Retrofit Controller – System Infra Solutions

Retrofit Controller

1.1 GENERAL INFORMATION:

SISPL Retrofit controller is an integrated multifunction high speed micro controller based System.  It’s having a provision of single phase/three phase mains and DG with Automatic /manual modes of operations. This controller includes protection for mains and DG (as per standards).This controller in having battery and room temperature monitoring facility.

System Retrofit Controller system is designed for telecom sites where any make of PIU/IPMS are not working or faulty. SISPL retrofit controller unit has features like remote management, inbuilt microwave provision, power scalability, etc that enhance the fuel and battery efficiency in the existing sites. This controller follows a rational approach towards power management through

  1. Integrated AMF Function.
  2. AC power measurement.
  3. DG parameter monitoring.
  4. Alarm Consolidation.
  5. Remote monitoring facility.

The highlighting feature of  Retrofit controller is that it reduces the operational costs through a well-researched fuel management system The fault management and functionality units of this system is  adaptable for Air-conditioners, Batteries, Fire alarms, Diesel Gen sets, Security, AC Power, DC power, lightening and surge protection, etc.

Other feature:

  1. AC distribution unit.
  2. Fire Alarm module.
  3. Aviation lamp controller.
  4. Auto phase Selector.
  5. IPMS logic.
  6. SVR controller.
  7. Battery Monitoring (Battery Current, SOC, Energy)
  8. Real time and events recording.
  9. One/Two DG control.
  10. Real time restriction for DG running in different time slot.
  11. Configuration (almost fifty programmable parameters).
  12. Calibration (on site calibration facility for all analog parameter).

1.2 OPERATIONS:

Three operation of Retrofit controller is given below:-

  • Key function
  • Calibrations
  • Configurations
  • System Operation

Key Function

There are five switches in Display Board

# SW1 for Increment and Reset

# SW2 for Decrement and Scrolling

# SW3 for Enter and Events

# SW4 for Configuration

# SW5 for Escape

#SW1:  This switch is used for two purposes one for increment and other for system reset. Normally this switch is working for system reset. When you go for configuration that time this switch working for increment.

#SW2:This switch is used for two purposes one for decrement and other for display scrolling. Normally this switch is working for display scrolling. When you go for configuration that time this switch working for decrement.

#SW3 : This switch is used for two purposes one for Enter and other for events log display. Normally this switch is working for events log display. When you go for configuration that time this switch working for enters.

#SW4: This switch is used for two purposes one for menu decrement and other for configuration normally this switch is working for configuration. When you go for configuration that time this switch working for menu decrement.

#SW5: This switch is used for escape. Purpose of this switch in any stage you can go for default display.

Calibration

For any analog parameter calibration you can go for calibration mode by configuration. In calibration mode you can go for that parameter which you want to calibrate. After you can set the value by increment and decrement key if actual value is equal to apply value press enter key and then press the escape key. And check that parameter is ok or not.

Configuration

For any programmable parameter changing you can go in menu setting by configuration mode. In configuration mode you can go for that parameter which you want to change after this you can adjust by increment and decrement key and then press enter key. Then go for escape.

System Operation

The operation of SISPL controller in two ways on is AUTO mode and other is manual mode. In auto mode controller control the DG function automatically and check the DG alarm status but in manual mode no control the DG operation. In auto mode when mains or LCU voltage out of range or not available then check BTS battery voltage if BTS battery voltage is below of specified limit and room temperature is above limit, then check DG alarm status if no fault of DG after that check for LLOP if LLOP enable and connected properly and LED indication of LLOP should be off, if not then show in LCD display LLOP OPEN and not DG start. After checking the LLOP give the crank for DG start and wait for DG voltage if DG voltage is not coming within 30 seconds after given the crank then give again crank for DG start and wait for DG voltage. If DG voltage is not coming after DG start the show DG fail to start and LED indication of fail to start should on. But if DG voltage is coming and within range then go for DG warm up otherwise generate the DG ALT fault. After DG warm up Load is on and LCD display show DG OK. And check DG alarm like LLOP, Half FUEL, Low FUEL, HCT, overload, over speed. If any alarm generated then give DG stop command. If DG is not stop after successful stop command then show for DG fail to stop and LED indication of fail to start will on. If no alarm is generated and mains healthy that case DG will go for stop and after DG stop load will change on mains.

Alarm checking

1) Fail to stop

If DG is running and any DG fault is generated or mains is restore then go for DG stop and after stop hold time DG is not stop then fail to stop alarm is generated. LED indication of fail to stop is continuing ON. Fail to stop and DG common fault relays will ON.     

2) Fail to start

If DG crank is active and DG voltage is not coming within 30 seconds then fail to start alarm is generated. LED indication of fail to start is continuing ON. Fail to start and DG common fault relays will ON.          

 

3) LLOP Fault

If DG is running and LLOP sensing input is close then LLOP fault is generated. LED indication of LLOP is continuing ON. LLOP and DG common fault relays will ON.                          

4) LOW FUEL

If DG is running and Low fuel sensing input is close then Low fuel alarm is generated. LED indication of low fuel is continuing ON. Fuel relay will ON.                           

5) Half FUEL

If DG is running and half fuel sensing input is close then half fuel alarm is generated. Fuel relay will ON.  

6) HCT/HWT Fault

If DG is running and HCT sensing input is close then high engine temperature fault is generated. LED indication of HCT/HWT is continuing ON. HCT/HWT and DG common fault relays will ON.         

7) OVERLOAD

If DG is running and output load of any phase is greater than specified limit then over load fault is generated. LED indication of overload continuing ON. Overload and DG common fault relays will ON. Overload alarm check also for mains.  

8) Over speed

If DG is running and DG speed is out of range then over speed alarm is generated .LED indication of over speed is continuing ON. Over speed and DG common fault relays will ON.              

9) Alternate Fault

If DG is running and DG voltage is out of range then DG alternate fault is   generated .LED indication of alt fault is continuing on. DG common fault relay will ON.  

10) Smoke Fire alarm

If Mains or DG running and smoke fire sensing input is close then smoke fire alarm is generated in this case mains and DG contractor is off. LED indication smoke fire alarm is continuing on and relay of smoke fire will ON.      

11) BTS battery Low

If BTS battery voltage is below than specified limit then BTS battery alarm is generated. LED indication of BTS battery low and Relay of BTS battery is continuing on.

12) DG battery Low

If DG battery voltage is below than specified limit then DG battery alarm is generated. LED indication of DG battery low and Relay of DG battery is continuing on.

13) High room temperature

If room temperature is greater than specified limit then high room temperature alarm is generated. LED indication of high room temperature and Relay of high room temperature is continuing on.

All above alarm will display in LCD display 3rd line continuing scrolling.

Real time Log         

When these alarm is generated the controller is logged that alarm in date and time stamping format. Logging format given below. In this controller 1000 event logging is possible like first in first out (FIFO).

List of Potential free contact

  1. A) Fail to start
  2. B) Fail to stop
  3. C) HCT
  4. D) Low Fuel
  5. E) LLOP
  6. F) Alt fault
  7. G) Over speed
  8. H) Overload
  9. I) Mains fail
  10. J) High Room temperature
  11. K) BTS battery Low
  12. L) DG Battery Low
  13. M) Load on DG
  14. N) Load on Mains
  15. O) Site on Battery
  • CONTROLLER LAYOUT:

1-5) CONTROLLER LOGIC:

Control logic diagram with LCU

Control logic diagram with Non LCU

  • Connection Details
  • CONTROLLER SPECIFICATION :

The Retrofit controller Standard as given below

Description Standard Specification
Capacity Range of 5 to 50 KVA
Multi Phase Logic Retrofit controller will work on 1Phase, 2phase or 3Phase.

Input voltage range on single phase – 145V–300V

Mechanical CNC Fabricated box, using CRC Sheet duly powder coated, 1.6 mm thick CRC sheet. Split type modular design.
Safety The equipment will ensure IEC 60950 safety standards
MTBF All material & workmanship will be of professional quality to ensure MTBF requirement. The MTBF of the retrofit controller  is more than 70000 hrs.
Compliance CE, Tested for safety, EMI/RFI  compliance
Micro Controller High-Speed micro controller

True RMS for all voltage & current

All the inputs to the measurement board will be duly protected against surge as per IEEE-62.41

The measurement circuit will be rated at least twice of the maximum input range, each indepen­dent for AMF & module

Time Real time & date-programmable
Event Logs Last 1000 events
RS 232t for SISPL use only For PC interface to adjust the critical data and unload the alarms, This Port will be used for configuration of PFCs.
Energy Will be able to measure the DG energy (Cumulative KWH &Hrs)

Will be able to measure the EB energy (Cumulative KWH &Hrs)

Will be able to measure the Battery  energy (Cumulative KWH & Hrs)

Data Transfer Retrofit controller will be equipped with suitable GPRS modem / GPRS DTU and able to process the data.
DG on load After DG starts and supply is healthy
Blackout delay 5  Seconds between mains and DG contactor changeover.
DG cooling time 15 minutes
DG start attempts Three attempts with delay between attempts ( 40 -40 -40 sec )(settable)
DG Lock time After three very short mains restora­tion 10-10-20 minutes, DG

will run for 1hrs (settable) continuously.

 

Stop Command duration Settable from 10 to 50 seconds
Battery charger & DG controller unit Automatic DG battery, SMPS charger with boost/trickle charging & with constant cur­rent charging facility (12V)

 

Provision of Auto manual mode selection

 

Auto Phase selector The Retrofit Controller will be inbuilt with auto phase selector which will select any two phase or single phase out of 3 Phase. There will be a electrical and mechanical interlock between each contactor to avoid short cir­cuit in case of electronic failure
Set point-for high tem­perature alarm Factory set (“ON” at 40°C and “OFF” at ON – 3°C)
DG set measurements Mains/DG status, DG accumulated hours, DG voltage, DG Energy Mea­surement (DG KWH)
Mains measurements Input Voltage, Output voltages for line conditioning module, Mains Energy Measurement (EB KWH)
Battery measurements Battery running hrs & KWH (Accumulated)
LED Indications: Mains ON, DG ON, Smoke/ Fire Alarm, DG Common Fault,  Fuel Low, System battery low,  High Shelter temperature
List of potential free dry contacts
 
Alarms will be extended to NOC / TOC through changeover contact (both ‘NO’, ‘NC’ ).

Mains fail, Shelter Door open/ Intruder, Low fuel level, Common fault — LLOP/Alt fault/HCT/HWT/V belt/Dg fail to start/DG fail to stop, Smoke/Fire, Load on DG, DG Fail to stop, DG Fail to start, DG over load, Shelter high temperature, Site on battery, BTS Battery Low.
Standard setting Setting in the Retrofit Controller can change manually & Laptop.
Site Calibration All measured parameter can you calibrate through S/W on field
Dual DG Logic Will be provided the Dual dg logic on sequential basis.

3)   Configuration (Programmable Parameters)

The configuration for controller module is as follows :-

S.NO Parameter Name Max Value Min Value Default Value
1 MAINS HIGH CUTOFF 500 240 300
2 MAINS LOW  CUTOFF 350 70 90
3 MAINS HIGH CUTIN 500 220 290
4 MAINS LOW  CUTIN 360 70 130
5 DG   HIGH CUTOFF 280 240 260
6 DG   LOW  CUTOFF 210 140 170
7 DG RPM  HIGH 3000 1550 1650
8 DG RPM  LOW 1500 1000 1350
9 ROOM TMP.HIGH ALARM 60 15 40
10 DG CRANK TEMP HIGH 60 15 35
11 DG OVERLOAD 150 1 35
12 EB OVERLOAD 150 1 35
13 BTS BATTERY LOW 60.0 20.0 47.0
14 DG AUTO RUN TIME 18 1 6
14 CRANK ACTIVE TIME 10 1 3
15 CRANK RETRIES 5 0 2
16 STOP HOLD TIME 50 10 30
17 STOP RETRIES 5 0 2
18 DG WARM UP TIME 90 10 10
19 MAINS RESTORE TIME 300 20 30
20 DG COOL DOWN TIME 900 30 60
21 DG LOCK TIME 150 10 10
22 LLOP DELAY TIME 50 5 5
23 DG START INTERVAL 240 30 40
24 CT RATIO 250 25 125
25 LLOP ENABLE/DISABLE     DISABLE
26 EB  FLUCTION TIME 30 1 20
27 EQUALIZE CHG NORMAL     DISABLE
28 EQUALIZE CHG MANNUALY     DISABLE
29 BATTERY CHARGE INTERVAL 1440 1 168
30 BATTERY CHARGE TIME 48 1 12
31 AVIATION ON TIME IN HOUR 23 0 18
32 AVIATION ON TIME IN MINUTE 59 0 0
33 AVIATION OFF TIME IN HOUR 23 0 6
34 AVIATION OFF TIME IN MINUTE 59 0 0
35 SVR HIGH CUTOFF 300 240 260
36 SVR LOW CUTOFF 210 150 180
37 PSEL ENABLE/DISABLE     ENABLE
38 PSEL HIGH CUT OFF 300 240 300
39 PSEL LOW CUT OFF 180 70 90
40 PSEL HIGH CUTIN 290 250 280
41 PSEL LOW CUTIN 200 70 120
42 PHASE UNBALANCE 90 20 50

4)   Calibration Parameter

The calibration parameters are as follows:-

S. No Parameter name Actual value Measured value
1 Main R-PH Voltage XXX XXX
2 Main Y-PH Voltage XXX XXX
3 Main B-PH Voltage XXX XXX
4 LCU#1  Voltage XXX XXX
5 LCU#2  Voltage XXX XXX
6 LCU#3  Voltage XXX XXX
7 DG R-PH Voltage XXX XXX
8 DG Y-PH Voltage XXX XXX
9 DG B-PH Voltage XXX XXX
10 EB I/P current R-Phase XXX.X XXX.X
11 EB I/P current Y-Phase XXX.X XXX.X
12 EB I/P current B-Phase XXX.X XXX.X
13 O/P current R-Phase XXX.X XXX.X
14 O/P current Y-Phase XXX.X XXX.X
15 O/P current B-Phase XXX.X XXX.X
16 Room Temperature XX.X XX.X
17 Ambient Temperature XX.X XX.X
18 BTS Battery voltage XX.X XX.X
19 DG Battery voltage XX.X XX.X

Actual values display what have you apply and measured value is measurement by controller.

5)   Retrofit Controller Snap