INNEXIV RTU Installation Batch 4 TP training.pdf

8/19/2019 INNEXIV RTU Installation Batch 4 TP training.pdf

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Remote Operational Visibility and Control Management

RMS Training Guide


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Notice of Confidentiality and Non-Disclosure

This document is protected from disclosure. It also contains commercially sensitive and confidential

business/proprietary information that is likewise protected from disclosure by other applicable privileges.

No part of this document may be circulated, quoted, or reproduced for distribution without prior written approval from

INNEXIV, Inc., and or INNEXIV (Private) Limited.

Copyright © 2013 INNEXIV, Inc. All Rights Reserved


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INNEXIV

INNEXIV® Remote Monitoring System (RMS)

Training ManualVersion 1.0 - DRAFT 11-N0v- 2013Copyright © 2013 INNEXIV, Inc. All rights reserved.

No part of this document may be reproduced in any form or by any electronic or mechanical means, including information storage and retrieval devices or systems,

without prior written permission from INNEXIV, Inc. This document or information it contains within may not be used, reproduced, or disclosed without written

authorization by INNEXIV, Inc.

C O N F I D E N T I A L

Contact:

Azeem Taj

Direct: +92(03458569320)

E-mail: [email protected]

INNEXIV (PVT) Limited

H 60, G11/2, Sachal Sarmast Road

Islamabad, Pakistan

Revision History

Version Date Author Approvals required

1.0 11-Nov-2013 Azeem Taj Karim Ullah


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CONTENTS

• Site Layout

• Core Components

• Main Modules diagrams and connection diagrams

• Sensors Used

• List of required Material

• Connections and routing and procedure


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Pictorial view of a site


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Graphical View of a typical BTS site

Fuel TankGenerator

Battery CabinetMain Power AC


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CONTENTS

• Site Layout

• Core Components


• Sensors Used




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BTS site core components

Battery Bank Rectifier Fuel Tank Generator

ATS External ATS Internal Main DB


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CONTENTS

• Site Layout

• Core Components


• Sensors Used




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MCU

HG I J K

ONMLL P

FE

QR

S

1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 1 2

1 2 3 4 1 2

1 2 3 1 2 3 1 2 3 1 2 31 2


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Battery Analyzer Module

T U V

W X

Y

1 2 3 4 5

1 21 2 3


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Battery Analyzer Module(BAM) connection reference

U,3U,2U,1


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A DCB

Auto Relay Module

1 2 3 4 5 6 1 2 3 4 1 2 3 41 2 3 4


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Delay gen

cut relayAC CUT

Relay

Gen Status

Relay

220

CP Status

Relay

220

Feed

Back

One

Feed

Back

Two

RTU

Battery

+ve

RTU

Battery

- ve

AC Cut

IN

AC CUT

OUT

GEN CUT

In

GEN CUT

OUT

CP

STATUS

Gen

Status

Delay Gen

Signal

AC Cut

Signal

220 +ve

CP MC

Energizing

point

220 +ve

GEN MC

Energizing

point

N

-VE 220N

-VE 220

A-1 A-2 A-3 A-4 B-1 B-2 B-3B-4 B-5

B-6C-1 C-3 C-2 C-4 D-1 D-2 D-3 D-4

Auto Relay Module


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CONTENTS

• Site Layout

• Core Components


• Sensors Used




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AC CT Coil Sensor DC CT Coil Sensor

Fuel Sensor

Sensors


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CONTENTS

• Site Layout

• Core Components


• Sensors Used




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12 Core Cable 6 Core Cable 4Core Cable

4Cor Power Cable Singe Core Cable 1.5mm Cat 6Cable

IRM (Installation Required Material) (1/3)


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PVC Spiral GI Spiral Saddle Clamp Din rill

PVC Box Connecting strip Lugs Jubilee clamp



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Tag ties Insolation Tape Rawal Plug

Silicon



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1

11

2

3

4

85

76

10

9

12

C

O

R

E

C

A

B

L

E

2

1

2

3

4

5

6

7

8

9

10

11

12

How to take cell voltages from the Battery Bank

12

C

O

R

E

C

A

B

L

E

1


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W X

Y

23

45

10

11

12

1

34

2

5

7 678

98

10

11

9

6

1

BAM inputs from the Battery Bank


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12 core cable 12 core cable

12 Core wire connections with BAM


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Before installation Process

1. Call Guard when reached on site

2. Call Innexiv NOC when reached on site

3. Call TP NOC for Access

4. Check Site status before installation (CP availability , Gen working Properly , ATS and MDB)

5. Select Place for MCU Mounting

Installation Process

1. Power Up MCU

2. Make BSB connection, See if Grid is Available and Generator is working

3. Connect Fuel Sensor

4. Make Main Distribution Board Connections and install AC CT

5. Install ARM and ATS connection

6. DDF Connection

7. NOC Testing

Installation Process


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Required H/W

BAM (Battery Analyzer module )

DC PSU

Required IRM

Din rill

Jubilee Clamp (3in)

Screw & nut

Process

Attach Din Rail (Hanging Instrument) behind BAM box

Pass Jubilee Clamp 3’’ below the Din rail and tight the

screws

Install BAM and DC PSU box to bottom right of BSB

(Battery Bank)

BAM & DC PSU Installation


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Required IRM

1.5 mm single core cable

Cat 6 cable

Spiral

Saddle Clamp

Lugs 5/8mm

Process Layout Spiral and Cable .5mm 12 core MCU to BAM

Meyer cable 1.5mm DCPSU to 1st Battery Negative and 24 # Battery positive

Connect lugs 8.5mm with 1.5mm Both cables in Onsite

1st battery negative connect DC PSU NEGATIVE 48VDC and 24# battery positive connect DC PSU POSITIVE

48VDC

DC PSU output POSITIVE 12VDC connect with BAM Y1

DC PSU output NEGATIVE 12VDC connect with BAM Y2

Powering up MCU


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Connection from Connected to Wire type Notes

BATTERY BANK to

DC-PSU

POSITIVE 48VDC from Battery # 24DC-PSU: DC+

RED Single Core

WRONG CONNECTION WILL

RESULT IN SERIOUS DAMAGE!NEGATIVE 48VDC from Battery # 1DC-PSU: DC-

Black Single Core

DC-PSU to

BAM

POSITIVE 48VDC from Battery # 24 (Input)

X - 12

RED Single Core

WRONG CONNECTION WILL

RESULT IN SERIOUS DAMAGE!NEGATIVE 48VDC from Battery # 1W - 1

Black Single Core

POSITIVE 12VDC (Output)Y - 1

RED Single Core

NEGATIVE 12VDC (Output)Y - 2

Black Single Core

DC PSU Connection With Bam and Battery Bank


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• Twist wire White Orange /Orange (Cat 6 cable) Connect one end of cable Connecting pad y

Port y1

• Twist wire white Green /Blue (Cat 6 cable) Connect one end of cable Connecting pad y Port

y2

• Twist wire White Orange /Orange (cat 6 cable) Connect other end of cable Connecting pad R

Port R1

• Twist wire r white Green /Blue (Cat 6 cable) Connect other end of cable Connecting pad R

Port R2

• Connect connecting pad y with BAM

• Connect connecting Pad R with RTU

• Now check MCU status if its ok Call to INNEXIV NOC and bind the RTU

Connection BAM to MCU For MCU Power up


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Required IRM

12 Core .5mm Cable

Lugs 5/8mm

Process

Route the 12 Core cable from BAM to both sides of the batteries separately (one from right and

one from left) as per wire numbering but do not connect the wires with battery terminal

Fix 23 lugs on each individual wire of 12 core cable on battery terminal side

Start the generator before connection of wires with batteries

Start connection lugs and wires on the Positive terminal side of batteries but do not connect top

right battery i.e. connect only 23 batteries but not the 24 th. Don’t connect Positive terminal of

batteries at this stage.

Connect one side of 0.5mm cable with DC positive terminal of DC (PSU) and the other side of

cable with intentionally left last port of right sided “X” connecting pad (X12) of BAM

BSB individual Battery Connection with BAM


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•White Blue Wire one side connect with DCCT Positive (+) And other site connect with connecting pad O

connecting port O1

• Green one side connect with DCCT Negative (G) And other site connect with connecting pad O connecting

port O2

•White brown /Brown one side connect with DCCT signal (M) And other site connect with connecting pad O

connecting

DC CT Connection with MCU


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Line

#

Signal

RoutingDescription / Type

BAMCAT 6

Color ReferenceMCU

Connector Pad & Port

Reference

Number of

wiresColor

Cable

numberConnector Pad & Port Reference

1

B

O

A

R

D

T

O

B

O

A

R

D

C

O

N

N

E

C

T

I

O

N

S

POSITIVE 12VDC Y - 1 2 white orange/orange

1

R - 1

2 GROUND Y - 2 2 white green /blue R - 2

3 BAM Feedback Y - 3 1 white blue R - 3

4 Transmit signal Y - 4 1 greenR - 4

5 Receive signal Y - 5 1 white BrownR - 5

Spare - 1 Brown -

6 POSITIVE 48VDC - TBV W - 1 2white orange

/orange

2

P - 1

7 NEGATIVE 48VDC - TBV X - 12 2 white green /blue P - 2

8

DC CT

DC CT 'POSITIVEDC-CT '+' Pin 1 white blue O-1

9 DC CT 'GROUND DC-CT 'G' Pin 1 Green O-2

10 DC CT Signal DC-CT 'M' Pin 2white

brown/BrownO-3

Connection from Connected to Wire type Notes

BATTERY BANK to DC-

PSU

POSITIVE 48VDC from Battery # 24 DC-PSU: DC+ RED Single CoreWRONG CONNECTION WILL RESULT IN SERIOUS

DAMAGE!NEGATIVE48VDC from Battery # 1 DC-PSU: DC- Black Single Core

DC-PSU to BAM

POSITIVE 48VDC from Battery # 24(Input)

X -12 RED Single Core

WRONG CONNECTION WILL RESULT IN SERIOUS

DAMAGE!NEGATIVE48VDC from Battery # 1 W - 1 Black Single Core

POSITIVE 12VDC (Output) Y - 1 RED Single Core

NEGATIVE12VDC (Output) Y - 2 Black Single Core

BATTERY ANALYZER (BAM) CONNECTION REFERENCE


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Line # Signal Routing Description / TypeBAM

Cable Number Reference Cable TypeIMPORTANT

NOTESConnector Pad & Port Reference

1

BATTERY BANK

CELLS

1-12

to BAM

POSITIVE - Battery # 1 W - 2 1

12 CORE CABLE

terminate on BAM first then battery cell

WRONG

CONNECTION

WILL DAMAGE

BATTERY

ANALYZER

2 POSITIVE - Battery # 2 W - 3 2 terminate on BAM first then battery cell







9 POSITIVE - Battery # 9 W -10 9 terminate on BAM first then battery cell

10 POSITIVE - Battery # 10 W -11 10 terminate on BAM first then battery cell11 POSITIVE - Battery # 11 W -12 11 terminate on BAM first then battery cell

12 POSITIVE - Battery # 12 W -13 12 terminate on BAM first then battery cell

13

BATTERY BANK

CELLS

13-23

to BAM

POSITIVE - Battery # 13 X - 1 1

12 CORE CABLE

terminate on BAM first then battery cell

WRONG

CONNECTION

WILL DAMAGEBATTERY

ANALYZER

14 POSITIVE - Battery # 14 X - 2 2 terminate on BAM first then battery cell




18 POSITIVE - Battery # 18X - 6

6 terminate on BAM first then battery cell19 POSITIVE - Battery # 19 X - 7 7 terminate on BAM first then battery cell



22 POSITIVE - Battery # 22 X -10 10 terminate on BAM first then battery cell

23 POSITIVE - Battery # 23 X -11 11 terminate on BAM first then battery cell

24 NOT IN USE NA NA THIS WIRE IS NOT BEING USED!

BATTERY ANALYZER (BAM) CONNECTION REFERENCE


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+

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+

+

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+

+

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+

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+

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+

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+ -

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+

-

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+

+ -

-

+

+ -

TBV (Total Bank Voltage) ,DC PSU and BAM Connection with MCU


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Required IRM & Sensor

1. Fuel sensor

2. PVC Box

3. Cable 6 core

4. Connecting strip

5. Spiral pipe

6. Gland

7. Saddle Clamp

8. Screw

9. Rawl plug

Process• Connect the 4 terminals connecting strip from left to right with three (3) fuel sensor wire in below mentioned

way;

• Connect from the same 4 terminal connecting strip left to right with 3 temperature sensor wires in same above

way except its signal wire should be connected to the Empty 4th terminal of the connecting strip. However Red

(Positive) with Red (Positive), Black ground (Negative) with Black ground (Negative).

• Now use the 6 core fuel sensor for connecting fuel sensor to MCU or RTU in following reference

Fuel Sensor To MCU Connection


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• Connect one side of the Red wire ( 6 core )fuel sensor wire on the opposite side of other two Red (Positive )

wires in connecting strip and connect the other side of the Red wire ( 6 core ) fuel sensor wire with port LLI of

connecting pad LL of MCU.

• Connect one side of Brown wire (6 core )fuel sensor wire on the opposite side of other two black ground

(Negative) wires in connecting strip and connect the other side of the Brown( 6 core ) fuel sensor wire with port

LL2 of connecting pad LL of MCU.

• Connect one side of Blue wire (6 core )fuel sensor wire on the opposite side of blue (fuel sensor signal ) in

connecting strip and connect the other side of the Blue wire (6 core )fuel sensor wire with port LL3 of

connecting pad LL of MCU.

• Connect one side of wire Green( 6 core) fuel sensor wire on the other opposite side of 4th

No. port oftemperature signal wire in the connecting strip and connect the other side of the Green wire ( 6 core ) fuel

sensor wire with port LL4 of connecting pad LL of MCU.

Connecting strip To MCU Connection


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Fuel Sensor connection with MCU


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Required IRM & Sensors

•

AC CT•Power cable 4 Core

•Cat 6

•Spiral

•Glands

Process

First check the space for insertion the cables in DB 4core cable use for Voltage measurement 1st Red cable

with Red (220V) 2nd Yellow connected with Yellow (220V) 3rd Blue with Blue (220) 4rh Black cable with Black

(Neutral)

AC CTs Connections

1st Ct fixed on with Red wire 1st phase

2nd Ct fixed on with Yellow wire 2st phase

3rd Ct fixed on with Blue wire 3rd phase

AC CTs RTU Connections

1st CT White Wire With Q1 and Black with Q2

2nd CT White Wire With Q3 and Black with Q4

3rd CT White Wire With Q5 and Black with Q6

Main Distribution Board to MCU Connection


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Line #Signal

RoutingDescription / Type

MCUCable

TypeCable Reference

Connector Pad & Port

Reference

1

MDB to MCU

Phase # 1 VOLTAGE (L1) HIGH VOLTAGE! E - 1

4-Core

Red

2 Phase # 2 VOLTAGE (L2) HIGH VOLTAGE! E - 2 Green

3 Phase # 3 VOLTAGE (L3) HIGH VOLTAGE! E - 3 Blue

4 NEUTRAL E - 4 Black

5

Load Phase # 1 AC-CT POSITIVE (AC-CT wire is

WHITE)Q - 1

Cat-6

White Orange

6Load Phase # 1 AC-CT NEGATIVE (AC-CT wire isBLACK)

Q - 2Orange

7


WHITE)Q - 3

white Green

8

Load Phase # 2 AC-CT NEGATIVE (AC-CT wire is

BLACK)Q - 4

Blue

9


WHITE)Q - 5

white blue

10Load Phase # 3 AC-CT NEGATIVE (AC-CT wire isBLACK)

Q - 6Green

11 reserved for future use NA White Brown

12 reserved for future use NA Brown

Main Distribution Board (MDB) Connection Reference


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MDB


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Wire colors Mentioned Below

AC Phase Voltage Sensors Connections

Q


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Required Module

ARM

Required IRM

Cat 6 Cable

1 mm cable

Spiral

Glands

Screw & Nut

1mm U Type lugs

1mm I Type lugs

ATS Connection


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Process

Install ARM inside the ATS

Off the breakers one by one to check the CP cut.

After tracing CP cut breaker Remove wire from The breaker connect it ARM Connecting Pad B Connect port B4

and connect wire port B6 ( ARM) Insert CP cut Breaker

Trace the Delay GEN signal.

After tracing Delay gen wire Remove wire from There connect it ARM Connecting Pad B Connect port B1 andconnect wire port B3 ( ARM) Insert Back to Removal place

While DG running MC (Magnetic Contactor) for GEN should be engaged.

Check for 220 V on auxiliary coil of GEN MC and connect it with D1.

While site on CP the MC (Magnetic Contactor) for CP should be engaged.

Check for 220 V on auxiliary coil of CP MC and connect it with D3.

Connect negative 220 load with B2 .

Use White orange /orange Pair ( Cat 6 ) For Gen Battery Positive connect to MCU Connecting Pad N Port N1

Use White Green /Green Pair (Cat 6) For Gen Battery Negative connect to MCU Connecting Pad N Port N2

ATS INTERNAL Connection


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Use Orange cable of (Cat 6 # 1) for connecting port A2 of connecting pad A of ARM with port N6 of

connecting pad N of RTU.

Use Cat 6 cable for connecting ARM to MCU. First Use white orange cable of (Cat 6 # 1) for connecting port A1 of connecting pad A of ARM with

port N5 of connecting pad N of RTU.

Use White Green cable of (Cat 6 #1) for connecting port A3 of connecting pad A of ARM with port

F1 of connecting pad F of RTU.

Use Blue cable of(Cat 6 # 1) for connecting port A4 connecting pad A of ARM with port F2 of

connecting pad F of RTU.

Use White Orange cable of (Cat 6 # 2) for connecting port C1 of connecting pad C of ARM with portM3 of connecting pad M of RTU.

Use Orange cable of (Cat 6 #2) for connecting port C2 of connecting pad C of ARM with port N4 of

connecting pad N of RTU.

Use White Green / Blue cable of( Cat 6 #2) for connecting port C3 of connecting pad C of ARM with

port H1 of connecting pad H of RTU.

Use White Blue /Green cable of ( Cat 6 #2) for connecting port C4 of connecting pad C of ARM with

port I-1 of connecting pad I of RTU

BAM to MCU Connection


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External ATS Internal ATS

Types of ATS


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Wire colors Mentioned Below

ARM to MCU Connections


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Line # Signal Routing Description / TypeARM

Cable Color/Type NOTESConnector Pad & Port

Reference

Color code check

1

ATS to ACP

Module

AC Cut - IN/COMMON RELAY1 HIGH

VOLTAGE! B - 1 RED Single CoreHIGH

VOLTAGE

CONNECTIO

NS!

2

AC Cut - OUT/NC OF RELAY1 HIGH

VOLTAGE!B - 3

RED Single Core

3 GenSet Cut - IN/COMMON POINT OF RELAY 2B - 4

Black Single Core

In case of IPS& Deep Sea use B - 6

in place of B - 5

4 GenSet Cut - OUT/NC POINT OF RELAY 2 B - 6 Black Single Core

5 CP Magnetic Contactor Energizer Point POSITIVE D - 1 1mm Single CorePUT SITE

LOAD ON

BATTERY6 Any NEGATIVE point from ATS (NOT GROUND)

D - 21mm Single Core

DO NOT USE GROUND FOR

NEGATIVE!!

7

GenSet Magnetic Contactor Energizer Point

POSITIVED - 3

1mm Single Core

Line # Signal Routing Description / Type

ARM CAT 6

Color RefrenceConnector Pad & Port

Reference Number of Wires Color Cable number

8 From ATS to

MCU

Generator Battery Voltage POSITIVE 12VDC 1 White orange

1

9 Generator Battery Voltage GROUND 1 Orange

10

B

O

A

R

D

T

O

B

O

AR

D

C

O

N

N

E

C

T

I

O

N

S

Feedback - Delay Gen Relay A - 1 1 White Green

11 Feedback - AC Cut Relay A - 2 1 Blue

12 RTU Battery POSITIVE 12VDC A - 3 2 White Blue /Green

13 RTU Battery Negative 12VDCA - 4 2

White Brown

/Brown

14 AC Status C - 1 1 White Orange

2

15 Generator Status C - 2 1 Orange

16 Delay Generator Signal C - 3 2 White Green/Blue

17 AC Cut Signal C - 4 2 White Blue /Green

Spare-1 - 1 White Brown

Spare-2 - 1 Brown

Automated Relay Module (ARM) connection reference


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In case of any quarries contact:

Azeem Taj

RM North

Cell: 03458569320

Sibtain Gul

RM Central

Cell: 03445666602

Documents

INNEXIV RTU Installation Batch 4 TP training.pdf