CHAPTER FOUR

INSTALLATION & MAINTENANCE OF SMPS

Installation & Commissioning
The power system installation is simple please do the following step by step.
• Unpack all the boxes. Check for physical damages. Compare the contents with the packing list.
• Put the main rack at the desired place then, the auxiliary rack in the left side of the main rack.
And then grow the extension racks in the extreme left.
• Connect the joining bus bars to link the main and the Auxiliary racks.
• Put the 5600W rectifiers in their respective slots in each rack. Any rectifier modules can be put in
any slot.
• Connect each ac input cable (White cable with nine pin male connector) to the respective female
socket provided in the right side in each module.
• Connect each pair of DC output cable (Red & blue cable) in the respective terminal block
provided in the left side in each module. PLEASE ENSURE THAT THE RED CABLE IS
CONNECTED TO THE TERMINAL MARKED AS ‘+’ ( RED TERMINAL BLOCK) AND
BLUE CABLE TO THE TERMINAL AS ‘-‘ ( BLUE TERMINAL BLOCK).
• 02 nos. of eight pin flat cable connectors are provided for each rectifier module (except the last
module, where only one connector is provided). Connect these on the sockets provided on each
module so that control bus is connected in daisy chain. Finally check that the common system
bus is extended to the connector JP3 of the PSC card. Ensure that there is no break in the daisy
chaining of control bus.
• Connect three phase four wire input to each rack at TB1. Input points are marked as R, Y, B, N
just below the terminal block TB1. Also the terminal blocks are provided with red, yellow and
blue markers. PLEASE ENSURE THAT THE NEUTRAL IS CONNECTED TO THE
TERMINAL MARKED AS “N” (HAVING NO MARKER).
• Ensure that all the AC side MCBs (mounted on AC distribution panel) as well DC side MCBs,
(mounted on DC distribution panel) are in OFF condition.
• Switch on the AC input. Check the availability of AC voltage on the front panel of the power
plant for each phase. If the AC I / P is within the range (320-480 volt) switch on the MCCBs in
the sequence given in the Table-1 and do the NO load test for each module.

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 NO LOAD TEST
No Load test: First ensure that all AC side MCBs (mounted on AC distribution panel), as well as DC
side MCCBs are in OFF condition . Switch ON the AC input. Check the availability of AC voltage
on the front panel of the power plant for each phase. If the AC I/P is with in the range(320-480)
switch on the MCBs in the following sequence.

TABLE -1
MCB MCB MODULE DC VM/AM DC output Remarks
AC SIDE DC SIDE ENERGISED SEL POSN. In all the 6
Position of
DC VM/AM
SEL
CB1 CBM1 M1 Posn. 1 – Eqpt 54.0 ± 0.5 v If every thing is OK
Posn. 2 – BTY1 isolate the module
Posn. 3 – BTY2 M1 by switching off
Posn. 4 – BTY3 the breakers CB1 &
Posn. 5 – BTY4 CBM1.
Posn. 6
SYSTEM
CB2 CBM2 M2 -do- -do- If every thing is OK
isolate the module
M2 by switching off
the breakers CB2 &
CBM2.
CB3 CBM3 M3 -do- -do- If every thing is OK
isolate the module
M3 by switching off
the breakers CB3 &
CBM3.

After each module has been energized separately at no load, switch ON all the MCBs and check that
DC out put remains within 54.0±0.5V in all the five positions of DC VM SEL.

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 Load Test:- Load Test of the unit has to be done with suitably rated resistive loads as per Table-2.
LOAD TEST TABLE-2
MCB MCB Module DC DC output Resistive load in different Remarks
AC DC Energy VM/AM In all the 6 paths
SIDE SIDE - SEL Posin of VM
sed POSN. SEL
CB1 CBM1 M1 Posn. 1 Auto float Eqpt. Path-increase the If every thing is OK
voltage –
– Eqpt current slowly from 0 to isolate the module M1 by
54.0 ± 0.5 v
Posn. 2 105 A. The voltage droop switching off the
– BTY1 phenomena will start at the breakers CB1 & CBM1.
Posn. 3 factory set current
– BTY2 limit(somewhere between
Posn. 4 100 to 105 A)
– BTY3 BTY1- No load
Posn. 5 BTY2- No load
– BTY4 BTY3- No load
Posn. 6 BTY4- No load
SYSTEM
Auto float Eqpt. Path no load.
voltage – BTY1- No load
54.0 ± 0.5 v BTY2- No load
BTY4- No load

Auto charge BTY3 –increase the BTY3

voltage – path current slowly from 0
55.2 ± 0.5 v to 100 A. The unit will go to
Auto charge mode when
current exceeds factory set
limit ( 1% of total AH
capacity of both the
batteries) for ex. In case of
4x2500 AH battery banks
these limit shall be 100 A.
Check that Auto float
voltage and auto charge
voltage are within the
limits.
CB2 CBM2 M2 -do- -do- -do- If every thing is OK
isolate the module M2 by
switching off the circuit
breakers CB2 & CBM2.
CB3 CBM3 M3 -do- -do- -do- If every thing is OK isolate
the module M3 by
switching off the circuit
breakers CB3 & CBM3.

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After each module has been checked on full load of 100 Ampere, switch ON all MCBs, and load 300
Ampere in equipment path, 100 Amp. In each battery path, and see that the rack voltage remains at
55.2 ± 0.5 volt for 600 A system.

BATTERY PATH CURRENT LIMIT PROGRAMMING:

Pot R86 in the PSC card is used to set the current limit in the battery path. For the 2200Amp power
system there is a provision of 4x2500AH batteries and for these batteries, the factory set values of
the current limit is 1000A (i.e., 10% of the total AH capacity of the batteries). However if the user
wants to change this value then the POT R86 needs to be varied carefully to set the current limit at
the desired value. For example, suppose initially the installed capacity is 3x2500 AH and accordingly
the battery path current limit may be set at 750 A. For these when the battery path draws more than
750 A, vary the pot slowly in one direction and stop when the bus voltage droops and battery path
current becomes 750 A. In these case, overload lamp ( yellow LED ) shall be lighted on all the
modules. If the voltage does not droop even when the pot has reached it’s extreme end, then vary the
pot in other direction and stop as soon as the bus voltage droops and battery path current becomes
750 A. In these case, overload lamp ( yellow LED ) shall be lighted on all the modules.

SURGE ARRESTER ASSEMBLY

Four numbers of surge arrestors has been installed directly across A.C. input terminals in the main
rack of the system to protect the rectifier modules (contained in all the racks) in the system from high
energy content surges caused by lightning or sudden switching OFF, off heavy inductive loads. The
surge arrestors contains two parts- plug and socket. In case of surge arrestors going faulty, there shall
be an indication on the front of the plug. In such case the plug need to be replaced.

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 TROUBLE SHOOTING CHART

Sr.No. Nature of Probable causes Remedy

Fault
1. FR/FC fail -Any one or more rectifier modules Check each rectifier module
LED is lighted has failed. front panel to find out which
on the front Following may be reasons of rectifier has failed.
panel of the failure:
main rack (i) Input MCB or AC input Switch ON the input MCB or
connector open, connect AC input connector.

(ii) Output MCB or output Switch ON the Output MCB or

connector open, connect AC output connector.

(iii) Improper load sharing Check that the 8-pin flat cable is
between the modules, connected properly in each
module and there is no break in
daisy chaining of the above
cable.
(iv) Internal failure of the Isolate the module by switching
rectifier module. off its i/p & o/p MCBs &
replace faulty modules.
- If none of the rectifier module Check for the faulty flat cable
shows the alarms LED then the and replace it.
problem may be in one of the 8-
pin flat cable connected in
daisy chain between the
modules or in the cable
connected from PSC card to the
first module. Replace the faulty PSC card.
- The PSC card may be faulty.
2. ‘Battery -Any one or more of the Bty path Close the knife switch properly.
Isolated’ LED knife switches are open.
is lighted on -The PSC card may be faulty. Replace the faulty PSC card
the front panel
of Main rack.
3. ‘Load Voltage -DC output voltage of the system is Press the ‘Load Voltage High’
High’ LED is higher than 57V because of some Reset push button provided on
lighted on the fault in any one of the module. the front panel. All the modules
front panel of will be again ‘ON’ if the fault
main rack. was of a temporary nature
otherwise all the modules will
be again “OFF” simultaneously
lighting the ‘Load voltage High’
LED on the front panel.
- The PSC card may be faulty. Replace the faulty PSC card
4. ‘Load Voltage -This may happen when the system Urgent action to restore the AC
Low’ LED is is working on the batteries for a input supply is required as the
lighted on the long time and the output voltage of batteries need to be manually
front panel of the system has become lower than disconnected for the safety of

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 the main rack. 44V batteries.

-The PSC card may be faulty Replace the faulty PSC card
5. ‘ Mains out of -Either the AC input supply to the Take the corrective action for
range’ LED is main rack is not coming or the the mains supply or start the DG
lighted on the mains supply is too low or too high. set.
front panel of -The fuse FO mounted inside the Open the terminal block and
the main rack DIN channel mountable terminal check for the continuity in the
block may have become open. fuse. If faulty , replace it.
- The PSC card may be faulty Replace the faulty PSC card
6. ‘Mains on -If by any reason the voltage of the Check for the equipment path
battery modules become less then the load, it may be too high
discharge’ voltage of the batteries, this lamp resulting in the current limit of
LED is lighted may come. the modules. Isolate the faulty
on the front rack by opening the knife switch
panel of the in the DCDB.
main rack - The PSC card may be faulty Replace the faulty PSC card
7. ‘System -The power system is getting Check the path which is drawing
overload’ LED overloaded. more current. Take the
is lighted on corrective action.
the front panel
of the main
rack - The PSC card may be faulty Replace the faulty PSC card
8. ‘Temperature - 4 pin flat cable coming from the Connect the 4 pin flat cable
compensation sensor kept in battery room is not properly.
fail’ LED is connected properly to the TEMCO
lighted on the card.
front panel of -8 pin flat cable from the TEMCO Connect the 8 pin flat cable
the main rack card to the PSC card is not properly.
connected properly.
-The sensor may be short or open. Replace the faulty sensor
assembly.
-Tempo card may be faulty. Replace the faulty Temco card.
- The PSC card may be faulty Replace the faulty PSC card
9. Any particular -The Display card has become Replace the faulty Display card
LED not faulty.
glowing when
‘LT’ push
button is
pressed on the
front panel of
the main rack.

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 Dimensioning of the bus-bars/cables for load & battery path with respect to
the ultimate capacity of SMPS power plants

(As per the specifications of TEC, the following calculations may be followed)
The basis for calculation ;
1, The Ultimate Load : x
2. Redundancy : 10% of Ultimate load (0.1 *x).
3. Battery-back-up : 6 hours
4. Battery capacity : 6 hour back-up up to 80% DOD (near available capacity)
5. Safety factor : 25% of the load.
6. Power plant Ultimate capacity : C

Calculations :

Load ;x

Redundancy : O.l x

Battery capacity : 6x/0.8 = 7.5x

Battery Charging Current @ Cio = 7.5x /10 = 0.75x

Power plant Ultimate Capacity : C= (x + 0.1x + 0.75x) = 1.85x

Therefore x = C/1.85

Safety factor for bus-bar/cable : 1.25

The bus-bar/cable shall be rated = 1.25*x = 1.25* (C / 1.85) = 0.68*C

So the bus bar / cable chosen for load path shall be capable to handle the 70%of the ultimate
capacity of the power plant.

As there may be an eventuality when only one battery is connected to the load, the size of
bus-bar in each battery path shall also be the same.

The size of the bus-bar/cable for load & each battery path shall be higher than 70% of the
power plant ultimate capacity. However the common bus-bar/cable used for connecting the FR/FCs
to the input of the distribution unit shall be the rating for the ultimate system capacity.

MAINTENANCE SPARES FOR POWER PLANT

As the power plant plays an important role in any telecom system, it has to be maintained in
fault free condition when any unit goes fault, it is to be attended on topmost priority to restore the

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power system. Hence it is necessary to keep Fuses, PCBs etc as spare. These are called “Maintenance
spares of power plant and are to be supplied along with power plant by the manufacturer.
As per TEC specification No. TP 120-M-91/TP-130-F-93/G PPL-01/03 FEB 93, the list of
spares to be supplied by the manufacturer is given in Table I and II.
TABLE-I(For Conventional Power Plant)
List of spares to be supplied along with each unit of power plant (general)
I. Fuses
AC Input fuses 100%
DC output fuses 100%
Semiconductor device fuses 100%
Smoothing condenser fuses 100%
Auxiliary circuit fuses 100% (each type)
Alarm type fuses 100% (each type)
II. Fuse mounting assembly 1 No. Each type.
II1.Semiconductor devices
Diode 50%
Thyristor 50%
Transistors 50%
IV. Surge suppression elements:
Resistors 2 nos.
Capacitors 2 nos.
MOVs 2 nos
V. Smoothing condenser 2 nos
VI. Auxiliary transformer 1 no. Each type
VII Glass epoxy PCB assembly complete
with component with card extender. 1 no. Each type
VIII. Control circuit components
Diodes 2 nos each type
SCRs -do-
ICs -do-
Transistors -do-
Zener diodes -do-
UJTS -do-
Pulse transformer -do-
Lamp/LEDs/mains ind lamps -do-
TABLE-2
List of spares to be supplied along with each set.
Description Qty Rating
100A 200A 400A 600A
Fuses
AC Input fuses 3 TIA20 TIS36 VSB63 VSB100
DC Output fuses 1 VSB125 VSF200 VSK400 VST630
Semiconductor device 6 GSA75 GS450/1 GS450/40 GS450/50
fuses 50 0 0
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 Smoothing condenser 2 TIA25 TIA25 TIS63 TIS63
fuses
Auxiliary Circuit fuses 2 NS4 NS4 NS4 NS4
Alarm type fuses 7 3.0A 3.0A 3.0A 3.0A
Fuse mounting 1 20 A 20 A 20 A 20 A
Semiconductor device thyristor 3 71RIA4 155RK40 600PE40 600PE40
0
Surge Suppression elements
Resistors 2 10 Ω 1 Watt
Capacitors 2 0.22 mfd 250V
Smoothing condenser 2 10,000 mfd 100V
Auxiliary transformer 1 0.415V/0.22, 0.22V
Glass epoxy PCB assembly 1 3 phase angle control card (30-3-0712/R1)
complete with component with
card extender
1 Power supply +Amplifier card(30-3-0672/R2
1 SCR Trigger card(30-3-0672/R2)
1 Supervisory card (12-92-01)
1 Sequential switching card (12-92-05)
1 Current sharing card (12-92-04)
Control circuit components
Diode 2 IN 4007
SCR 2 SN 104 BO
ICs 2 741
2 4050
2 555
2 7812
2 7912
Transistors 2 CL 100
2 2N 3501
2 2N 2222
Zener Diodes 2 5.6V
2 13.0V
Pulse Transformer 2 4503
LEDs 2 5mm Red
Main Indicting LEDs 2 10mm Red
2 10mm Yellow
2 10mm Green

SAFETY NOTICE
Before applying power to the system , please ensure that the body of the cabinet is properly earthed
if the earthing is not proper , the surge protection set installed in the system /at the site may not work
& the consequential damage to the SMPS modules because of this shall not be governed by the
warranty clause .
Before taking the insulation test of the rack , isolate the SMPS modules & remove the surge arrestor
plug from it’s base.

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 WARNING
• Hazardous voltages of 415 V rms will be present when a AC input power is energized .
Qualified personnel must use extreme caution when operating & maintaining the system.
• Initial battery connection & exchange connection shall be done without energizing the
system. When the system is under operation adequate precaution has to be taken while
installing & removing SMPS modules since high voltages (400V AC) are available on the
front panel.
• Please ensure that there is no ceiling fan over the power system racks , as this disturbs the
natural convention cooling of the racks.

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