Professional Documents
Culture Documents
and Rectifier
Input and
output
interface
Control and
fault reset
Connection
indicator
ATS panel outlay
1. Trickle battery
charger
2. Fuses/surge
3. Current transformers
4. Generator Contactor
5. Mains Contactor
6. Input breaker
7. Output/Load
connector
8. Binary Digital Signals
9. Control panel
10. Indicator/selector/
emergency stop
Module 1.2-
Basic functions of the ATS
and AMF
This would give an insight to the
functionality of the ATS/AMF
• Functions
• Effect
ATS/AMF Functions
AMF
1. Monitors individual parameters of the generator – temperature, oil
level etc
Automatic load transfer
• Mains is usually set to priority zero which means it’s the first line of
use
Control function
• Uses Interlock to avoid the generator from feeding into the grid
Generator
supply
Mains Control
supply signal
Load
supply
Connect ATS/AMF Layout-2 gens
MCB
feedback
to both
controllers
Connect
each
generator
feedback
to its AMF
Connect
Bin1 to
Bout 2
and vise
versa
Timing
programming
Grid with 2 generators- done in both
Master slave operation controllers
Multiple generator parallel
system
A
synchroscope
is used to
synchronized
the generator
Synchronization operation
panel
Contactor layout
Definition
Datakom
Bernini
Gennext
Intellite Deepsee
Bout
Interlite 25
Current
sensor
Binary
input
Gen
voltage
in
Mains
voltage Binary
in output
Analogue Start
input 1-oil signal
2-temp 3- Communication and fuel
fuel and config port soleniod
Module 1.4-
Basic Operation of the ATS
This would give an understanding to the
ATS operational principle
• Operation
Operation of ATS
• Auto transfer-Transferring the load to the backup generator
• Auto start-Command the backup generator to start, based on
the voltage monitored on the primary supply
• Back feeding isolation-Isolates the backup generator from the
electric utility when the generator is on r
• Transition mode-Switch transition mode of a transfer switch
may be Open Transition (OT) (the usual type), or Closed
Transition (CT))
• Power relays-switching device to shift the load circuits to and
from the power source
• Logic controller-Transfer logic controller to monitor the
condition of the power sources and provide the control signals
to the power switching device
• No overload-Prevents overload
• Controller mode-Control power source to supply operational
power to the controller and switching device
Open transition-break-before-make
operation
• An open transition transfer switch is also called a
break before make transfer switch. A break
before make transfer switch breaks contact with
one source of power before it makes contact
with another.
• It prevents back feeding from an emergency
generator back into the utility line.
• During the split second of the power transfer the
flow of electricity is interrupted
Advantages of open transition
• Low cost-Lowest-cost automatic power transfer option
available due to the simplicity of the controls and
mechanism needed and the simplicity of the interface to
the generator set.
• Synchronization time delay-If facility loads are very stable, the two
power systems may require an objectionably long time to synchronize.
This “failure” mode may be intermittent
Mains
Panel on load
interlock
1. Mains fail
G Timer
relay
7
NO Timer
relay NC
10. Disable timer
Mains return
Start/Stop 5b.voltage feedback
module to disable crank
Timer
NC
4.Crank at time relay
interval 2b cranking relay
Fuel
solenoid NO
3. Fuel solenoid
opens
Start and stop sequence (contd)
5. When the engine starts, the generator voltage rises as it
approaches operating speed. The generator voltage energizes
the Stop Cranking Relay Coil. This opens the SCR normally
closed contacts to:
a disconnect the engine starting circuit
b disconnect the overcranking relay timing element timer
E
Load
Identify the Gen
parts of this ATS
Mains Contactor
connector Input input with Relay
interlock
Some terminologies
Specifications:
IP (or "Ingress Protection") ratings are
defined in international standard EN
60529 (British BS EN 60529:1992,
European IEC 60509:1989). They are used
to define levels of sealing effectiveness of
electrical enclosures against intrusion
from foreign bodies (tools, dirt etc) and
moisture.
First Digit (intrusion protection)
Second Digit (moisture protection)
IP Ratings
First Digit (intrusion protection)
1. No special protection<
2. Protection from a large part of the body such as a hand (but no protection from
deliberate access); from solid objects greater than 50mm in diameter.
3. Protection against fingers or other object not greater than 80mm in length and
12mm in diameter.
4. Protection from entry by tools, wires etc, with a diameter of 2.5 mm or more.
5. Protection against solid bodies larger than 1mm (eg fine tools/small etc).
6. Protected against dust that may harm equipment.
7. Totally dust tight
Function:
Note:
It’s the return path for current
and neutral leakage /failure In event of common
could cause shock if circuit is neutral connection some
broken with poor earthing panels have a common
above 5 ohms to ground neutral bar
Grounding bar
Every contactor transfer switch is provided with
a copper ground bar for ground connections.
Its prevents the ATS from being damaged by
lighting strike
Note:
Improper earthing lead to
equipment damage in event
of lighting or surge.
NEC and IEEE standard
recommends 5 ohms or less
Mechanical interlock in panel
Mechanical interlock
An mechanical interlock is a device used to prevent undesired
states in an electrical system, which in a general sense can include
any electrical, electronic, or mechanical device
Mechanical interlock is used to help prevent the two sources which
could be out of sync to jam and only one source feeds the load.
Arranging forward and reverse contacts so that it is physically
impossible for both sets of contacts to close at the same time
Note:
It prevents two sources to feed the
load at the same time because they
are not synchronized.
Synchronization require voltage,
phase and frequency to be aligned.
A sync panel is required
Electrical interlock in line diagram
Electrical interlock
• An arrangement of two relays operating in
opposite functionality i.e mutually exclusive
• Arranging it forward and reverse contacts so
that it is physically impossible for both sets of
contacts to close at the same time
Note:
Usually two relays
interconnected in a reverse
contact signaling where both
Relay 1 and two can not close
contactor 1 and 2 at the same
time.
Isolation transformer
An isolation transformer is a transformer used to transfer
electrical power from a source of alternating current (AC)
power to some equipment or device while isolating the
powered device from the power source, usually for safety
reasons
.
Isolation transformers provide galvanic isolation and are used
to protect against electric shock, to suppress electrical noise in
sensitive devices, or to transfer power between two circuits
which must not be connected.
Note:
Not compulsory but helps for
high level of protection
Microprocessor
Microprocessor is a multipurpose, programmable
device that accepts digital data as input,
processes it according to instructions stored in its
memory, and provides results as output.
It is a sequential digital logic, as it has internal
memory.
Microprocessors operate on the binary input
system used in ATS control
Note:
Most time this function is
effected by the AMF panel.
Metering equipment
Used in reading off voltage, current and
frequency on an ATS panel
Note:
It is interfaced with sensors ,
calibrated and used to read
parameters.
This is usually in the AMF panel
or microprocessor.
Remote connection
RS 232 defines the signals connecting between a
DTE (data terminal equipment) such as a computer
terminal, and a DCE (data circuit-terminating
equipment such as a modem.
The RS-232 standard is commonly used in
computer serial port
RS 485 is a standard defining the electrical
characteristics of drivers and receivers for use in
balanced digital multipoint systems
Note:
Serial port interface enables
communication and data transfer
between user and controller
Battery trickle charger
Battery Trickle charger is used in charging a fully charged
battery under no-load at a rate equal to its self-
discharge rate, thus enabling the battery to remain at its
fully charged level.
A battery under continuous float voltage charging is said
to be under float-charging
Note:
The triggle charger is interfaced
with the load voltage and used
to continuously charge the
batteries
Frequency sensor
A frequency sensors and monitors are available in
both AC powered and DC powered models.
When the power line frequency is within the
specified limits, the output of the frequency monitor
will energize.
When the frequency is over or under or outside the
specified frequency range, the output relay of the
frequency sensor will de-energize
Note:
Required for proper parameter
monitoring in absence of AMF
/microprocessor.
Timer
A timer is a specialized type of clock for measuring
time intervals. a device which counts down from a
specified time interval
• Time Delay Normal to Emergency (TDNE)
• Time Delay Engine Start (TDES)
• Time Delay Emergency to Normal (TDEN)
• Time Delay Engine Cool down (TDEC)
Note:
Required in a two generator
arrangement to have even hour
operation between the
generators
Module 1.6-
Designing, understanding and
reading the panel one-line wiring
diagram
This gives an understanding of flow of the
one line diagram
• Symbols
• Flow path
Overview
line diagram or single-line diagram (SLD) is a simplified
notation for representing a single/three-phase power
system.
Battery
Relay
switch
CT
Gen
Ground
Mains
Description
• Wiring (connection) diagram – a diagram that
shows the connection of an installation or its
component devices or parts
• Wiring diagrams show, as closely as possible, the
actual location of each component in a circuit,
including the control circuit and the power circuit
• Manual control circuit – any circuit that requires a
person to initiate an action for the circuit to
operate.
Note:
One line diagram shows the
logical flow of current and
sequence of connection
Illustration
• A line diagram may be used to illustrate a
manual control circuit of a pushbutton
controlling a pilot light.
• A line diagram may be used to illustrate the
control and protection of a 1 device using a
manual starter with overload protection
• Solenoids, contactors, and magnetic motor
starters are used for remote control of devices.
Note:
Always refer to legend which
gives details of symbol and it
use.
Load connection details
• No more than one load should be placed in any one
circuit line between L1 and L2.
• Loads must be connected in parallel when more than
one load must be connected in the line diagram.
• Control devices are connected between L1 andL2 the
operating coil (or load).
• Operating coils of contactors and starters are
activated by control devices such as pushbuttons,
limit switches, and pressure switches
Note:
Ensure all load connection are
distinguished so as not to
cause logical flow distortion
Relay insight
• Relays, contactors, and magnetic motor
starters normally have more than one set of
auxiliary contacts.
• These contacts may appear at several
different locations in the line diagram
• To differentiate between NO and NC, NC
contacts are indicated as a number which is
underlined
Note:
Relay symbols are connected to
the switching device they
control. A relay may switch more
than one device
Terminal numbering
• Manufacturers of electrical relays, timers, counters,
etc., include numbers on the terminal connection
points.
• These terminal numbers are used to identify and
separate the different component parts (coil, NC
contacts, etc) included on the individual pieces of
equipment.
• Manufacturer’s terminal numbers are often added to a
line diagram after the specific equipment to be used in
the control circuit is identified
Note:
Terminal numbering helps
identify where to locate the
device and ease of part
replacement
Signal decision and action
• A circuit must respond as designed, without any
changes.
• To accomplish this consistency, all control
circuits are composed of three basic sections:
the signals, the decisions, and the action
sections
• A signal starts or stops the flow of current by
closing or opening the control device’s contacts
Note:
The signal decision assist to
understand the logical flow of
current and operation
Logic functions
• Control devices such as
pushbuttons, limit switches,
and relay switches are
connected into a circuit so that
the circuit can function in a
predetermined manner.
• All control circuits are basic
logic functions.
• Logic functions are common to
all areas of industry
Note:
Logic functions help to understand
the exclusivity or otherwise of
devices. E.g interlock
AMF Panel wiring
Switch Breaker Load Mains
device Generator
Module 1.7-
Designing of an ATS using various
AMFs, relays, contactors and interlocks
This gives an understanding of flow of the
one line diagram
• Design process
• Interconnect
Methodology
1. Determine the number of input sources
2. Select a control process(manual/AMF processor)
3. Select your switching functions( relays, contactors etc)
4. Dimension the required capacity (breakers, contactors,
wires etc)
5. Determine if you want timing delay and select the
appropriate timer relay
6. Determine if you require a feedback control and select the
appropriate switching function
7. Draw a one line logical connection of the panel
8. State your flow process for both operations
Note:
In designing your circuit you must
adhere to basic electrical energy
flow principle and switching
functionality
Simple design flow 5.Required
delay
3.Switching
function function
1. Sources
2.Controller
6.Feedback
4.Conrator loop
capacity
Note:
Designs should be simple
logical and able to achieve
your set out objective
Sample Panel layout
Exercise- Innovation
1. Design a one line diagram to interface 2
generators and mains to feed a load.
You can assume a microprocessor for remotely
starting the generator
The generators can work interchangeable between
12 hours interval
a. Draw the one line diagram
b. State the step of logical flow when mains is
present
c. State the steps of logical flow when mains is off
Module 1.8-
Contactor, wire gauge and relay
capacity dimensioning
This gives an understanding of flow of the
one line diagram
• Contactor capacity dimensioning
• Wire dimensioning
• Choice of relay
Rating of ATS
• ATS is rated based on what load it should
supply
• Output load-32A, 63A,100A,1000A etc
• Output breaker -Single ,dual or three pole
• Voltage-220V 415V
• Input type- Single, double triple
Note:
AMF ratings against load should
be continuously monitored
Single Phase ATS Load support
• Voltage- 230V
• Current capacity-Load Contactor rating (the
rating of the ATS-32A, 63A,100A etc)
• Pf- 0.8-0.9 approx. Note:
Single phase has limitation
in compared to 3 phase
Power= VxIxpf balancing
- 32X230x0.9=6624VA = Approx 7kVA
- 63X230x0.9=13041VA = Approx 14kVA
- 100X230x0.9=20700VA = Approx 21kVA
Three Phase ATS Load support
• Voltage- 415V L-L
• Voltage – 230V L-N
• Current capacity-Load Contactor rating (the
rating of the ATS-32A, 63A,100A etc)
• Pf- 0.8-0.9 approx. Note:
Three phases generators are
more balanced and support
Power= V(L-L)/1.73)xIxpf more load
Where R = resistance
r - resistivity of the material
L-Length in consideration
A- Area
Note:
The load distance to the panel
is of great importance to avoid
cable heating
Exercise
Calculate the required cable dimensioning to be
used on a single 6kVA load @ 230V to be
connected at 60meters to the ATS panel using
R=V/I
P=VI pf
R=8.8
L-60m= 60000mm
p- 2.65x10-8 ohms mtr= 2.65x10-5 ohms mm
Note:
Relay should be selected
based on switching
parameters
Module 1.9-
Sensor understanding- Current
sensors, frequency sensor etc
This gives an understanding of flow of the
one line diagram
• Current sensor
• Calibration
Sensor
• Required to monitor operational parameters
of the ATS and ensure that the supplied power
is within acceptable range
• It protects the load from damage –Overload,
over/under frequency etc
• Required to manage the ATS performance and
determine when upgrade is required
Note:
Sensor help in monitoring and
supervision of the equipment
Current sensor types
a. Hall effect IC sensor.
b. Transformer or current clamp meter, (suitable
for AC current only).
c. Fluxgate Transformer Type, (suitable for AC
and/or DC current).
d. Resistor, whose voltage is directly proportional
to the current through it.
e. Fiber optic current sensor, using an
interferometer to measure the phase change in
the light produced by a magnetic field.
f. Rogowski coil, electrical device for measuring
alternating current (AC) or high speed current
pulses.
Current Sensor Calibration
Required: two appliances with different power
draws, ideally one around 20 to 200 watts and the
other closer to 1000 watts.
Note:
Refer to each manufactures manual
for the sensor curve table
Voltage sensor
Voltage sensor is a true RMS sensor for
sensing
voltage in single- and three phase
installations.
In fixed or adjustable trip point units, the circuit continuously senses the input
or line frequency.
In band pass fixed or adjustable units, the circuit also continuously senses the
input frequency.
When the input frequency is within the band pass the output relay energizes
and sends an alarm.
When the input frequency is below the lower end of the band pass or above
the higher end the output relay de-energizes sends an alarms and remains in
this state until input frequency returns to the limits of band pass.
Module 1.10-
Dual Generator AMF design –
Master/Slave implementation
This gives details of interfacing of two
generators with the mains connection
• Feedback looping
• Timing delay function
Connect Dual AMF using intellite
MCB
feedback
to both
controllers
Connect
each
generator
feedback
to its AMF
Connect
Bin1 to
Bout 2
and vise
versa
Timing
programming
Grid with 2 generators- done in both
Master slave operation controllers
Overview
Dual AMF is system of two mutual stand-by gen-sets, which switches in
supplying the load.
Usual work operation is that after mains fails, first genset starts, takes the load
and works for dedicated time interval, e.g. 6 hours.
This operation system continues as long as Mains is failed. Transfer of load from
one gen-set to other one is with blackout.
For correct operation both controllers have to have set identical times/delays
for mains protections, mains return delays and other delays
Mechanical interlock between GCB of one gen-set, GCB of second gen-set and
MCB breaker is required due to safety reasons.
Details
• Binary input and binary output adjust their function automatically based on fact if there
are used in Master or in Slave controller.
• Master controller has information about Slave controller and when Slave failure or
cannot work the Master will substitute it.
• AMF start of Slave controller can be blocked by Master but when Master controller has
failure or cannot work the Slave will substitute it.
• Every time when any Alarm is occurring both of the controllers are switched to normal
AMF operation. That meaning that at least one of the controllers will be able to supplying
the load until failure on both of them.
• To decide which genset should start in case of mains fail, there is rule set in the
controller.
• Master controller will prevent unnecessary blackout in case, when it is slave genset fails
• In case one gen-set should run in stand-by, but it fails, the other gen-set runs instead.
After failed gen-set recovers there is 60s delay for load transfer back to this gen-set.
• Control time period of gen-sets switching in supplying the load. Settings are [1..24], step
= 1 hour. Default setting is 6 hours. This timer is reset when load is transferred back to
healthy mains
Settings
1. Copy the identical configurations to the two controller
2- Use wiring with mechanical/electrical interlock between all breakers (GCB1,
GCB2 and MCB)
3- Configure one binary input on each controller.
4- Configure one binary output on each controller.
5- Interconnect binary in from one controller with binary out on second
controller. So you have two wires interconnecting both controllers.
6- Set setpoint “MCB Opens On” to MAINSFAIL on both controllers.
7- Set to time period in which you wish to switch gensets in supplying the load.
For example 6 hours. Make this setting on Master controller. Only Master
controller controls this timer.
8- Set Operation Mode to MASTER on first controller and to SLAVE on second
controller.
9- Change the mode of both controllers to AUTo.
10- System is now ready for Dual AMF function
Module 1.11-
Remote start and stop procedure of
the ATS- Manual option with design
This gives an understanding of remotely
starting the generator
• The circuitry
• Interconnect
Overview
• A module is required to automatically start & stop a
generator.
• You can purchase a module or design a generator auto
start circuit.
• Then, we are required to set up parameters like a
scheduler or to configure inputs connected to level
switches, pressure switches, climate control systems,
mains failure detection relays or other.
• When the generator is working and the engine is running,
the Generator Auto Start Module protects the entire
system.
• Correctly program parameters and settings is required.
• If the engine temperature exceeds the limit, the auto
start interface with the temperature sensor will prevent a
damage by shutting down the engine.
Auto Start circuit
Load
Gen contactor Mains contactor
Mains
interlock
G Timer
relay NO Timer
relay NC
Start/Stop
module
Timer
NC
relay
Fuel
solenoid NO
Auto Start circuit
Exercise: Identify and state the function of the circled parts in red
Resolution
Current transformers (2)
battery (11),
Point to note
• Understand the functionality and
dimensioning of various parts
• Switching functions
• One line diagram
• Process flow
Module 2-Installation, commissioning,
maintenance, troubleshooting and
repair of ATS/AMF
Module 2.1-
Installation process of the ATS/AMF-
Mounting, requirement, positioning
and conditions
This gives consideration to the
requirements for panel installation
• Standard practices
• Procedure
Process
• Plinth: Secure a suitable space on a plinth, align the
placement with the panel dimensioning
• Mount: Drill and bolt the panel down as described in
the installation manual
• Cabling: Run the power cable along the cable run
from mains, generator and load ensure you adhere to
IEEE dimensioning guidelines or follow the SID
• Grounding: Correctly ground the panel to the site
earth ring and measure the resistance it must be
close to 0 ohms
• Signal cables:Run the signal cables to the
generator(assuming that the panel is pre-wired
• Manual:Follow all installation manual instructions
Warnings
Grounding: The Transfer Switch MUST be
correctly grounded for proper operation.
Note:
Installation must be carried
out with IEEE standards
Tools
Note:
All tool should have a static
electrical discharge before
usage
Mounting
The Automatic Transfer Switch should be mounted
(1) As a stand alone unit,
Note:
Termination must
be as described
in the installation
drawing.
If you perform
the design ensure
you have a flow
process
Connection overview another
installation
Proper
ground
Firm
termination
Neatly laid
cables
Module 2.2-
Commissioning procedure and
functionality test procedure of the ATS
Enlightenment into the required testing
and reporting process
• Equipment testing
• Critical parameters
Verify connections
Step 1: Verify all termination are done all provided
in the one-line diagram
Controller check
Calibration of sensor
Circuit breakers
System voltage
Battery current
Load current
Load status
Surge protection
Generator test run
Genset current Note:
Genset state All test must be recorded and
Genset Fuel low submitted as part of the
Alarm relay commissioning document
Module 2.3-
Alarm management of the ATS
Note:
Proper monitoring of alarm
ensure total system failure is
avoided
Critical Alarms
A Critical alarm indicates a serious problem
that can cause damage to the array or data
loss. Correct the problem that causes a critical
alarm immediately.
• Line voltage loss
• Low frequency (below threshold)
Note:
Critical alarms can shut the
system down if not resolved on
time. Most critical alarm require
manual intervention
Non-critical alarms
A Non-critical alarm indicates a condition that is
not as per design and not damaging to the
system. Correct the problem that causes a non-
critical alarm immediately.
• Not utilizing all three phases
Note:
These don’t shut the system
done but shows its operating
outside its designed parameters
Warning alarms
A Warning alarm indicates a condition that
decreases performance or can become critical if
you do not correct it.
Warning alarms occur at the between 30-40% of
the threshold valve
• Surge protector is blown
Note:
These should be promptly
attended to has it has tendency
of shutting system down
Observation alarm
Note:
These can affect the system
later but not immediately
Module 2.4-
Various forms of ATS/AMF alarm
Proposed solution:
Note that the ATS takes approximately 30- 50 seconds to complete the transfer from
shore power to generator power after the generator is started. If this amount of time
has passed and the generator contactor still does not engage, check the following:
• If available, check the display screen to see if an error message is displayed. Refer to
manual for further troubleshooting.
• Check the voltage level on the incoming generator lines. If it is outside of 215-240V,
the ATS will protect equipment by not letting the contactor pull in. fix the incoming
voltage to within acceptable limits.
• Check the incoming generator circuit breaker to make sure that it is not tripped.
• Check to make sure that the incoming power is within 50 Hz range in frequency.
• Verify that the incoming neutral is at the same voltage as the green incoming
ground wire.
• Double check all wiring connection
• Double check all wiring connections into the ATS and make sure that they are all
properly torqued down.
ATS/AMF Alarm
Issue:
No Ground
Proposed solution:
Check to make sure that the ATS is properly grounded.
The green wire going into the transfer switch should be properly attached to the
terminal block (see installation diagram).
The other end of the green wire should be properly grounded to the earthring. If
there is a voltage difference between the incoming neutral (white) and the
ground (green), the transfer switch will not allow the contactor to engage.
If all of the connections are correct and this message still displays, then there is a
bad ground at the input power pedestal and a different pedestal should be used
ATS/AMF Alarm
Issue:
High/Low Voltage
Proposed solution:
If it is outside of 205-240V, the ATS will protect your equipment by not letting
the contactor pull in.
Proposed solution:
The transfer switch constantly monitors the incoming frequency to
verify that it is within 50 Hz range.
If it is outside these limits, the transfer switch will protect the load by
keeping the contactor open.
If this error message occurs on generator power, check the generator
documentation to adjust frequency to within acceptable limits. (Via
the Governor)
ATS/AMF Alarm
Issue:
L1, L2 Open
Proposed solution:
This indicates a possible faulty connection on the input power to the transfer
switch.
With the power off, verify that all input cables are properly connected to the
transfer switch.
Solution:
This indicates that one of the fuses for the surge protectors on the
transfer switch control board has blown.
This will not affect normal transfer switch operation; however, the
fuse on the board must be replaced in order to keep the surge
protection capability.
ATS/AMF Alarm
Issue:
Controller not powering on.
Solution:
Check starting batteries;
Check DC fuse.
ATS/AMF Alarm
Issue:
Generator shutdown
Solution:
Check the water/cylinder temperature is too high or not;
Check DC fuse.
.
ATS/AMF Alarm
Issue:
1. Low oil pressure alarm after crank disconnect
2. High water temperature alarm after crank disconnect
Solution:
Solution:
Check emergence stop button is correct or not;
Check whether the starting battery positive be connected with the
emergency stop input;
Check whether the circuit is open.
ATS/AMF Alarm
Issue:
Unable to communicate via RS485
Solution:
Check connections;
Note:
Standard defining the electrical
characteristics of drivers and receivers
for use in serial communications
Connection
Controller
Controller
Controller
Controller
Module 2.6-
Maintenance of the ATS/AMF
8. Erosion confirmation: Inspect all main arcing contacts for excessive erosion.
9. Arcing Inspection: Inspect all main current-carrying contacts for pitting and
discoloration due to excessive heat.
10. Switching and control relays: Inspect all control relay contacts for excessive
erosion and discoloration due to excessive heat.
12. Torque verification: Check all cable and control wire connections are
tighten if necessary.
Note:
Multimeter is also used for
continuity test of connectors
and conductors
Power analyzer
Power analyzers provide accurate measurements
on the complex real-world waveforms of power
Note:
Power analyzer assist to monitor
and predict equipment and load
performance
Screwdrivers-Torque
• A torque screwdriver is a screwdriver with
components that ensure tightening to a
specified torque, ensuring tightening which is
sufficient, but not excessive.
Note:
Testing lamp is used along with
multimeter to ensure correct
current flow and path failure
Module 2.8-
Troubleshooting process
Note:
All parts to be replaced must
be same specification as faulty
part
Flowchart
Module 2.9-
Repairing faulty ATS panel
Suggested Solution:
1. Take the reading of the parameters
2. Ensure that there is no overload situation on the
load end(you can isolate the load)
3. Trace each line for continuity
4. Ensure there is no bridging along the path
5. Read the K curve of the breaker against the load to
ensure its not caused by instantaneous overload
6. Trace to ensure no arcing along the line
7. Replace and try another breaker of same capacity
Burnt relay contactor
Fault: Burnt relay contactor
Suggested Solution:
1. Check all termination on the relay
2. With a clamp meter measure the supply
current and compare it with the relay
rating
3. Evaluate the connected cable by
calculation the cross sectional are as
related to distance and resistivity
Exercise
State the process you would use to resolve this faults
1. Fault: Mains breaker not closing
2. Fault: Load cable excessive heating
Suggested Solution:
1. Check the parameters of the input
circuit if it meets set parameters
2. The cable surface area is under-
dimensioned
Module 2.10-
Remote monitoring of the ATS/AMF-RS
232, RS 485 connections
A process of remotely monitoring the panel
performance for optimal operation
• Using GSM
• Using internet
Remote connection
An ATS/AMF controller can be remotely controlled via a modems.
The modem must be equipped with a sim card and have access to the
network
Note:
Panels that use static IP address
do not require a modem, it only
requires TX via SNMP
Modem connection layout
Controller
Controller
Controller
Controller
Connection procedure
• Analog modems do not require any setup. (not readily
available)
Note:
Setup differs from m controller to
controller but refer to the
installation manual for configuration
Internet/Intranet connection
The controller can be remotely monitored via Ethernet
(internet, intranet).
Note:
Internet access is required for
communication at a minimum bit
rate of 10kbits/s
Internet/Intranet connection
layout
Controller
Controller
Controller
Controller
Controller
Module 2.11-
SNMP Protocol, Modbus and
communication object implementation
of the ATS
The protocols and managed objects of
communication with monitoring
• Simple Network Management protocol
• Modbus bit rate
SNMP
• Simple Network Management Protocol (SNMP)
is a popular protocol for network management.
Application
interface
Network
UDP
Transport
IP
Internet
SNMP support
Most controller supports SNMP function
Read only:
Binary inputs
Binary outputs
Analog inputs
Gen V Voltage L-N Note:
Gen freq Protocols for communication
Gen kWh
with the controller
Gen kVArh
SNMP –protocols
Read only:
Line KW Line kVArh
Pwr factor Load char
Act power Mains V L1-N
Mains V L1-L2 Mains freq
Mains kWh Mains kVArh
Num starts Run hours
Read / Write:
Controller operation Mode
Maintenance hours
Action argument Note:
Write only:
Protocols are transferred over
User identification number
serial communication
Password
interface
Action command
MODBUS
• Modbus is a serial communication protocol
Point to note
• Installation and commissioning
• Maintenance overview
• Common Alarms and suggested resolutions
• Troubleshooting and repair
Rectifier-
overview, dimensioning,
installation, operation,
maintenance
Troubleshooting and repair
Schedule
Overview, designing , implementation and repair of the Rectifier
• Overview of the Rectifier
• System description
• Batteries
• Rectifier common models
• Rectifier dimensioning
• Rectifier installation
• Rectifier configuration
• Commissioning
• Remote connection
• Troubleshooting and repair of faulty rectifier
Module 3.1-
Rectifier Overview
.
Forms of rectification
Half Wave: Either the positive or negative wave is passed
through and the other wave is blocked. It is not efficient
because only half of the input wave form reaches the output.
Full Wave: Reverses the negative part of the AC wave form and
combines it with the positive
.
Rectifier efficiency
Rectifier efficiency (η) is defined as the ratio of DC
output power to the input power from the AC
supply.
.
Redundancy
Modular rating- Module
AC Input:
Input Voltage, Nominal 200 to 250 V AC
Input Voltage, Permitted Variation 85 to 290 V AC
Line Frequency 45 to 55 Hz
Max Input Current 20A
Power Factor 0.99
DC Output:
Output Voltage, Adjustment Range -42 to -58 V DC
Output Power 3200W@Vout >48VDC
Output Current 67A
Output Current Limit Set Point 0 to 67A
Efficiency 92%
Rating- System
In rectifier system rating it’s the total
capacity a rectifier can support plus the
charging capacity
.
Module 3.2-
System description
Actura 48220
Rectifier Build up
Common terms
• Load-A load is any kind of equipment that draws power from a power
supply system
• AC Supply-The AC supply to a building is normally a single radial supply.
• Rectifier-A rectifier converts incoming AC from mains to DC.
• Battery-A battery backup supplies the telecom equipment with DC.
• Battery Disconnection unit-The battery is connected to a battery connection
unit that functions like a switch or fuse in case of failure in the system
• DC Distribution Unit-The distribution unit distributes the current via
distribution circuit breakers or fuses and DC distribution cables to the
telecom equipment
• AC distribution Unit-split up from one large AC-cable into a number of
smaller AC-cables
• AC protection-The main function of AC-protection is to stabilize the
incoming AC and to neutralize short, harmful voltage variations (transients)
• Power Supervision-The power supervision unit is a product for supervising
the AC-mains.
Common terms(contd)
• DC-DC Converter-DC/DC power modules converts one DC-
voltage to another DC-voltage (e.g. +24V to - 48 V
• Integrated Power Unit-Rectifiers, DC-distribution,
Alarms/Control Units and Battery Connection Units are
physically distributed and integrated within the equipment
they feed.
• UPS/Inverter-UPS (Uninterruptible Power Supply) takes the AC
from the mains and transforms it into DC that charges an
internal battery. Climate Cooling Unit-Part of the power
supplied to the switching equipment dissipates as heat
• Back Up climate(extractor fans)-If the AC-mains go down then
the climate system goes down too that is why fans are used as
backup for climate system
• Energy management-Energy Management is the supervision,
control and maintenance of all sorts of energy equipment
RBS Site
Core Site
In all
Low Voltage Disconnect
The LVD protects the batteries. The LVD
disconnects the load from the batteries
when a preset low voltage, which can
cause permanent battery
damage, is reached.
The Low Voltage and Low Voltage
Disconnect alarms are visually displayed
on the LVD unit and can also be monitored
externally
Low Voltage Disconnect
Operation
The battery voltage is monitored by the low voltage disconnect .
When the voltage drops to approximately -47 VDC, the LVA LED lights
up/
When the battery voltage drops to the low voltage disconnect level,
the
contactor opens, disconnecting the load from the battery.
This turns theLVD LED ON and activates the low voltage disconnect
alarm.
The LVD potentiometer sets the level at which the load disconnects
and the
LVDR potentiometer sets the level at which the load reconnects.
Rectifier cabling connection
Monitoring and Control
DC output
Module 3.3-
Battery
Cable resistance
-Since all\
• There
Module 3.4-
Rectifiers common Models
PIAPS 11608
(SM50 Supervisory module) PIAPS 11616
(SM65 Supervisory module)
Introduction of Rectifier (Emerson)
PS48300-3-25 PS48300-3-30
Introduction of Rectifier (Emerson)
PS48300-1800 PS48180-1800
Introduction of Rectifier (Emerson)
Actura 48701
Module 3.5-
Rectifier capacity Dimensioning
.
Step 2- Required system rating
and battery capacity(contd)
i.e Required system capacity
= 3+1.5 = 4.5kW
Factoring growth 20% margin of 4.5kW= 5.625kW
AC Side
System capacity is 10 KW
Neglecting losses Pdc =Pac
AC @ 230V
I= 10/230= 43.4 A
So AC breaker in ACDB should idealy be about 50A, however 63A with
certain trip curve characteristics can be used
.
Step 5- Estimate required
Generator capacity
System load =10kW
Note Pdc=PacXpf
Hence Pac=10kVA
Assuming 0.8 pf
Pac=10/0.8=12.5kVA
Assuming this is the only load on the generator and all others are
negligible
It is recommend that for continuous or prime operation
generators should not be loaded more than 70-75%
Hence @ 70% loading
12.5/0.7= 17.8kVA
Hence 18kVA is adequate for the side using AC generators
Diagonal pliers Wire stripper Ratchet crimp Claw hammer Insulation tape Multimeter Socket Heat shrink
tool wrench sleeve
Industrial Tape measure Electric knife Gloves Bundling tapes Heat gun
horizontal ruler
Safety measures
• De-energize-When work is being done in a power cabinet, it is
recommended that the power supply system is de-energized. The
mains supply and, if any, the battery voltage should be disconnected.
• Neat Cable arrangement-The distribution cables shall be arranged and
protected in such a way that no involuntary contact with them can occur
during work with the equipment connected to voltage.
• Clear Labeling-The feeding mains fuses shall be marked so that it is clear
to what load
each of them is connected, for instance the cabinet numbers of the
system.
• No metal on while working-Take off metallic bracelets, rings or similar
that may cause short circuits in the equipment.
• Insulate your tools-When working with batteries or live equipment the
tools used shall have an insulating cover. Always use an ESD wrist strap
connected to the chassis or to earth when working with printed board
assemblies and components.
Disconnector
• Disconnect before working-The power supply system
shall be provided with approved disconnectors to
make it possible to disconnect the mains supply and,
where applicable, the battery voltage from the system.
The mains disconnector must be designed so that all
the phases can be cut off with one manipulation. Local
rules must be adhered to.
B.)Ensure all
connections are
as per installation
manual
Fit the rectifier
module into the
housing as
specified by the
manufacturer
Page 262
Installing battery cabinet
Note:
1. At least two persons are required in the transport of batteries.
Otherwise, batteries may fall and cause injuries .
2. Install batteries according to the diagram so that connect battery
cables properly and prevent short-circuits of battery.
3. Before connecting the cables to batteries, wear a pair of gloves
and wrap the handle of the wrench with black PVC insulating tapes.
Tighten the bolts of batteries after connecting the cables
4. Remove the protection caps for battery terminals when connecting
cables. After the cables are connected, Install the protection caps
on the battery terminals.
Page 263
Installing battery cabinet
4.1. Turn off battery switch.
Page 264
Installing battery cabinet
Installing temp
sensor
Installing the
temperature sensor
on the battery shelf
by bundling tapes
Page 265
Installing battery cabinet
Page 266
Connecting the system cables
Connecting the system cables
• Get familiar with system cable before installation:
Power cable of AC to Rectifier
Power cable between battery and power system
Power cable between Rectifier to the load
Signal cable of current sensor(could be internal)
Signal cable of temp sensor(could be internal)
Rectifier ground cable
Safety Notes:
1.Turn off AC DB breaker before connect for safety.
2.During cable connecting, make sure there is no
short circuit
between AC and DC
3.Follow the steps of this guide
Cabling-proper cabling
Main Cabling
Earthing
2. Room: Mount the temperature sensor on a wall about 1.5 m above the
floor. Do not mount it where it is affected by airflow from fans or by
sunlight.
Clean thoroughly the surface where the sensor is to be placed.
3. Wind up the excessive cable and fix it with tie wraps on a suitable place.
If the cable is too short, it can be extended by means of 0.82 mm2
(AWG18) standard copper conductors and connecting terminals.
• Configuration steps
Install DCTools-1.10.0 software application on your PC;
Connect the serial port cable, Ensure that the serial port cable is not
disconnected during the programming and configuration procedure;
Configure the parameter; The particular process is as below:
Page 280
Battery Technologies rectifier system
Step 2
Step 3
Page 281
Battery Technologies rectifier system
• Configure the limit
current to C10
Modify this
parameter to
Modify this Enable
parameter
to
8%
Modify this
parameter
Step 4
to 8%
•
Modify this
Configure the voltage parameter to
Enable
Modify this
parameter
to 43.2V
Step 5
Page 282
Emerson rectifier system
• Configure the parameter via
the LCD panel and the ENT
keyboard of the front-panel
The password is 2
by default
Page 283
Emerson rectifier system
( Actura 48 701)
Enter the
Press Enter
Password 1
Press Enter
and
• Configure the parameter via the LCD panel and the keyboard of the front-
panel
• Configure the quantity of battery strings according to the actual battery strings.
• Configure the total rated capacity of battery according to the actual capacity of
every battery string
• Configure the LVD1 Voltage to 44V
Emerson rectifier system-Password
initialization
Password initialization is used when the user password is forgotten.
Through password initialization the user password is restored to the
default password:123456.
Initialization path:
Page 285
Module 3.8-
Commissioning
Power
supply
Earthing
Start Up and Test Installation
AC
protection
Rating and
dimensioning
Torque
Labelling
Start Up and Test Installation
Avoid
bridging
Preparation
Disconnect
Take no load
readings
Start Up and Test Installation
Disconnect
Disconnect
Start Up and Test Installation
Disconnect
Disconnect
Module 3.9- remote connection
Air interface
Controller-
Data
processing
unit
Interface
System architecture-using LAN
controller
Interface
System architecture-using VPN
controller
Firewall
Interface
Module 3.10-
Troubleshooting and repair faulty
rectifier
Suggested Solution:
1. Verify that the input AC voltage is within the
specified limits.
2. Cycle the AC breaker off/on to reset the unit from a
possible HVSD
3. shutdown.
4. Make sure the HVSD potentiometer is adjusted
properly
5. If the unit is used in parallel with other units this
means that the float voltage is too low. Increase the
float voltage by turningthe FLT potentiometer
clockwise until the ON/RFA led turns green
Fan failure
Fault: Fan failure
Suggested Solution:
1. Turn the rectifier off. Remove the rectifier from the shelf.
Wait five minutes to allow all internal capacitors to fully
discharge
2. Remove the fan assembly by pulling it from the chassis.
3. Remove the four retaining screws which hold the chassis
plate, fan and fan grill together
4. Place the mounting clips on the replacement fan
5. Mount the replacement fan in the same orientation as the
old one,
6. Secure the fan, fan grill and chassis plate and Reconnect
the fan connector and mount the fan assembly
7. Plug the unit back in and power it up.
Low Voltage Disconnect
Fault:
1. Low Voltage Test/Bypass LED lit
2. LVA and LVD LED lit
3. The LVD disconnects the load
Suggested Solution:
1. The switch is on the Test/Bypass position
2. Check the voltage level at the test jacks and the
position of the Test switch. Verify the LVA and
LVD adjustment. Set the test switch to the
Test/Bypass position to verify their operation.
Replace the circuit pack if it is still not
operational.
3. Verify the voltage at the test jacks. Remove the
faceplate and check the fuse located on the
control PCB.
Review
Point to note
• Installation and commissioning
• Maintenance overview
• Common Alarms and suggested resolutions
• Troubleshooting and repair