immunity IEC 61000-4-6:2001Environment TEC QM 333 B2MTBF Product material & workmanship shall be of professional quality and meet the

MTBF requirement. The MTBF of the Product is more than 70000 hrs.Safety IEC 60950

Construction Sheet metal fabricated cabinet of 1.6mm thick sheets for covers and 2 mm thick forhinged door.

Earthing /Grounding A common earth busbar provided inside top of the UNIT and all the internal earthwires are terminated to the common earth busbar. Provision is made to connectexternal earth cables to the green/ Yellow TB and common busbar.

Cable entry Cable entry provision is made at the top of UNIT and cable entry holes are pro-vided with rubber grommets or plastic cable gland.

Foundation holes 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

8 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 9: PACE PMU USER'S GUIDE

SECTION - III

INSTALLATION AND COMMISSIONING PROCEDURE

SAFETY PRECAUTION1. Read and understand the safety instructions before operating / maintenance /

trouble shooting of the product.

PRE INSTALLATION CHECKS1. Ensure that shelter is ready / installed.2. Ensure Equipment layout drawing is available.3. E B Power supply is available at the site.4. Check that AC Cables are laid from Meter Box to UNIT.5. Check that Battery Bank is installed and cables are laid from Battery Bank

to UNIT.6. Ensure that DG Installed and commissioned cables laid from DG to UNIT.7. Check that Grounding cable is routed from Grounding bus bar to Unit.

INSTALLATIONThe 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 theInstallation site.

ACCESSORIES:

• Multimeter with Probes.

• Lap top with the Communication cable (I/F) - Optional

• M10x50 Coach Screw for shelter mtg. (use Anchor bolts for RCCshelter)

• 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)

• Alarm Cable for BTS ground cable as per spec (part of PSU shipment)

• Mechanical Tool Kit

• Wire cutting & Crimping tool

• Ferrules A/R

• Wire Gray color 1.5 mm square – A/R

• Drilling m/c with bits to take up to 15 mm

• Power chords & extension box.

9 PACE POWER SYSTEMS PVT. LTD., Bangalore

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1.0 RECEIPT OF ITEMS / MATERIALS

1.1 RECEIPT OF PRODUCT WITH PACKING.• Ensure that the packing is not damaged.• 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, componentsmust be replaced before installation continues.

2.0 INSTALLATION PROCEDURE2.1 Lift and place the Product cabinet on the required location in the shelter.• 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 TRANSFORMER INSTALLATION.• 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 BATTERY CHARGER BOX / DG CONTROLLER• Identify the battery charger box mounting location in the DG canopy and Drill dia 8.0mm

hole, two places on canopy side wall (or on the stand provided by the customer)• Use the M6 fasteners listed under the accessories and mount the battery charger box on to

canopy side wall or (on to the vertical stand provided by the customer). Ensure that bolt headand plain washer is on the side the canopy.Apply water sealant around the bolt / washer on the canopy out side wall to protect the waterleakages.

3.0 CABLE / WIRING TERMINATIONS3.1 GENERAL TERMINATION:• Connect the cables from Unit to the DG Battery charger Box / DG Controller Relay Board

connector.

10 PACE POWER SYSTEMS PVT. LTD., Bangalore

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• Connect the Alarm cable on to the Relay board or from the terminals provided and the otherend has to be taken through the BTS end connection. Customer to identify the location forconnection.

• Connect the customer supplied wire from Unit TB located at left hand top side of the cabinetto the Door Switch, Smoke detector and PCM. The lengths of the wires have to be decided atsite based on location of these components.

• Customer Supplied DC Cables routed from Power Plant Batteries to be terminated on to theUNIT 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 termination:• Identify the termination wires coming from SVR terminal block, the wire no 0 to 5 are to be

terminated on to the Transformer 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 andtightened properly at both ends.

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 requirement.• 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 and 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, room temp. High (pre-set) and system battery low (pre-set) & then Controller gives command to start the DG byconsidering the above three conditions.

• IF MAINS restores in normal range, controller gives the command to change over the loadto 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

load on DG manually.• The controller displays O/P voltage, current and frequency simultaneously all other messages

will be displayed 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.

11 PACE POWER SYSTEMS PVT. LTD., Bangalore

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SECTION -IV

2. MAINTENANCE

This system is conservatively designed. It is completely static with all advanceddigital circuits. This system will provide trouble free service with minimum maintenance.However a regular periodic maintenance program should be followed. Table given belowprovides the schedule of maintenance procedure in detail.

5.1 TABLE OF PERIODIC INSPECTION AND MAINTENANCE

ITEMS INSPECTION PROCEDUREPERIOD

Ventilation and Daily Check that intake and exhaust air openings are not obstructedOpenings

Cabinet Assemblies Weekly Remove dust and foreign particles within the Chassis usingcompressed air or blower. Check mounting bolts and terminalslooseness. Tighten them

Cabinet 3 Months Inspect transformers for evidence of over heating, damagedinsulation or loose mounting screws Correct any malfunctioningbefore operating the unit. Tighten any loose screws or nuts.Clean electrical contacts with a cloth dampened carbontetrachloride. Do not use cleaning solvents on electrical contacts.Replace if found defective

Controls & Indications 3 Months Check all LEDs

6 Months Check all controls for operability. Replace if any damageor malfunctioning is observed.

12 Months Check the cable for input and output power and internal wiringto components. Check for cracks or broken insulation. Replaceas indicated.

12 Months Inspect the general conditions of PCB. Check the componentsfor evidence of over heating cracks or peeling. Repair orreplace board if necessary

12 Months Inspect Diodes, Silicon Controlled Rectifiers (SCRs) & MOSFETSand their heat dissipaters for loose mounting or defective electricalconnections. Tighten screws and nuts.

Internal components 12 Months Inspect PCB, Sockets for loose electrical connections, Tightenthe mounting screws and replace defective sockets, if any.

12 Months Inspect electric wiring for broken solder connections, evidenceof peeled insulation and general deterioration, Repair or replacedamaged wiring.

Quarterly

Half-yearly

Yearly

CAUTION

ONLY AUTHORISED PERSON TO HANDLEMAINTENANCE

12 PACE POWER SYSTEMS PVT. LTD., Bangalore

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4.2 MAINTENANCE TIPS :

When replacing the components, observe the following

1. When replacing the components 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 regardingrepair 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 ofappropriate circuit is necessary.

SECTION - V

INPUT/OUTPUT TERMINATION DRAWINGS

1 Block Diagrams

2 Single line diagrams

3 SVR Connection Diagrams

4. Control Wiring Diagrams

5. Terminal Details

6. Alarm Details

13 PACE POWER SYSTEMS PVT. LTD., Bangalore

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BLO

CK

DIA

GR

AM

(3

-1 P

H M

AIN

S &

1-

PH

DG

) 1

SVR

14 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 15: PACE PMU USER'S GUIDE

BLO

CK

DIA

GR

AM

(3

PH

- 1

PH

MA

INS

& 3

PH

DG

) 2

SVR

15 PACE POWER SYSTEMS PVT. LTD., Bangalore15 PACE POWER SYSTEMS PVT. LTD., Bangalore

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19 PACE POWER SYSTEMS PVT. LTD., Bangalore

NEUTRAL BUS BAREARTH BUS BAR

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22 PACE POWER SYSTEMS PVT. LTD., Bangalore

DATESIGNATURENAMEDRAWN

CHECKED

APPRVD.

MFG.

OK

RAMESHDIAG. NOT TO SCALE REV. -01

PACEPOWER SYSTEMS PVT. LTD.,

STATIC VOLTAGE REGULATOR

BANGAR

VENUGOPAL

SVR CONTROLLER

1 2 0 1 2 3 4 5

P/STX

STATIC VOLTAGE REGULATOR (PRIMARY CONTROL)

POWER TRANSFORMER

LN

OUTPUT 220 V

TWO - PHINPUT - R&Y

orSingle - PH

INPUT - L & N

0 1 2 3 4 5L N

22 PACE POWER SYSTEMS PVT. LTD., Bangalore

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DATESIGNATURENAMEDRAWN

CHECKED

APPRVD.

MFG.

OK

RAMESHDIAG. NOT TO SCALE REV. -01

PACEPOWER SYSTEMS PVT. LTD.,

STATIC VOLTAGE REGULATOR

BANGAR

VENUGOPAL

SVR CONTROLLER

L N 0 1 2 3 4 5

P/STX

STATIC VOLTAGE REGULATOR (SECONDARY CONTROL)

POWER TRANSFORMER

L NOUTPUT 220 V

TWO - PHINPUT - R&Y

orSingle - PH

INPUT - L & N

0 1 2 3 4 51 2

23 PACE POWER SYSTEMS PVT. LTD., Bangalore

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WIRING DRAWING

NAME SIGNATURE DATE REV-01DO NOT SCALE DIAGRAM

DRAWN

CHKD

APPRVD

MFG

QA

RAMESH

BANGAR

VENUGOPAL

WIRING DIAGRAM

PACEPOWER SYSTEMS PVT. LTD.

SMOKESENSOR

RED

BLUE

GREEN

BLACK

+ve

- ve

NO

COMMON

MODEM

+

-

32

31

BTS ALARMSRELAY BOARD

FROM MCU

TO BTS

A2K1 K3 K5 C2 E6 E7 A2 C12 C13 C14 C15

RELAY BOARD

C3 E4

VMR -1PH VMR -3PH

DG BATT. CHARGER

E

L

K1 (+ve)

N1

K2 (-ve)

A10A9

J1

A1DC - DC CONVERTERLN1

J1

81SYS. BATT.CHARGERE

51

A1

A10A9

32

31DC - DC CONVERTER

81

7 AH BATTERY51

+ve

-ve

25 PACE POWER SYSTEMS PVT. LTD., Bangalore

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27 PACE POWER SYSTEMS PVT. LTD., Bangalore

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DATESIGNATURENAMEDRAWN

CHECKED

APPRVD.

MFG.

OK

RAMESHDIAG. NOT TO SCALE REV. -01

PACEPOWER SYSTEMS PVT. LTD.,

DG AUTOMATION DRAWING

BANGAR

VENUGOPAL

DG BATT. +ve (4 Sq.)

DG AUTOMATION DRAWING WITH PMU(For Individual DG Controller)

DG TERMINALS

DG BATT. +ve (4 Sq.)

DG BATT -ve (4 Sq.)

DG START (4 Sq.)

DG STOP (4 Sq.)

LLOP (1.5 Sq.)

HCT (1.5 Sq.)

HALF FUEL (1.5 Sq.)

LOW FUEL (1.5 Sq.)

V- BELT (1.5 Sq.)

PMU TERMINALS

DG BATT +ve (4 Sq.)

DG BATT -ve (4 Sq.)

V-BELT (1.5 Sq.)

LOW FUEL (1.5 Sq.)

DG START (1.5 Sq.)

DG STOP (1.5 Sq.)

LLOP (1.5 Sq.)

HCT (1.5 Sq.)

HALF FUEL (1.5 Sq.)

1

2

3

4

5

6

7

9

10

1

2

3

4

5

6

7

8

9

10

DG CONTROLLER

DG BATT -ve (1.5 Sq.)

DG START FROM PMU (1.5 Sq.)

DG STOP FROM PMU (1.5 Sq.)

DG BATT +ve (1.5 Sq.)

NOTE :The cable from PMU to DG will beof 4 sq. mm. 2-core and 1.5 sq. mm.8-core Armoured.

28 PACE POWER SYSTEMS PVT. LTD., Bangalore

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1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

SVR FAIL

MAINS FAIL

SMOKE /FIRE

DOOR OPEN

HIGH ROOM TEMP

CONTACTOR FAULT

BTS BATT. LOW

LOAD ON DG

DG BATT. LOW

DG FAULT

OVER LOAD

LOW FUEL

LLOP FAULT

HCT / HWT

FAIL TO STOP

FAIL TO START

ALARM DETAILS

29 PACE POWER SYSTEMS PVT. LTD., Bangalore

DG CONTROLLER

DG

CO

NTR

OLL

ER

DG BATT.+ve (1Sq.)

DG BATT.-ve (1Sq.)

DG START from PMU(1Sq.)DG STOP from PMU(1Sq.)

---

---

DG STOP- 4 Sq.

OPEN

DG STOP from PMU(JACKSON) -1 Sq.

(JACKSON)

DG BATT +ve(4 Sq.)

DG STOP(4 Sq.)

DG BATT +ve(4 Sq.)

DG START(4 Sq.)

29 PACE POWER SYSTEMS PVT. LTD., Bangalore

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12

34

56

78

9

BTS BATT.INPUT

+ve

-veSMOKESENSOR

}

COMN.

‘NO’SMOKESENSOR

}

DOORSWITCH

HOOTER

}

}

TO R

OO

M C

ON

TRO

L

1011

12 TO D

G B

ATT. CH

G. & D

G C

ON

TRO

LLER U

NIT

+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.

13

25

47

69

810

1112

13

K1

K2

K3

K4

K5

K6

K7

K8

K9

C1

C2

C3

KC

DG

INPU

T

MAI

NS

INPU

T

SMPS

-1

BATT

. CH

G.

AC-1

SMPS

-2

RO

OM

LIG

HT

AC-2

SMPS

-3

POW

ER P

OIN

TAC

-3

AVI.

LAM

P

FIELD WIRING DIAGRAM

FAN -ve

PCM +ve

+ve

-ve

+ve

-ve

TERMINAL BLOCK DETAILS(FOR INBUILT BATT. CHARGER & SEPERATE DG CONTROLLER)

TO DG CONTROLLER

+ve

DG

BAT

TER

Y

-ve

DG

BAT

TER

Y

DG

STA

RT

V-B

ELT

DG

STO

P

LLO

P

HW

T/H

CT

HAL

F FU

EL

LOW

FU

EL

DG

CO

MM

ON

.

1 32 54 76 98 10

K1 K2 K3 K4 K5 K6 K7 K8 K9 KC(D

G +

ve fo

r -ve

Ala

rms

or D

G -

vefo

r +ve

Ala

rms)

30 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 31: PACE PMU USER'S GUIDE

12

34

56

78

910

-ve FAN

+ve

-veBTS BATT.INPUT

+ve PCM

+ve

-veSMOKESENSOR}

COMN.

‘NO’

SMOKESENSOR}

DOORSWITCH

+ve

-veHOOTER

}

}TO

RO

OM

CO

NTR

OL

TO D

G B

ATT. CH

G. & D

G C

ON

TRO

LLER U

NIT

+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.

13

25

47

69

810

1112

13

K1

K2

K3

K4

K5

K6

K7

K8

K9

C1

C2

C3

KC

TO DG CONTROL1. +ve DG BATTERY2. -ve DG BATTERY3. START (Normal & Jackson)4. V - BELT5. STOP (Normal), START (Jackson)6. STOP (Jackson)7. LLOP8. HCT / HWT9. HALF FUEL10. LOW FUEL11. DG COMMON (+ve Normal DG)

(-ve Jackson DG)12. CANOPY FAN DRY O/P13. CANOPY FAN DRY O/P14 CANOPY LIGHT LINE15. CANOPY LINE NEUTRAL

FROM UNIT TB DETAILS1. +ve DG BATTERY2. -ve DG BATTERY3. START (Normal & Jackson)4. V - BELT5. STOP (Normal), START (Jackson)6. STOP (Jackson)7. LLOP8. HCT / HWT9 HALF FUEL10. LOW FUEL11. DG FAULT12. RESET13. CANOPY FAN14. DG COMMON (+ve Normal DG)

(-ve Jackson DG)

} 230V ACFROM UNIT

15. PH16. N17. E

1112

BATTERY CHARGER TB DETAILS

(+ve Normal DG) (-ve Jackson DG)

TERMINAL BLOCK DETAILS(FOR INDIVIDUAL BATT. CHARGER & DG CONTROLLER)

31 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 32: PACE PMU USER'S GUIDE

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 frommobile or central console through specific SMS command.

5. Control functions through mobile or Start DG, Stop DG, Reset System bytyping message in capital like START, STOP, RESET.

MESSAGE FORMAT :

a) Status - Status of a remote site can be sought from a designated mobile phonesor 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.XV, 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, FUELLVL = 17.5, ID : BANGALORE.

Sent Message : CSTAT (For Central Console)

Response from Site : S/SITE ID / MAINS V / DG 1V / DG2V/BTY1V / BTY2V / 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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b) ERROR / ALARM : Site Master Control will broadcoast error message to designatedmaintainance 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) Some more Commands :

a) Adding the Site Identification name / Tower ID

COMMAND MESSAGE : ADDSN <SITE ID (Maximum 10 Characters)>

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 <FIRST MOBILE NUMBER>

ADD2C <SECOND MOBILE NUMBER>

ADD3C <THIRD MOBILE NUMBER>

ADD4C <FOURTH MOBILE NUMBER>

ADD5C <FIFTH MOBILE NUMBER>

ADD6C <SIXTH MOBILE NUMBER>

33 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 34: PACE PMU USER'S GUIDE

The General Packet Radio Service (GPRS) is a new nonvoice value added service thatallows information to be sent and received across a mobile telephone network. It supplementstoday’s Circuit Switched Data and Short Message Service. GPRS is NOT related to GPS (theGlobal 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 achievablewith GPRS using all eight timeslots at the same time. This is about three times as fast as thedata transmission speeds possible over today’s fixed telecommunications networks and ten timesas fast as current Circuit Switched Data services on GSM networks. By allowing information tobe transmitted more quickly, immediately and efficiently across the mobile network, GPRS maywell 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 imme-diately 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”. Immediacyis one of the advantages of GPRS (and SMS) when compared to Circuit Switched Data. Highimmediacy is a very important feature for time critical applications such as remote credit cardauthorization where it would be unacceptable to keep the customer waiting for even thirty extraseconds.

GPRS facilitates several new applications that have not previously been available overGSM networks due to the limitations in speed of Circuit Switched Data (9.6 kbps) and messagelength of the Short Message Service (160 characters). GPRS will fully enable the Internet applicationsyou are used to on your desktop from web browsing to chat over the mobile network. Other newapplications for GPRS, profiled later, include file transfer and home automation - the ability toremotely 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 customerservice requirement);

§ a destination to send or receive information through GPRS. Whereas with SMS this wasoften 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 firsttime. From day one, GPRS users can access any web page or other Internet applications-providing an immediate critical mass of uses;

§ Having looked at the key user features of GPRS, lets look at the key features from anetwork operator perspective.

KEY NETWORK FEATURES OF GPRSGPRS 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

GENERAL PACKET RADIO SERVICE(GPRS - OPTIONAL)

34 PACE POWER SYSTEMS PVT. LTD., Bangalore

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network architecture with packet switching is quite a major upgrade. However, as we shall seelater, the GPRS standard is delivered in a very elegant manner - with network operators needingonly to add a couple of new infrastructure nodes and making a software upgrade to some existingnetwork elements.

With GPRS, the information is split into separate but related “packets” before beingtransmitted 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 andput into a plastic bag. During transportation of the now boxed jigsaw from the factory to the enduser, the pieces get jumbled up. When the recipient empties the bag with all the pieces, theyare reassembled to form the original image. All the pieces are all related and fit together, butthe way they are transported and assembled varies. The Internet itself is another example ofa packet data network, the most famous of many such network types.

Packet switching means that GPRS radio resources are used only when users are actuallysending or receiving data. Rather than dedicating a radio channel to a mobile data user for afixed period of time, the available radio resource can be concurrently shared between severalusers. This efficient use of scarce radio resources means that large numbers of GPRS userscan potentially share the same bandwidth and be served from a single cell. The actual numberof users supported depends on the application being used and how much data is being trans-ferred. Because of the spectrum efficiency of GPRS, there is less need to build in idle capacitythat is only used in peak hours. GPRS therefore lets network operators maximize the use of theirnetwork 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 pre-

viously was sent using SMS to GPRS instead using the GPRS/SMS interconnect that issupported by the GPRS standards.

For the first time, GPRS fully enables Mobile Internet functionality by allowing interworkingbetween the existing Internet and the new GPRS network. Any service that is used over the fixedInternet today - File Transfer Protocol (FTP), web browsing, chat, email, telnet - will be as availableover the mobile network because of GPRS. In fact, many network operators are considering theopportunity 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 theInternet for entertainment and information collection, the intranet for accessing company infor-mation 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 ofinterest. There is a trend away from storing information locally in specific software packages onPCs to remotely on the Internet. When you want to check your schedule or contacts, insteadof using something like “Act!”, you go onto the Internet site such as a portal. Hence, web browsingis a very important application for GPRS.

Because it uses the same protocols, the GPRS network can be viewed as a sub-networkof the Internet with GPRS capable mobile phones being viewed as mobile hosts. This meansthat 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 designedto 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 towardsthird generation mobile phone networks concluded in early 1999 by the industry associationsthat support these two network types.

35 PACE POWER SYSTEMS PVT. LTD., Bangalore

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DESCRIPTION DISPLAY TYPE

MAINS VOLTAGE XXXLCU1 VOLTAGE XXXLCU2 VOLTAGE XXXMAINS FREQUENCY XX.XDG R-PHASE VOLTAGE XXXDG Y –PHASE VOLTAGE XXXDG B-PHASE VOLTAGE XXXDG FREQUENCY XX.XLOAD CURRENT R-PHASE XX.XLOAD CURRENT Y-PHASE XX.XLOAD CURRENT B-PHASE XX.XDG BATTERY VOLTAGE XX.XBTS BATTERY VOLTAGE XX.XSYS BATTERY VOLTAGE XX.XROOM TEMPEARTURE XX.XMAINS RUN HOURS XXXX.XDG RUN HOURS XXXX.XBATTERY RUN HOURS XXXX.XMAINS ENERGY XXXXXX.XDG ENERGY XXXXXX.XAC1 RUN HOURS XXXX.XAC2 RUN HOURS XXXX.XFREE COOL RUN HOURS XXXX.XDATE XXMONTH XXYEAR 20XXHOUR XXMINUTE XXMAINS OK ALARM LEDDG OK ALARM LEDDG BATTERY LOW ALARM LEDBTS BATTERY LOW ALARM LEDAC1 ON ALARM LEDAC2 ON ALARM LEDAVATION LAMP ON ALARM LEDLOW FUEL ALARM LEDHALF FUEL ALARM LEDOVERSPEED ALARM LEDHIGH ENG TEMP ALARM LEDLLOP FAULT ALARM LEDOVER LOAD ALARM LEDFAIL TO START ALARM LEDFAIL TO STOP ALARM LEDMANUAL MODE LEDDG ALT. FAULT ALARM LEDEB CONTRACTOR FAIL LEDDG CONTRACTOR FAIL LEDDOOR OPEN FAULT LEDDG DOOR OPEN FAULT LEDMAINS FAIL LEDHIGH ROOM TEMP LEDSMOKE FIRE LEDLCU FAIL LEDDG COMMON FAULT LEDSYS BATTERY LOW LED

MONITORING PARAMETER DETAILSUSING GPRS

36 PACE POWER SYSTEMS PVT. LTD., Bangalore

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37 PACE POWER SYSTEMS PVT. LTD., Bangalore

PACE PMU MICRO CONTROLLER

INTRODUCTION:

PACE PMU MICROCONTROLLER is an integrated multifunction high speed micro controllerbased 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 includesprotections for mains and DG (as per standards).The microcontroller module includes total threebattery monitoring and room temperature monitoring facility. And the same can be enabled ordisabled as per requirements. There are two options for DG start depends on battery modeoperation (Fuel saver mode). One is, If battery mode operation is ON , mains and LCU voltagesare not healthy then controller will keep the site running on BTS battery by monitoring continuouslybattery voltage and room temperature. If the battery voltage goes below set limit or temperaturegoes 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’scontroller will release the stop command to the generator and keep generator in off mode tillto get the condition of battery voltage and room temperature. Second is , If battery mode operationis OFF , controller will run the generator for set run hours , then it will stop the generatorand keep in off mode still to finish the set rest hours. After finish of set rest hours controllerwill 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 likeGSM 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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38 PACE POWER SYSTEMS PVT. LTD., Bangalore

DESCRIPTION

MONITORING PARAMETERS

1. ANALOG PARAMETERSa) Mains Input voltage.b) SVR input voltage.c) SVR output voltage.d) Three or single Phase DG voltage.e) Three or single phase output load.f) BTS battery voltage.g) DG battery voltage.h) System battery voltage.i) Room Temperature.j) Mains frequency.k) DG frequency.l) Mains Run hours.m) DG Run hours.n) BTS Battery Run hours.o) Mains Energy.p) DG Energy.q) Free cooling run hours.r) Air conditioner run hours.

2. DIGITAL PARAMETERSa) Mains Fail.b) DG Fail to START.c) DG Fail to STOP.d) DG LLOP.e) DG HALF FUEL.f) DG LOW FUEL.g) High engine temperature.h) V-belt cuti) High room temperature.j) SVR fail.k) Contactor fails.l) Smoke Fire.m) Door open.n) Overload.o) DG over speed.p) BTS battery lowq) DG battery low.r) System battery low.

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39 PACE POWER 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

Page 40: PACE PMU USER'S GUIDE

40 PACE POWER SYSTEMS PVT. LTD., Bangalore

31 LLOP Delay Time 99 2 10 Seconds

32 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 8

49 Hour 23 0

50 Minute 59 0

S.NO Parameter Name Max Value Min Value Default Value

CALIBRATION PARAMETERS:

The calibration parameters are as follows.

S.No Parameter name Actual value Measured value

1 Mains Voltages XXX XXX2 LCU1 Voltage XXX XXX3 LCU2 Voltage XXX XXX4 LCU3 Voltage XXX XXX5 DG R-Phase XXX XXX6 DG Y-Phase XXX XXX7 DG B-Phase XXX XXX8 Load current R-Phase XX.X XX.X9 Load current Y-Phase XX.X XX.X10 Load current B-Phase XX.X XX.X11 BTS Battery voltage XX.X XX.X12 DG Battery voltage XX.X XX.X13 INT Battery voltage XX.X XX.X14 Room Temperature XX.X XX.X

Actual value – Means to set whatever is coming on the terminal by standard meter Mea-sured value – Means whatever controller is measuring the value.

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41 PACE POWER SYSTEMS PVT. LTD., Bangalore

SMS MODULE (OPTIONAL)

SMS feature of Pace controller is having two-way communication facility and the detailsare as below.

1) If any alarm is generated at the site , controller will send SMS to SIX differentmobile numbers on specified format. ( The alarm details )

2) If User Send Some command like START, STOP, RESET, CSTAT, STAT to thesite , then controller gives response according to specified format. ( The sitestatus )

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 function2) Calibrations3) Configurations4) System operations5) Aviation Lamp control6) SMS Feature7) Events logging8) Smoke/fire control9) Emergency Shutdown

Key FunctionThere are five push buttons on the front panel of Microcontroller to operate and

monitor the controller & site details.

# SW1 for Increment and Reset# SW2 for Decrement and Scrolling# SW3 for Enter and Events# SW4 for Configuration (Menu setting & Calibration)# SW5 for Escape from inside program to main menu

SW1

SW2

SW3

SW4

SW5

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42 PACE POWER SYSTEMS PVT. LTD., Bangalore

#SW1

This switch can be used for two purposes one for increment the value and other forsystem reset.Normally this switch will act as system reset. When you go for configuration that timethis switch will act as a increment the value.

#SW2

This switch can be used for two purposes one for decrement the value and other forverifying the various parameter values.Normally this switch will act as a scroll function. When you go for configuration that timethis 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 vari-ous events.Normally this switch is working for events log display. When you go for configuration thattime this switch will work as enter button.

#SW4

This switch can be used for two purposes one for going backward during menu settingand calibration , other for entering in menu setting and calibration mode. Normally thisswitch will work to enter in configuration mode.

#SW5

This switch can be used for escape only. Purpose of this switch is to come out of thesetting mode to the default display mode.

CALIBRATION:For any analog parameter calibration follow the following steps.

1. Press menu button.2. Enter password by increment, decrement & enter push buttons.3. Enter into calibration mode.4. Check the values by multimeter and calibrate the same.5. Press enter button to go forward.6. Press menu button to go backward.7. Press escape button to come out.

ConfigurationFor any programmable parameter configuration (setting) follow the following steps

1. Press menu button.2. Enter password by increment, decrement & enter push buttons.3. Enter into menu setting mode.4. Set the parameters as per requirement.5. Press enter button to go forward.6. Press menu button to go backward.7. Press escape button to come out.

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43 PACE POWER SYSTEMS PVT. LTD., Bangalore

SYSTEM OPERATIONThe operation of pace controller in two way on is AUTO mode and other is MANNUALmode. In auto mode controller control the DG function automatically and check the DGalarm status but in manual mode no control the DG operation.

ALARM CHECKING

1) Fail to stopWhile running the DG in auto mode , create any DG fault and don’t stop the DG, thencontroller will generate the fail to stop alarm.

2) Fail to startWhile running the controller in auto mode , create DG start condition and don’t startthe generator , after three cranks trial controller will generate the fail to start alarm.

3) LLOP FaultWhile running DG in auto mode , create LLOP fault ( short battery –ve and LLOP) , then controller will generate the LLOP fault.

4) LOW FUELWhile running DG in auto mode , create LOW FUEL fault ( short battery –ve and lowfuel ) , then controller will generate low fuel fault.

5) Half FUELWhile running DG in auto mode , create half fuel fault ( short battery –ve and halffuel ) , then controller will generate the low fuel fault and display the half fuel in LCD.

6) HCT/HWT FaultWhile running DG in auto mode , create HCT fault ( short battery –ve and HCT) thencontroller will generate the HCT fault.

7) OVERLOADWhile running DG in auto mode on load , create overload or short battery –ve andoverload , then controller will generate the overload fault.

8) Over speedWhile running DG in auto mode , if speed of the generator goes beyond the limits, then controller will generate the overspeed fault.

10) Alternate FaultWhile running DG in auto mode , switch off the DG MCB , then controller will generatethe alternator fault.

11) V-belt FaultWhile 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 alarmWhile 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 stopWhile 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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44 PACE POWER SYSTEMS PVT. LTD., Bangalore

14) Contactor FailAfter giving command of contactor on by the controller , if contactor is not gettingon , then controller will generate the contactor fail alarm.

15) BTS battery LowIf battery voltage goes below set limit then controller will generate the BTS batterylow alarm.

16) DG battery LowIf battery voltage goes below set limit then controller will generate the DG batterylow alarm.

17) High room temperatureIf room temperature goes above set limit then controller will generate the highroom temperature alarm.

18) Door openIf controller gets the sensing as open from door switch then controller will gener-ate the door open alarm.

All above alarms are displayed in LCD display 3rd line continuous scrolling type andby LED’s .

Aviation Lamp function :

While running the system , if real time matches the lamp on time then con-troller will switch on the lamp . if real time matches the lamp off time then control-ler will switch off the lamp.

Page 45: PACE PMU USER'S GUIDE

NO PARAMETER STANDARD SETTING UNIT 240 - 480 V 155 - 465 V 200-495V

1 MAINS HIGH CUT OFF 485 465 495 VOLT2 MAINS LOW CUT OFF 240 155 200 VOLT3 MAINS HIGH CUT IN 470 450 485 VOLT4 MAINS LOW CUT IN 265 180 225 VOLT5 DG HIGH CUT OFF 260 260 260 VOLT6 DG LOW CUT OFF 180 180 180 VOLT7 DG RPM HIGH 1650 1650 1650 RPM8 DG RPM LOW 1350 1350 1350 RPM9 DG REST TIME 60 60 60 MINUTS10 ROOM TEMP.HIGH 35 35 35 DEGREE11 OVERLOAD 45 45 45 AMP12 BTS BATT.LOW LIMIT 47 47 47 VOLT13 DG BATT.LOW LIMIT 10 10 10 VOLT14 DG AUTO RUN TIME 6 6 6 HOURS15 CRANK ACTIVE TIME 3 3 3 SECONDS16 CRANK RETRIES 2 2 2 TIMES17 STOP HOLD TIME 25 25 25 SECONDS18 STOP RETRIES 2 2 2 TIMES19 DG WARM UP TIME 5 5 5 SECONDS20 MAINS RESTORE TIME 5 5 5 SECONDS21 DG COOL DOWN TIME 30 30 30 SECONDS22 DG LONG LOCK TIME 10 10 10 MINUTS23 LOW FUEL SHUT DN. TIME 1 1 1 SECONDS24 AVIATION ON TIME 18 18 18 HOURS25 AVIATION OFF TIME 6 6 6 HOURS26 CONSOLE REPORT TIME 10 10 10 HOURS27 BATT. MODE OPERATION ON ON ON FUNCTION28 LLOP DELAY TIME 2 2 2 SECONDS29 DG START INTERVAL 40 40 40 SECONDS30 CT RATIO 75 75 75 FUNCTION31 LCU HIGH CUT OFF 260 260 260 VOLT32 LCU LOW CUT OFF 180 180 180 VOLT33 LLOP ENABLE / DISABLE ENABLE ENABLE ENABLE FUNCTION34 MAX MOBILE NUMBER 6 6 6 FUNCTION35 SITE ID 1234 1234 NUMBER NUMBER36 SYSTEM NAME NAME NAME NAME NAME37 SITE NAME NAME NAME NAME NAME38 SET 1ST MOBILE NUMBER NUMBER NUMBER NUMBER NUMBER39 SET 2ND MOBILE NUMBER NUMBER NUMBER NUMBER NUMBER40 SET 3RD MOBILE NUMBER NUMBER NUMBER NUMBER NUMBER41 SET 4TH MOBILE NUMBER NUMBER NUMBER NUMBER NUMBER42 SET 5TH MOBILE NUMBER NUMBER NUMBER NUMBER NUMBER43 SET 6TH MOBILE NUMBER NUMBER NUMBER NUMBER NUMBER44 SET DATE PRESENT PRESENT DATE NUMBER45 SET MONTH PRESENT PRESENT MONTH NUMBER46 SET YEAR PRESENT PRESENT YEAR NUMBER47 SET HOUR PRESENT PRESENT HOURS NUMBER48 SET MINUTE PRESENT PRESENT MINUTS NUMBER

STANDARD SETTINGS FOR DIFFERENT RANGES

45 PACE POWER SYSTEMS PVT. LTD., Bangalore

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In case there is any fault in the system, it is preferable that the unit is tested step by step. It is furtherdesirable 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. SYSTEM FAULT PROBABLE CAUSE REMEDY

1 DG fail to start a)DG battery voltage low. a) Check battery voltageand charge battery.

b) Loose contact at DG start b) Tighten all connections.relay, start solenoid.

2 DG fails to stop. a) Battery is a) Keep the battery indischarged charged condition

b) Loose contact at DG stop b) Tighten the connections.relay, stop solenoid.

3 OVER LOAD a) Load surge. a) Switch on the load one byIndication comes on one or overload setting.while the load isswitched on

4 Alternator fault a) DG is on but voltage not Check alternator of DG.coming at o/p of DG.

5 Room temperature a) Temperature sensor not a) Check temperaturehigh working. sensor.

b) Sensor wire open. b) Connect the wire.c) False indications due to c) Check the setting and

defective setting of temp. correct itin controller.

6 Smoke / Fire a) Smoke sensor not working a) Check sensor or connector sensor wire open. the wire.

7 LLOP(Low lube oil a) LLOP switch faulty or oil a) Check the LLOP switch orpressure) pressures less. fill the oil.

8 DG fuel low a) Fuel sensor faulty or a) Check the sensor or fillfuel less the fuel.

9 Engine temperature a) Sensor fault, wire open or a) Check the sensor, connecthigh engine running for the wire or stop the DG for

more time. some time.

10 DG battery low a) Battery discharged a) Check battery charger,charge the battery.

11 System battery low a) SMPS supply off a) Check SMPS switch.

12 PSU battery low a) Battery charger not working a) Check battery charger.

SECTION - VI

TROUBLE SHOOTING CHART

46 PACE POWER SYSTEMS PVT. LTD., Bangalore

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SECTION - VII

1. LIST OF CRITICAL SPARES

Sl. No. Item Description Qty for 100 installation

01 SVR Module 5 Nos02 MCU 5 Nos03 SVR Transformer 3 Nos04 AC contactor’s 10 Nos05 Mcb’s all types 5 Nos

SECTION -VIII

1. SAFETY INSTUCTIONS

8.1 Use electrical safety hand gloves while working on the live Product.8.2 Ensure that ground cables are terminated to the product as well as protective grounding

system.8.3 Use insulated tools while working on live product.8.4 Check the site wiring to the product as per the drawing before power-ON the product.8.5 Before power-ON the product check the supply by using test lamp / tester8.6 Ensure that there is NO continuity between product body and Phase terminal.8.7 Ensure the all the terminations are firmly tightened.8.8 While working on product, follow the tag out and lock out process at incoming supply

source.8.9 While working on the Printed Circuit Boards, and controller, use wrist band, which

should be properly grounded.8.10 Panel door key shall be kept in a secured place. Only authorized personnel shall open

the door and operate the product.8.11 Electrical Safety ground symbol is provided below.

8.12 Read and understand the safety instructions before operating / maintenance / troubleshooting of the product

WARNINGDO NOT ATTEMPT TO OPERATE THE PRODUCT UNTIL THE INSTRUCTIONS GIVENIN THE USER’S MANUAL ARE READ AND UNDERSTOOD. BE SURE THAT ALLSWITCHES ARE IN OFF POSITION AND THAT THE INPUT SUPPLY VOLTAGE IS ASSPECIFIED IN THE USER’S MANAUL.

HAZARDOUS OPETATING VOLTAGE IS PRESENT IN THE PRODUCT. HENCE EXTREMECARE SHOULD BE TAKEN WHEN PERFORMING MAINTENANCE TASK OR TROUBLESHOOTING THE PRODUCT, TO PREVENT ACCIDENTAL ELECTRIC SHOCK.

!

47 PACE POWER SYSTEMS PVT. LTD., Bangalore

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SERIAL NUMBER :

SYSTEM DESCRIPTION :

RATING : KVA

THE EQUIPMENT REFERED ABOVE IS GUARANTEED AGAINST ALLMANUFACTURING DEFECTS AND WORKMANSHIP PROBLEMS, IF ANY FOR APERIOD OF 18 MONTHS FROM THE DATE OF DESPATCH.

THIS GUARANTEE IS VALID ONLY WHEN THE EQUIPMENT HAS BEENUSED WITHIN ITS ELECTRICAL, ELECTRONICS, MECHANICAL AND THEENVIRONMENTAL SPECIFICATIONS.

For PACE POWER SYSTEMS PVT. LTD, BANGALORE.

AUTHORISED SIGNATORY

48 PACE POWER SYSTEMS PVT. LTD., Bangalore

Page 49: PACE PMU USER'S GUIDE

SR.NO.:

DATE OF RECEIPT AT CONSIGNEES PLACE:

DATE OF INSTALLATION:

FEED BACK CHART

DATESr.No.

Nature of Defect Nature of RemedialAction taken

Remarks with Sign.and Designation

CONTACT PHONE NUMBERS : FOR ANY ASSISTANCE.

080 - 28437792 / 94 (Operational during 9.30 a.m. to 7.00 p.m.)+91 - 99019 78709 (Operational during the round clock)+91 - 94160 23777 (Operational during the round clock)+91 - 98800 32312 (Operational during the round clock)

49 PACE POWER SYSTEMS PVT. LTD., Bangalore