ipmu ic procedure

PACE POWER AFRICA LTD

IPMU

Introduction IPMU is an integrated power management unit which integrates SMPS & PMU. The

concept of IPMU comes after development of switch mode power supply with wide voltage operation. It reduces the application of large rating line condition unit and only low rating auto transformer is required for air condition and lighting. It is well designed to send data of complete site through SMS and GPRS.

Features: 1. It can work on 1 Phase, 2 Phase, and 3 Phase Mains. 2. If Mains Voltage is above 170V,it will directly feed to Rectifier Modules (RN.YN & BN) 3. If Mains Voltage is below 150V then Boost Voltage is supplied to the Rectifier Modules

Tools Required:

• Clamp meter with AC current meter and Probes.

• Crimping tool (6sqmm to 70sqmm).

• Drilling Machine with bits to take up to 15 mm

• Mechanical Tool Kit (Spanner set ,Wire Cutter & Screw Drivers set) .

ACCESSORIES Required for I &C:

ACCESSORIES TYPE QTY MAKE

Aluminium Lugs M8, 16 Sqmm (Mains /

Generator Cable) Ring 16

ASCON/Any Others

Copper Lugs 50 Sq mm (Bat. Bank) Pin 2

Copper Lugs M13 50 Sqmm (Bat. Bank) RING 2

Copper Lugs 4 Sqmm (Generator Bat.

Charging) Pin 4

Insulation Tape Red Colour -- 0.25m

Insulation Tape Yellow -- 0.25m

Insulation Tape Blue -- 0.25m

Insulation Tape Black -- 0.25m

Steel Clamps (As Per Cable Spec.) -- 40

Cable Ties(200mm) -- 40

Cable Ties(300mm) -- 10

Hexagonal Bolt 25mm x M8 -- 16

M8 Nut Hexagonal -- 16

M8 Plane Washer -- 32

M8 Spring Washer -- 16

Hex HD Bolt Steel M6 x 30 (For Generator

Controller)

--

2

Plain Washer (For Generator Controller) -- 2

Spring Washer M6(For Generator Controller) -- 2


Hex Nut M6 (For Generator Controller) -- 4

M10x50mm Hexagonal nut Bolt(for IPMU

Panel fixing)

--

4

M10 Plane Washer(for IPMU Panel fixing) 8

M10 Spring Washer(for IPMU Panel fixing) 4

� SITE READINES CHECKUP

• Ensure that site is ready for installation.

• Ensure that Mains Power is available at the site.

• Ensure that Battery Bank is installed

• Ensure that Generator Installed and commissioned

PRE INSTALLATION CHECKS:

� Please check all Mains, Generator, Bat., BTS & Earth Cabling is done or do it as the below mentioned.

• Lay the AC Cables from Mains Meter Box to IPMU with proper clamps & Cable Ties.

• Lay the Generator control cable from Generator to IPMU

• Lay the AC Cables from Generator to IPMU.

• Lay the (PE) Earth cable (16sqmm copper) is routed from Earth bus bar to IPMU.

• Lay the (TE) Earth cable (16sqmm copper) is routed from Earth bus bar to SMPS DC +ve Bus bar in IPMU.

• Lay the cables (50sqmm Copper Red& Black) from Battery Bank to IPMU with proper clamps & Cable Ties

� Please check voltage across all the below mentioned points.

• Check Neutral to Earth Voltage by Multimeter in 20v Range, it should be 0 to 3V only.

• Check the AC voltage across RN, YN& BN.

• Check the Phase to Phase AC voltage across RY, YB & BR. It should not be Zero.

Note: PMU is designed to work on Phase and Neutral. So it is necessary to check the neutral health before installation. Proper earthing is also recommended in the site.


Check IPMU Packed items received at site as per below given list:

IPMU UNIT WITH ELTEK MODULE WITH SMPS & Module


Unpacking:

• Unpack the IPMU at the Site and Check for Physical damages.

• Position at the specified location to mark the mounting holes location and take the cabinet out.

• Drill the four holes for mounting with M10 coach screw, then Place the Panel and fix it. Make sure the coach Screws are tightened properly.

• Unpack the SVR 1&2 Transformers, (2X4KVA, 8 KVA). Check for Physical damages and fix it at the specified location inside the IPMU.

• Unpack the SMPS, Check for Physical damages and fix at the specified location inside the IPMU.

• Unpack the Rectifier Modules, Check for Physical damages and insert at specified location inside the SMPS.


Accessories Packing List(Separate Box kept inside the IPMU)

Sl. No Item Description Qty( Nos)

1 Smoke Sensor with Relay Based 1 For Shelter

2 Magnetic Door Switch 1 For Shelter Door

3 Generator Controller 1 For Generator Start, Stop

4 Transformer Cables 5 SVR to TXFR

5 Cable 4SQ, 4Core, 1mtr 1

Generator Controller To Generator

Terminal Block

6 6Pair/ 0.5sqmm cable with lugs & ferrule marking 20mtr 1 SMPS Alarm Extension to BTS

7

12pair/0.5sqmm cable with lugs & ferrule marking

11mtr 1

IPMU Alarm Extension to BTS

8 4 Core/0.5sqmm cable with lugs & ferrule marking 5mtr 1 SMPS Alarm Extension to IPMU

9 3 Core/0.5sqmm cable with lugs & ferrule marking 5 mtr 1 SMPS DC Energy meter to GPRS

Modem

10

12 core/1.5sqmm + 2 core/4sqmm with lugs & ferrule

marking 25 mtr 1

IPMU to Generator

IPMU COMMISSIONING PROCEDURE (IPMU Part): 1. Connect the Mains Input Supply R, Y, B, at I/P MCCB and Neutral at I/P Neutral TB.

2. Connect Earth cable (16sqmm copper Green) from Earth Bus bar to the IPMU earth TB.

3. Connect Genset Supply R, Y, B, at Generator MCCB and if it is Single Phase Genset same

phase will be looped in other two terminals & Neutral at I/P Neutral TB.

4. Install the Transformer in the IPMU using its own fasteners. Make sure that the terminal

block of the transformer is facing front side of the cabinet.

5. Connect SVR I/P Red cable to SVR Bus bar & black cable at TXFR COM. Terminal.

6. Connect SVR TXFR 1, 2,3,4,5 taps to SVR 1, 2,3,4,5 SCRs.

7. Connect Blue/Yellow Cable to the TXFR O/P terminal.

8. Connect AC Loads (Air con & Power Points) to the 32A MCB (Output ACDB).

9. Connect Aviation Lamp wires at Aviation Lamp 6A MCB & TB.

10. Connect 48 V sensing cable from 48V Battery bank to BTS battery sensing MCB in the

IPMU.

11. Connect 3 core .5sqmm 485 communication cables from SMPS DC energy meter to

modem in the IPMU.

12. Extend the Alarms to the Krone box/BTS from 16 relay board.

13. Connect Generator Battery Charging Cable (4sqmm copper) from IPMU Generator

Automation TB No.1 & 2 to Generator Battery TB +ve, -ve respectively.

14. Connect IPMU TB no 3 start signal to Generator Controller start point.

15. Connect IPMU TB no 5 stop signal to Generator Controller stop point.

16. Connect LLOP IPMU TB NO 6 to Generator TB LLOP point. If not required disable the

LLOP from the controller.

17. Connect HCT IPMU TB NO 7& LOW FUEL TB NO 9 to Generator TB HCT & Low Fuel

Points.


� COMISSIONING PROCEDURE IPMU Part:

• Check the Earth w.r.t EB Input Neutral with Multimeter 20V range (i.e 0 to 3V), Input

R, Y, B (230v) with Multimeter 750V range &Chassis (0V) with Multimeter 20V range.

• Check the earth w.r.t Generator I/P Neutral (i.e 0 to 3V) with Multimeter 20V range

& Phase (230v) with Multimeter 750V range.

• Switch ON Control supply & Check the Menu parameters as per given list below.

• Keep the Auto manual Switch in Manual Mode, Switch ON the Input Mains MCB &

check the EB contactor ON manually & then switch OFF manually

• Switch ON the Input Generator MCCB & check the Generator contactor ON

manually& then switch OFF manually

• Check the Input, Output Voltages & Currents with standard multi meter and

Compare Controller LCD Display voltages. 5V difference is acceptable if more that is

there, Calibration is required.

• Keep AUTO MANUAL switch in AUTO mode.

• Check the Auto Change Over( Mains, Battery Mode, Generator & Retransfer to

Mains)

• Check the alarm extension to BTS operators

� SMPS (EMERSON/ELTEK/ZTE)Details

• Connect Input Supply RN,YN,BN at INPUT MCBs

• Connect PE Earth cable (16 Sqmm copper Green) to the earth TB

• Connect TE Earth cable (16 Sqmm copper Green) from earth Bus Bar to the SMPS

output DC +Ve Bus bar.

• Insert the Rectifier Modules.

• Connect SMPS O/P DC +ve Busbar (Red Cable) to Batt. Bank +ve terminal (50 Sqmm

Copper Red Cable –Use Copper Lugs with proper crimping).

• Remove the Bat. Fuse with Fuse puller & Connect Batt. Bank –ve terminal with ring

type thimble at the top of the Fuse end (50 Sqmm Copper Black Cable –Use Copper

Lugs with proper crimping).

• Extend the SMPS Alarms from SMPS TB to IPMU External alarm TB.


Installation & Commissioning Procedure Eltek SMPS


Installation & Commissioning Procedure ZTE SMPS

� Commissioning SMPS PART:

o Measure the AC Input Voltage with multimeter 750V range at I/P MCBs RN, YN & BN

and verify its polarity, Separate Neutral Should come for the each Phase R, Y&B.

o Switch ON the Input 63A MCBs of RN, YN & BN and check the supply.

o Switch ON the Input 32A MCBs of Rectifier Modules and Measure the O/P DC Voltage

(54.6V) with Multimeter 200 DC Range.

o Check Battery connections have correct Polarity.

o Connect Battery Fuse with Fuse holder(Arcing may come while connecting Batteries)

o Switch ON the Load MCBs of BTS & Microwave.

o Verify the rectifiers current Sharing that each of the rectifiers delivers the same output

current.1A deviation is acceptable.

o Extend the SMPS PFC Alarms to IPMU External Alarm TB (Refer Table 2&3 for Alarm

details as per SMPS make).

Table 1: PFC Alarm Extension Details (IPMU to SMPS ELTEK/EMERSON) 4 core Cable

Description

IPMU Ext.

Alarm TB No.

ELTEK SMPS TB NO. EMERSON SMPS TB No.

Common

TB No.18(A1) Loop all common points 11,17,

20 & Connect to IPMUTB No.18

Loop all common points 90,98,

96 & Connect to IPMUTB No.18

Rectifier Fail

TB No.15 Connect the NO terminal of Pin

No.12

Connect the NO terminal of Pin No.91

DC Fuse Fail

TB No.13 Connect the NO terminal of Pin

No.18


Other Cable TB No.14 Connect the NO terminal of Pin

No.21


Insert the Rectifire modules

DC Energy meter, Connect 485 cable on the back side of meter from Modem.

Connect -48 of Battery Bank

Connect AC input supply RN, YN, BN

Connect -48V for load. (+ve Bus Bar is behind the MCBs. Remove Top cover to access).

Alarm Terminal Block.


Table 2: PFC Alarm Extension Details (IPMU to SMPS ZTE)

GENERATOR CONTROLLER

• Identify the Generator controller box mounting location in the Generator canopy and Drill dia 8.0mm whole, 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 Generator controller box on to canopy side wall or (on to the vertical stand provided by the customer). Ensure that bolt head and plain washer is on the side of the canopy.


GENERATOR Controller Wiring Details Open the GENERATOR controller cover. Change the position of the white connector to short the 1 and 2 No. Pin of the connector. Close the cover of the Generator controller and fix it in the Generator.

1. Change the position of the connector to short the 1 & 2 no. pin. By default 2 & 3 are shorted.


GENERATOR Controller Wiring Details

2. Connect Generator -ve wire (1 sqmm) to the Generator Controller J1 Connecter Pin No.1.

3. Connect Generator start signal, PMU Generator Controller TB No.3 to the Generator Controller J1 Connecter Pin No.2 (1

4. Connect Generator stop signal, IPMU Generator Controller TB No.5 to the Generator Controller J1 Connecter Pin No.3 (1sqmm).

5. Connect Generator start signal, Generator Controller TB to the Generator TB start point (1 sqmm wire).

6. Connect Generator start signal, Generator Controller TB to the Generator TB start point (1 sqmm wire).

1. Connect Generator +ve wire (1 sqmm) to the Generator Controller J1 Connecter Pin No.1.


Site Wiring Details

S.

NO CABLE RATING CABLE COLOUR FROM TO

1 4 Core 16 Sq mm CU

armoured

Red cable EB Energy Meter R-ph IPMU Mains Input MCCB R-ph

Yellow Cable EB Energy Meter Y-ph IPMU Mains Input MCCB R-ph

Blue Cable EB Energy Meter B-ph IPMU Mains Input MCCB R-ph

Black Cable EB Energy Meter NEUTRAL IPMU Mains NEUTRAL Terminal

2 4 Core 16 Sq mm CU

armoured

Red cable Generator Output R-ph IPMU Generator Input MCCB R-ph

Yellow Cable Generator Output Y-ph IPMU Generator Input MCCB R-ph

Blue Cable Generator Output B-ph IPMU Generator Input MCCB R-ph

Black Cable Generator Output NEUTRAL

IPMU Generator Input NEUTRAL

Terminal

3 2 Core 50 Sqmm Copper Red Cable SMPS Output +ve Bus Bar Battery Bank +ve Terminal

Black Cable SMPS Output -ve Fuse Battery Bank -ve Terminal

6 1 Core 16 Sq mm Copper Green Cable DC Earth (TE) SMPS Earth Terminal

7 1 Core 6 Sq mm Copper Green Cable AC Earth (PE) IPMU Earth TB

8 3Core 4 Sqmm Copper

Red Cable IPMU Output MCB AC-1&AC-2 Input MCB

Black Cable IPMU Output MCB AC-1&AC-2 Input MCB

Green Cable IPMU Earth TB AC-1&AC-2 Earth Point

9 2 Core 2.5 Sqmm Copper Red Cable IPMU Output MCB Aviation Lamp Input

Black Cable IPMU Output MCB Aviation Lamp Input

10 3 Core 2.5 Sqmm Copper

Red Cable IPMU Output MCB Power Point MCB

Black Cable IPMU Output MCB Power Point MCB

Green Cable IPMU Earth TB Power Point Earth Point

11 3 Core 1.5 Sqmm Copper

Red Cable IPMU Output MCB Room Light MCB switch

Black Cable IPMU Output MCB Room Light MCB switch

Green Cable IPMU Earth TB Room Light MCB switch

12 2 Core 1 Sqmm Copper Red Cable IPMU Room Control TB No. 5 Door Sensor at the site

Black Cable IPMU Room Control TB No. 6 Door Sensor at the site

13 4 Core 1 Sqmm Copper

Red Cable IPMU Room Control TB No. 1

+ve of the Smoke Sensor at the site

Black Cable IPMU Room Control TB No. 2 -ve of the Smoke Sensor at the site

Green Cable

IPMU Room Control TB No. 3 Common of the Smoke Sensor at the

site

White Cable IPMU Room Control TB No. 4 N/O of the Smoke Sensor at the site

14 12 Pair .5 Sq mm IPMU Alarm card TB Krone Box

15 12 Core 1.5 Sqmm

IPMU Generator Control TB Generator TB Points

IPMU Generator Control TB

No. 3

Generator Controller J1 Connecter

Pin No.3


No. 4 Generator TB V Belt Point


No. 5

Generator Controller J1 Connecter

Pin No.4


No. 6 Generator TB LLOP Point



No. 7 Generator TB HWT Points


No. 8 Generator TB Half Fuel Point


No. 8 Generator TB Low Fuel Point

16 2 Core 6 Sqmm Red

IPMU Generator Control TB pin

1 Generator TB Battery +Ve

Black

IPMU Generator Control TB pin

2 Generator TB Battery –Ve

17 2 Core 1 Sqmm Red Cable IPMU BTS battery input MCB SMPS +ve bus bar

Black Cable IPMU BTS battery input MCB SMPS –ve distribution MAC

18 3 Core .5 Sqmm

Red Cable IPMU Modem 485 comm +ve

SMPS DC Energy meter 485 comm

+ve

Black Cable IPMU Modem 485 comm -ve

SMPS DC Energy meter 485 comm –

ve

Green IPMU Modem 485 comm GND

SMPS DC Energy meter 485 comm

GND

30KVA IPMU Menu Parameters - V 105.1

S.No. Parameter Default Value

1 MAINS HIGH CUT OFF 305 V

2 MAINS LOW CUT OFF 85 V

3 MAINS HIGH CUT IN 285 V

4 MAINS LOW CUT IN 115 V

5 GENERATOR HIGH CUT OFF 280 V

6 GENERATOR LOW CUT OFF 180 V

7 GENERATOR RPM HIGH 1650 RPM

8 GENERATOR RPM LOW 1350 RPM

9 GENERATOR REST TIME 300 Minutes

10 ROOM TEMP HIGH ALARM 38 Degree

11 High Temp. GENERATOR Crank 35 Degree

12 EB OVERLOAD 150 Amps.

13 GENERATOR OVERLOAD 45 Amp

14 BATTERY MODE OPRTN <ON>

15 BTS BATTERY LOW 47 V/ as per customer

16 GENERATOR AUTO RUN TIME 06 hrs.or required

17 CRANK ACTIVE TIME 3 seconds

18 CRANK RETRIES 2 no. of times

19 STOP HOLD TIME 30 seconds

20 STOP RETRIES 2 no. of times

21 GENERATOR WARM UP TIME 10 seconds


22 MAINS RESTORE TIME 30 seconds

23 GENERATOR COOL DOWN TIME 60 seconds

24 GENERATOR LOCK TIME 10 minutes

25 GENERATOR LONG LOCK TIME 10 minutes

26 AVIATION ON TIME 18::00 HH::MM

27 AVIATION OFF TIME 06::00 HH::MM

28 LLOP DELAY TIME 5 seconds

29 GENERATOR START INTERVAL 40 seconds

30 GENERATOR CT RATIO 125 Ampere

31 EB CT RATIO 125 Ampere

32 LCU HIGH CUT OFF 270 V

33 LCU LOW CUT OFF 180 V

34 LLOP ENABLE/DISABLE <DISABLE>

35 SITE NAME as per customer

36 Bat. Run Time 6 Hour

37 DATE Actual

38 MONTH Actual

39 YEAR Actual

40 HOUR Actual

41 MINUTE Actual

ipmu ic procedure

Engineering