ATS- Automatic Transfer Switch

and Rectifier

ATS and Rectifier overview, component design

process, requirement and specifications.
 Course Objective
This course provides an in-depth knowledge and
skill to understanding ATS and Rectifier overview,
component design process, requirement and
specifications with expected quality assurance.

It makes for a better understanding of all the

troubleshooting process and understanding the
components that make up ATS and Rectifier helping
participant to be able to supervise, manage and
implement an alarm free site for smooth operation.
 Learning Objective
On completion of this course the participants will be able
to:

• Explain the scope and objectives of this course.

• Understand the various composition of the ATS/AMF
• Design an ATS circuitry
• Ensure optimal operation of the ATS/AMF
• Know the various forms of ATS /AMF alarms
• Carry out an alarm clearing on ATS/AMF
• Effect repairs of ATS panel
• Install ATS panel
• Investigate the on-site alarm status
• Better supervise the contractor in maintenance
• Ensure an optimally performing site thereby improving
network quality
 Schedule
Module 1: Understanding, designing and implementation of the ATS/AMF
• Overview of the ATS and AMF
• Basic functions of the ATS and AMF
• Review of various types of ATS
• Basic operation of the ATS
• Understanding the components and their functionality-relays, interlocks,
contactors
• Designing, understanding and reading the panel one-line wiring diagram
• Designing of an ATS using various AMFs, relays, contactors and interlocks
• Sensor understanding- Current sensors, frequency sensor etc
• Contactor, wire gauge and relay capacity dimensioning
• Dual Generator AMF design – Master/Slave implementation
• Remote start and stop procedure of the ATS- Manual option with design
 Schedule
Module 2: Installation, commissioning, maintenance, troubleshooting and
repair of ATS/AMF
• Installation process of the ATS/AMF-Mounting, requirement, positioning and
conditions
• Commissioning procedure and functionality test procedure of the ATS
• Alarm management of the ATS
• Various forms of ATS/AMF alarm
• Logging on to the AMF
• Maintenance of the ATS/AMF
• Understanding and usage of required tool for ATS repair
• Troubleshooting process
• Repairing faulty ATS panel
• Remote monitoring of the ATS/AMF-RS 232, RS 485 connections
• SNMP Protocol, Modbus and communication object implementation of the
ATS
 Schedule
Module 3: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
Review of workshop and test

I. On-site visit/Panel design evaluation

II. Questions and revision
 Day 1-
Module 1-Understanding, designing
and implementation of the ATS/AMF
 Module 1.1-
Overview of the ATS and
AMF
This would give an insight to the
understanding of the ATS
• Definition
• Outlay
 Definition- ATS

• An automatic transfer switch is an electrical device that

switches a load between two or more sources. It manages
the control without manual intervention and ensures back-
feeding .

• Automatic Transfer Switch (ATS) is often installed where a

backup generator is located, so that the generator may
provide temporary electrical power if the utility source
fails.

• ATS prevents main and generator power to be connected at

the same time
 Definition- AMF
• An auto mains failure is an electronic module
that automatically controls a standby
generator.

• It’s a programmable device with parameters

that allows it to detect mains failure and a
mains restore.
 Exercise A
Question- Differentiate between ATS and
AMF, or are they the same?

Answer: In a way we can say that ATS controller is similar to a

AMF controller

However AMF controller, once in AUTO mode of operation,

provides a global control of the engine and generator

ATS However it takes care to concentrate all logic on switching

in a safe way the LOAD to MAINS or GENERATOR. The control
panel is more simple, because it does not include the
monitoring of all parameters of the engine.
 Generator
AMF module Outlay voltage
interface

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

1. Load transfer between generator and mains/generator

2. Control start and stop of Generator
3. Isolates Back-feed
4. Uses relays and switched to operate without manual intervention
5. Prevents Overload
6. Prevents mains and gen power jamming(without synchronization)

AMF
1. Monitors individual parameters of the generator – temperature, oil
level etc
 Automatic load transfer

• Uses relays and contactor to load between Generator and Mains

• Uses interlock to avoid dual feed without synchronization

• Uses monitored parameter to determine which supply would be used

• Mains is usually set to priority zero which means it’s the first line of
use
 Control function

• Controls the start and stop of the generator

• Uses monitored parameters to determine the required supply

part

• Protects the load form damage via overload

• Protects the generator for damage via parameter mismatch

 Back-feed isolation

• Uses Interlock to avoid the generator from feeding into the grid

• Prevents damage on the generator by connecting to infinite bus

bar

• Avoids unsynchronized power source feed

 Generator Synchronization
Synchronization is the matching of two different sources of power
to achieve higher capacity.
it is crucial to synchronize both sides of the circuit breaker before
closing. If "synchronizing" process is not done correctly, a power
system disturbance will result and equipment (including
generators) can be damaged
Five conditions needs to be met to synchronize two sources.
• line voltage
• frequency
• phase sequence
• phase angle
• waveform
A synchroscope is a simple piece of equipment that is used to
monitor the three important synchronizing variables
 Module 1.3-
Various types of ATS layout
This would give an insight to the ATS
interconnection layout
• Layout type
 ATS Layout

Grid and generator Two generators

ATS
 Layout of the ATS/AMF

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

ATS control module interfaces with the design to

operate the ATS, extrapolate alarms , and log
operational activates of the ATS
It contains
• Binary input/output-control and relay switching
• Analogue input/output-temp, oil pressure
• Power source
• Grounding point
• Remote control connection point-RS232/485
• Internal microprocessor
 Types of ATS control module

Datakom
Bernini
Gennext

Intellite Deepsee

Various types of control modules

DSE-interconnect
Bin

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.

• Simplicity-Most reliable option available, again due to

simplicity, and the fact that there is no external utility
protection or generator equipment needed.

• Interlock-Most designs incorporate a mechanical

interlock that positively prevents inadvertent utility
paralleling.
 Disadvantage of open transition
• Arc should decay-During retransfer from the
emergency generator to the utility following
restoration of normal power a fixed open time is
needed to allow the arc developed on opening the
contacts to decay. Typically this time requirement is
approximately five electrical cycles.

• Inductive load delay:In applications with a high

percentage of inductive loads need added
functionality to control the speed of operation of
the mechanical switch and keep the contacts open
for one-half to three seconds to allow time for the
residual voltage in inductive load devices to decay.
 Sub-cycle

Sub-cycle transfer devices: Open and then re-

close on the new source in less than one-quarter
of an electrical cycle. The resultant interruption
is so short that most load devices aren’t affected
by it.

They are used primarily in UPS systems and only

occasionally with a generator set. These devices
are very expensive in relation to mechanical
switches and are typically protected with fuses.
Duty cycle is the proportion of time during
which a component, device, or system is
operated. The duty cycle can be expressed as a
ratio or as a percentage
 Closed transition-make-before-break
operation
• A closed transition transfer switch (CTTS)
is also called a make-before-break
transfer switch.
• Its outage is inconsequential,
particularly if it is less than 1/6 of a
second
Advantages of closed transition

• “non-load-break” system, due to

simplicity of controls and lack of generator
set governor synchronizing controls.

• They prevent momentary breaks in

power during generator set failure and
when closing back to a restored utility
source.
 Soft loading

A soft-loading transfer switch (SLTS) makes

use of a CTTS, and is commonly used to
synchronize and operate onsite generation
in parallel with utility power, and to
transfer loads between the two sources
while minimizing voltage or frequency
transients.(incorporates synchronization)
 Disadvantage of Closed transition
• Load transient-The overlap time is very brief, so voltage and frequency
transients will be imposed on the system which may be just as disruptive
as a short total interruption, especially upon switching 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

• Damage due to poor synchronization-Generator sets used with this

equipment may be subjected to abnormal stresses due to poor
synchronizing accuracy. The premature damage to the excitation system
due to imprecise paralleling with the utility does not necessarily occur at
the instant of paralleling, and may cause failure of the generator set
under emergency conditions.
 Static transfer switch
• A static transfer switch uses power semiconductors
such as Silicon-controlled rectifiers (SCRs) to
transfer a load between two sources.

• There are no mechanical moving parts, the transfer

can be completed rapidly, perhaps within a quarter-
cycle of the power frequency.

• Static transfer switches can be used where a

reliable and independent second source of power
is available and it is necessary to protect the load
from even a few power frequency cycles
interruption time, or from any surges or sags in the
prime power source
 Start and stop sequence
Normal Transfer of Load Sequence with power failure:

1. Stop/Start Relay coil is de-energized

2. The SSR NC contacts close to apply a ground signal to

a. the gas solenoid through the closed contacts of the over-
cranking relay
b. the starting system is also controlled by the ground signal
from the SSR contact and the OCR. This ground passes
through the normally closed contacts of the stop cranking
relay which will open to interrupt the cranking when the
engine starts.
c. the ground is also applied to the timing element (heater
coil) of the over-cranking relay to begin the cranking interval
timing.

3. the gas solenoid valve opens to allow fuel to the engine

4. the engine cranks and starts

 Auto Start circuit
Load
Gen contactor Mains contactor

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

6 A set of N.O. contacts on the SCR and a transfer delay relay

(TDR) allow the engine to reach full speed for 20-45 seconds
before the generator voltage is applied to actuate the transfer
switch contactor.

7. The TDR is a thermal timing device that begins timing when

the generator voltage(230V) is applied to the TDR heater coil
through the NC contacts of an auxillary switch mounted on the
transfer contactor. After timing out, the TDR contacts close to
apply power to the transfer switch contactor coil.
 Start and stop sequence (contd)
8. when energized, the transfer switch
contactor opens the line contacts and closes
the generator contacts to apply generator
power to the load.

9 the NO contacts of the Aux. switch close to

lock up the contactor coil

10 the NC contacts of the Aux. switch open to

de-energize the control ground signal on the
TDR heater element.
 Module 1.5-
Understanding the components and
their functionality
This would give a detail digest of the ATS
components
• Components
• Functionality
 Identify the parts of this ATS
D C
B A

E
 Load
Identify the Gen
parts of this ATS
Mains Contactor
connector Input input with Relay
interlock
 Some terminologies

• NC- Normally closed Relays

• NO- Normally opened Relays
• Source
• Load
• Generator
• Utility
• Contactor
• Interlock
Exercise
 Exercise
1. Trickle Charger
2. Fuses/surge protector
3. Current Transformer
4. Mains Contactor
5. Generator Contactor
6. Generator Input breaker
7. Mains and Load connection
8. Signal connection
9. Control panel
10.Bypass switch/emergency switch
 Components of ATS
• CT- Current Transformer
• Relays
• CB-Circuit Breaker
• Contactor
• Control Panel
• Bypass switch
• Neutral bar
• Grounding bar
• Mechanical interlock
• Electrical interlock
• Isolation transformer
• Microprocessor/controller
• Metering equipment
• Remote communication
• Battery trickle charger
• Frequency/voltage sensor
• Timer
Current Transformer in panel
CT in circuit
 CT
A current transformer (CT) is used for measurement of alternating
electric currents. Current transformers, together with voltage
transformers (VT) (potential transformers (PT)), are known as
instrument transformers.

When current in a circuit is too high to apply directly to measuring

instruments, a current transformer produces a reduced current
accurately proportional to the current in the circuit, which can be
conveniently connected to measuring and recording instruments.

A current transformer isolates the measuring instruments from

what may be very high voltage in the monitored circuit. Current
transformers are commonly used in metering and protective relays
Relay in panel
Relay in circuit
 Relays
A relay is an electrically operated switch.
Relays use an electromagnet to mechanically operate a
switch, but other operating principles are also used, such
as solid-state relays.
Relays are used to control a circuit by a low-power signal
(with complete electrical isolation between control and
controlled circuits) and when several circuits must be
controlled by one signal
It can be AC or DC operated
Circuit breaker in panel
Circuit breaker in line diagram
 CB
A circuit breaker is an automatically operated electrical switch
designed to protect an electrical circuit from damage caused by
overload or short circuit. Its basic function is to detect a fault condition
and interrupt current flow.
Unlike a fuse, which operates once and then must be replaced, a
circuit breaker can be reset (either manually or automatically) to
resume normal operation.
Circuit breakers are made in varying sizes, from small devices that
protect an individual household appliance up to large switchgear
designed to protect high voltage circuits
Tension
spring
Latch
mechanism
Basic
functi
Magnetic
on:
Protec
tion in
trip
event
of
electri
Thermal
cal
param
eters
overload
mism
atch
 Choice of Circuit Breaker
• Installation type : Electrical characteristics of the installation for which
the CB is intended
• Ambient temperature: Its eventual environment, surrounding ambient
temperature,
• Short-circuit current breaking and making requirements –Icu and Isc
• Operational specifications: discriminative tripping, requirements (or not)
for remote control and indication and related auxiliary contacts, auxiliary
tripping coils, connection
• Installation regulations; in particular: protection of persons
• Load characteristics: such as motors, fluorescent lighting, LED ligthing,
LV/LV transformers
Forms and terms
• Uncompensated magnetic trip-Circuit-breakers with uncompensated thermal tripping units
have a trip current level that depends on the surrounding temperature
• Compensated magnetic trip-These tripping units include a bi-metal compensating strip
which allows the overload trip-current setting (Ir or Irth) to be adjusted, within a specified
range, irrespective of the ambient temperature
• Icu is really the maximum perspective fault which a circuit breaker can clear (with the fault
current being expressed as rms for ac)
• Isc is the maximum perspective fault current which the circuit breaker can clear and still
remain serviceable
instantaneous, or short-time-
delay, tripping threshold
The curved portion at
the top represents the
time it takes for the CB
to trip on overload. An
overload condition will
cause heat buildup
around the current path,
within the CB as well as
along the power
conductors. This heat,
which is generated by the
current flow, is actually
what causes the CB to
trip in this region not
simply the magnitude of
the current flow.
Contactor in panel
Contactor in line diagram
 Contactor
Contactor transfer switch is a power transfer
switch which is mechanically/electrically operated

It could be a two-position or a three-position

mechanism.

Contactors have two cross shafts, one for Source 1

(S1) contacts and one for Source 2 (S2) contacts.

The arc chute is used to stretch the arcing that is

created when contacts open, until the voltage can
no longer be sustained to keep it going.

The neutral pole is operated on a common shaft

with the power contacts, thereby ensuring
simultaneous opening and closing of the switched
neutral

Basic function: Automatically circuit

breaker operated via signal to pass power
to load
Types-Contactor Based Automatic Transfer Switches
It is momentarily energized solenoid operating
mechanisms offer a fast and reliable method of
transfer. The operating mechanism ie electrically and
mechanically interlocked in open transition applications
to prevent inadvertent paralleling of source 1 and
source 2.

It has field-selectable multi-tap transformer panel

permits operation on a wide range of system voltages.

It has keyed quick-disconnect plugs are provided for

easy and complete isolation of the control circuitry.
Types-Magnum Breaker Based Automatic Transfer Switches
Magnum Transfer Switches have a thirty cycle short
time rating

It uses optional electronic trips allows performance

curve shaping to facilitate proper system coordination
and application.

It has multi-Tap Voltage Selector provides for

application on a variety of system voltages.

Its has keyed quick-disconnect plugs are provided for

easy and complete isolation of the control circuitry.
Types-Breaker Based Automatic Transfer Switches
It can withstand ratings on low amperage switches
without derating.

Field-selectable multi-tap transformer panel permits

operation on a wide range of system voltages.

It uses unidirectional gear motor mechanism which

allows for fast, powerful, safe power switching.

It has completely enclosed contacts ensuring the

integrity of the contact assemblies.
 Solenoid
A solenoid is an electrical transducer device that converts
electrical energy into a linear mechanical force

It is usually a relay that internally uses an electromechanical coil

to operate an electrical switch; for example, an generator starter
solenoid, or a linear solenoid, which is an electromechanical
solenoid.
Placement: Its in relays ,contactors
generator fuel pump and generator
starting coil. It closes and opens
based on feed electrical signal
Basic function: Automatically operated
breakers and starting functions of generator
 Control panel housing
The housing that holds all the component for the ATS.
It contains din-rail, cable trucking, clips, contactors,
relays, breakers, timer etc etc.

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

Second Digit (moisture protection)

1. No protection.
2. Protection against condensation
3. Protection against water droplets deflected up to 15° from vertical
4. Protected against spray up to 60° from vertical.
5. Protected against water spray from all directions.
6. Protection against low pressure water jets (all directions)
7. Protection against string water jets and waves.
8. Protected against temporary immersion.
9. Protected against prolonged effects of immersion under pressure.
 Frequency/voltage sensor
Its has the following functions:
• Monitoring and Protection
• Three-Phase Rotation Protection
• All-Phase
Undervoltage/Underfrequency Note:
Protection Required for
• All-Phase optimal
Overvoltage/Overfrequency operation of
Protection the system.
• Three-Phase Voltage Unbalance/ Function
Phase Loss usually resides
• Generator Utility Sensing in the control
panel but can
be manual
 Bypass switch
• Its a hardware device that provides a fail-safe
access port for failure of ATS
• The bypass switch removes point of failure by
automatically shunting power around the ATS
whenever it is faulty.
• This connection is fully passive
AMF/ATS
panel
Note:
Required in event
of component
failure
Also used during
panel maintenance
 Bypass Isolation Transfer Switches
• Contactor Bypass Isolation Transfer Switches
• Magnum Bypass Isolation Transfer Switches
They are design with separation between control and
power components. The ATS and Bypass isolation
contactors are mounted in separate compartments with
protective barriers between them
 Neutral bar
Transfer switches applied
in a single-phase, three-
wire system or a three-
phase, four-wire system
include a 100% rated solid
neutral connection for
current flow.

Function:
It’s the return path for current
and neutral leakage /failure
could cause shock if circuit is
broken with poor earthing
above 5 ohms to ground
Note:
In event of common
neutral connection some
panels have a common
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.

An isolation transformer is built with special insulation between

primary and secondary, and is specified to withstand a high
voltage between windings

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.

The one-line diagram has its largest application in power

flow studies.

Electrical elements such as circuit breakers, transformers,

capacitors, bus bars, and conductors are shown by
standardized schematic symbols.

Instead of representing each of three phases with a separate

line or terminal, only one conductor is represented.

It is a form of block diagram graphically depicting the paths

for power flow between entities of the system
Electrical symbol
Electrical symbol contd
 One line diagram of an AMF

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

- 32x(415/1.73)x0.9=6908VA = Approx 7.5kVA per

phase
- 63x(415/1.73)x0.9=14961VA = Approx 16kVA
- 100x(415/1.73)x0.9=21589VA Approx 23kVA
Allowing +/- 10%
 Wire dimensioning
• R=r l/A

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

A. Aluminum resistivity@ 2.65x10-8

B. Copper resistivity@1.68x10-8
 Solution
R-pL/A

R=V/I
P=VI pf

R=8.8
L-60m= 60000mm
p- 2.65x10-8 ohms mtr= 2.65x10-5 ohms mm

A= 16mm sq i.e approx. 16mmsq is adequate

Cu= 11mm sq i.e apprx 10mmsq is adequate

 Relay switch selection
Always select relay that is switched by the power
of the signal to be switch i.e to close a contactor
with 230V use a 230V AC relay
To close a battery start with 12 volts use a 12V
relay

Ensure you use the right contact when switching

i.e NC or NO

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.

Procedure: Measure the voltage generated by the

current sensor for those two loads individually

Datasheet: then substitute your data points in for

V1, P1, V2, and P2, in the current sensor table.

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.

Application: 120V, 240V and 480

The voltage sensor provides a

fully isolated analog output
proportional to rated nominal
voltage in both sinusoidal and
non-sinusoidal (variable
frequency) situations.
 Voltage Sensor Calibration
To correct measuring error of each analog input
(voltage) calibrating constants within 10 % of
measure range should be set.

Two calibrating constants are set in physical units –

Volts

Calibration is made by adding the value of setpoint

directly to the calculated value at analog input.

Default sensor curves

A default voltage curve is established and all
measured current that fall within this limit are
calculated on the sensor curve as provided for by
the manual
 Frequency sensor
The frequency sensor monitors line frequency.

In fixed or adjustable trip point units, the circuit continuously senses the input
or line frequency.

When the frequency reaches a specific set trip point the

circuit pulls in on increasing frequency or drops out on decreasing frequency,
switching the output relay contacts send in an alarm and opening the breaker
circuit.

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.

One controller is Master and second is Slave.

System needs one binary input and one binary output in each controller.
System works only in AUTO mode

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)

input voltage sensing circuit via fuses (5).

The circuit breaker ON/OFF coil [6].

Key switch (10).

battery (11),

resistive sensors Analog/Digital inputs for

miscellaneous functions (13)
 Module 1 Review

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.

Disconnects: The Mains line connecting to the

panel must be protected by a circuit breaker
certified for this use in accordance with the local
electrical code. The size of the circuit protection is
based on the maximum input AC current

Note:
Installation must be carried
out with IEEE standards
 Tools

• Slot head screwdriver

• Drilling machine
• Multimeter
• Power analyzer

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,

(2)On a firm ground

(3) Away from rain if its not IP55/65 enclosure

(4) Most suitable location with minimal distance to

load and source
Note:
Installation must conform to the
panel installation instructions
 Wiring
All electrical wiring must be performed by a
qualified electrician or trained personnel.

Follow the wiring diagram as provided in the panel

one line diagram

Ensure proper grounding

Surge protection device must be present

Note:
All panel come with its wiring diagram,
this must be ensured
 Installation- control module
1.Connect both supplies and the outgoing load cables ensuring
correct phase sequence throughout.
2. Module requires a constant supply from the battery in the
generator start panel. The negative in the start circuit should
be wired to ‘Gen. Start signal’ terminal in the ATS panel.
3. When in Auto mode the controller will automatically start up and
switch over to the linked generator.
4. Configure the controller module setting as stated in the
installation manual
Note:
There are different module
config but all are operated on
the same principle
 Reconfirm with the schematics
Verify that all installation are according to the ATS
panel schematics

Use a multimeter to read continuity at various

points

With the breaker open ensure that all breaker

don’t have continuity hence proper operation
Note:
It is important that all connections
are properly torqued to prevent
arching and burning
Single phase controller
Installation

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

Step 2: Verify all termination conform to the

required torque level

Step 3: Ensure there are no unconnected wires

Step 4: Ensure proper grounding is carried out

 Commissioning- No power
reading
Step 1: With the breakers in off position take all the
voltage readings
Mains Voltage L-L, L-N
Generator Voltage L-L ,L-N
Generator battery Voltage

Step 2: With the one breakers(Mains/Gen in on

position take all the voltage readings
Mains/Gen Voltage L-L, L-N
Load Voltage L-L ,L-N
 Test procedure
With the multi-meter test the operation and
reading from the panel

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

Types of alarm and severity

• Alarm severity
• Cautions
 Alarms definition
Alarm management is the application of human
factors along with instrumentation engineering and
systems thinking to manage the design of an alarm
system to increase its usability.

However, there can also be other problems with an

alarm system such as poorly designed alarms,
improperly set alarm points, ineffective
annunciation, unclear alarm messages
Note:
Alarms prevent system
malfunctioning and failure by
sending faults when operating
outside the set parameterd
 Alarms management
Step 1: Understand the alarm generation
Step 2: Alarm performance benchmarking
Step 3: Continuously monitor alarm
Step 4: Have the defined alarm documentation
Step 5: Alarm system audit and enforcement
Step 6: Real-time alarm management
Step 7: Control and maintain alarm system
performance

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

A Observation alarm indicates a condition that

lead to decreases in performance or but not
performance affecting.
i.e Generator low battery

Note:
These can affect the system
later but not immediately
 Module 2.4-
Various forms of ATS/AMF alarm

Common alarms and resolutions

• solution steps
• Checks and enforcement
 ATS/AMF Alarm
Issue:
Unit does not transfer to generator power correctly when the
generator is turned on.

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:

Check the voltage level on the incoming generator lines.

If it is outside of 205-240V, the ATS will protect your equipment by not letting
the contactor pull in.

Refer to the generator documentation to adjust the incoming voltage to within

acceptable limits. (Via the governor)
 ATS/AMF Alarm
Issue:
High/Low Frequency

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.

Also confirm that the generator circuit breaker is not tripped.

After these steps, measure the voltage on the incoming generator

connection to verify that it is within limits.
 ATS/AMF Alarm
Issue:
Surge is red

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 controller connection wirings;

Check DC fuse.
 ATS/AMF Alarm
Issue:
Generator shutdown

Solution:
Check the water/cylinder temperature is too high or not;

Check the genset AC voltage;

Check DC fuse.
.
 ATS/AMF Alarm
Issue:
1. Low oil pressure alarm after crank disconnect
2. High water temperature alarm after crank disconnect

Solution:

• Check the oil pressure sensor and its connections

• Check the temperature sensor and its connections

.
 ATS/AMF Alarm
Issue
emergency stop

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;

Check setting of COM port is correct or not;

Check RS485’s connections of A and B is reverse connect or not;

Check RS485 transfer model whether damage or not; Check

communication port of PC whether damage.
 Module 2.5-
Logging on to the AMF

Procedure for accessing the AMF module

• Fundamentals of logging on
• Reading of required data
 Logging on to AMF module
You would require a PC with Windows 95 or newer platform)

You can perform the following functions:

• read the quantities
• adjust all set points
• control the engine
• configure the controller
• select software configuration
• modify alarm inputs and outputs
• modify password, commands protections
• direct, modem or Internet communication
Note:
Most modules can be accessed
via a web log on page, however
some require you have a SW
installed
 Requirement
• An external communication module is necessary to
enable direct cable connection to a PC.
• The module is plugged into the slot located on the
controller.
• A RS232, USB or RS485 interface can be used for
direct cable connection to a PC.
• The setpoint (according to the interface used) must
be set to DIRECT position for communication

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

Review the process of ensuring optimal

performance of AMF/ATS via proper
maintenance
• Maintenance steps
 Maintenance steps
1.De-energize: De-energize the switchgear (ATS with isolation
bypass feature do not need to be de-energized).

2.Visual inspection: Remove the arc chutes and pole covers.

3. Test and recalibrate: Test and recalibrate all trip-sensing and

time-delay functions in the switchgear.

4. Remove Dust: Vacuum the accumulated dust from the

switchgear and accessory panels.

5. Moisture elimination: Inspect for moisture or signs of

previous wetness or dripping.

6. Clean Thoroughly: Clean grime with an approved solvent.

 Maintenance steps contd
7. Crack Inspection: Inspect all insulating parts for cracks or discoloration due
to excessive heat.

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.

11. Operation inspection: Manually operate the main transfer movement to

check proper contact alignment, deflection, gap, and wiping action.

12. Torque verification: Check all cable and control wire connections are
tighten if necessary.

13. Re-energize:Re-energize the switchgear and conduct a test by simulating a

normal source failure.
 Module 2.7-
Understanding and usage of required
tool for ATS repair
Required tools used for repairing the ATS
• Tools details
• Usage area
 Overview
When working on clearing electrical faults you
would require the following items(minimum);
• Multimeter (ammeter and voltmeter)
• Tester
• Power analyzer
• Screw driver- torque
• Testing lamp
Note:
It is advisable to have a full
tools box with spanners,
measurement tools etc
 Multi-meter
• An ammeter is a measuring instrument
used to measure the electric current in a
circuit
• A voltmeter is an instrument used for
measuring electrical potential difference
between two points in an electric circuit

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

The PA series of power analyzer / wattmeter

instruments provide precise measurements of
power (watts), power factor, harmonics and
efficiency

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.

• An insufficiently tightened screw connection

may loosen in operation, and excessive
tightening can damage parts
Note:
Loose contact could cause
arcing and burning of device
 Testing lamp
Test light, test lamp, voltage tester, or mains
tester is a simple piece of electronic test
equipment used to determine the presence or
absence of an electric voltage in a piece of
equipment under test.

Note:
Testing lamp is used along with
multimeter to ensure correct
current flow and path failure
 Module 2.8-
Troubleshooting process

An insight into how to resolve issues

experienced on panel malfunctioning
• Identified procedure
• Solution flowchart
 Process-Initial
To identify the issue, you must:
1. Gather information.
2. Verify the issue.
3. Try quick fixes.
4. Use appropriate diagnostics(some scenarios in
AMF alarms resolution).
5. Perform a split-half search( Eliminate faulty area).
6. Use the test equipment along with one-line
diagram to identify failed paths
Note:
The installation one-line diagram
and flow path enables quick
identification of failed part
 Process-After
After you have identified the issue(via one-line diagram
and path flow), you must:
1. Secure a replacement for the faulty part with same
specifications
2. Test functionality of the new part
3. If repaired ensure that equipment is in good
condition.
4. Verify the repair by testing the product thoroughly.
5. Log the replaced part for monitoring

Note:
All parts to be replaced must
be same specification as faulty
part
Flowchart
 Module 2.9-
Repairing faulty ATS panel

This gives a bit of details on some common

faults with ATS and suggested repair
procedure
• Contactor not closing
• Generator not starting
 Faulty Contactor
Fault: Generator/load/mains contactor fail
to close
Suggested Solution:
1. Switch the panel to bypass if site is critical if not
take it to auto
2. With the aid of the one line diagram trace the
switching relay of the generator contactor
3. Isolate the switching contactor and toggle the
logic i. if NC change it to NO
4. If it works replace the relay if fault persist feed
the contactor directly with required power.
5. If it closes trace the circuit and replace the relay
6. if not replace the contactor
 Generator breaker tripping
Fault: Generator breaker tripping

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.

Either an analog, GSM or ISDN modem must be connected to the RS232

interface

The RS232 interface uses serial interface port of the controller.

The modem must be equipped with a sim card and have access to the
network

A Demodulator is required at the other end

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)

• GSM modems need to be set up prior to using them

with the controller.

• Use the gsm program to perform initial setup of the

modem.

• The setup must be done while a SIM card is inserted.

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).

An appropriate Ethernet communication module must

be used. (not required for controller with static IP
address

A plug-in communication module may be required( IB-

Lite or IL-NT-GPRS)

The setpoint Mode must be set to the DIRECT position. .

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.

• It is used for collecting information from, and

configuring, network devices on an Internet
Protocol (IP) network.

• Some controllers provides SNMP agent

software that works with third-party SNMP
management software to monitor the status of
managed devices and applications.
 SNMP
Management
Protocol
SNMP Management Remote
app
SNMP Service
SNMP Trap Management
service AP1 Sub
Subagent 2
agent 1
SNMP AP1

SNMP Utility API

Application

interface
Network

UDP
Transport

IP
Internet
 SNMP support
Most controller supports SNMP function

Three types of objects are supported:

Read only
Read/Write
Write only

Read only cannot be modifies and only read off as configure

Read/write are modifiable

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

• It uses programmable logic controllers (PLCs).

• It is a method used for transmitting information

over serial lines between electronic devices.

• The device requesting the information is called the

Modbus Master and the devices supplying
information are Modbus Slaves.

• In a standard Modbus network, there is one Master

and up to 247 Slaves, each with a unique Slave
Address from 1 to 247.
 MODBUS
• Modbus is transmitted over serial lines
between devices.

• The simplest setup would be a single

serial cable connecting the serial ports
on two devices, a Master and a slave
•
• The data is sent as series of ones and
zeroes called bits.

• Each bit is sent as a voltage. Zeroes are

sent as positive voltages and a ones as
negative. The bits are sent very quickly.
A typical transmission speed is 9600 Note:
baud (bits per second). A transmission
interface is
required
 MODBUS
• Modbus is an open protocol

• It is a standard communications protocol.

• Modbus is typically used to transmit signals from

instrumentation and control devices back to a main
controller or data gathering system.

• Modbus is often used to connect a supervisory

unit(controller) with a remote terminal unit (RTU) in
supervisory control and data acquisition (SCADA)
systems. Note:
Modus is an industry acceptable standard data
communication

• Versions of the Modbus protocol exist for serial lines

(Modbus RTU and Modbus ASCII) and for Ethernet
(Modbus TCP).
 Review

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

Gives a general understanding of the

rectifier system
 What is a rectifier
A rectifier is an electrical device composed
of one or more diodes that converts
alternating current (AC) to direct current
(DC).
A diode is like a one-way valve that allows
an electrical current to flow in only one
direction. This process is called
rectification.

.
 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

Single-Phase AC: Two diodes can form a full-wave rectifier if the

transformer is center-tapped. Four diodes arranged in a bridge
are needed if there is no center-tap.

Three-Phase AC: Generally uses three pairs of diodes

.
 Rectifier efficiency
Rectifier efficiency (η) is defined as the ratio of DC
output power to the input power from the AC
supply.

Even with ideal rectifiers with no losses, the

efficiency is less than 100% because some of the
output power is AC power rather than DC which
manifests as ripple superimposed on the DC
waveform.

Efficiency is reduced by losses in transformer

windings and power dissipation in the rectifier
element itself
.
 Modular rectifier
In design so as to minimize the following:
• Total system collapse
• Ease of maintenance
• Upgrade

The modular rectifier was designed

.
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

It’s a sum of individual modules n where

the N+1 Redundancy is excluded. i.e in a
5kW +1 rating the rectifier capacity is
10kW

Its is also rated via it Power source i.e

single phase or 3phase supply

.
 Module 3.2-
System description

Details of the system architecture and its

composition
Introduction of Rectifier (Emerson)

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.

When thebattery voltage rises by approximately 8 V (adjustable)

above the release level, the load is reconnected to the batteries and
the alarm is cleared.

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

The MCA provides a single point of

adjustment for such features as float
voltage,
test/equalize voltage, high voltage shut-
down and current limit for all
rectifiers in the entire power system
Netsure -General Specification
System
rating
Netsure -Rectifier Specification
Operating
conditions

DC output
 Module 3.3-
Battery

Understanding of the battery technology

and its operation essentials
 Battery terms
• Actual capacity-The real capacity of a battery for a specific set of conditions.
It may be lower or higher than the rated capacity .
• Battery-The functional unit for the electro-mechanical storage of energy
• Block/Monoblock-The mechanical unit for the storage of energy in
electrochemical form.
• Cell-The primitive building unit of a battery comprising of a set of positive
plates and negative plates
• Float charge Voltage-The voltage suitable for float charge.
• String-A set of cells connected in series which form a battery for example
48V.
• Norminal Capacity-The capacity of a battery that the manufacturer has
assigned to it. For stationary batteries the nominal capacity refers to the 10
hour capacity at 20 C
• Depth of Discharge-The degree of discharge of a battery
• Open circuit Voltage-The voltage the battery will have when no current is
taken from it
• Cycle-A discharge followed by a recharge
 Battery Build Up

A battery consists of individual cells or battery

blocks interconnected in series. The battery’s
voltage is the sum of the battery cells’ or
battery blocks’ voltages
 Temperature Effect on batteries

An increase of the battery acid’s temperature will fasten the chemical

reaction in the battery cells and therefore the lifetime of the battery will
be reduced. If instead the temperature decreases the chemical
reaction will be slower and the wanted capacity might not be reached
 Temperature and charging

If the battery temperature is higher than the temperature

specified by the battery manufacturer the chemical reaction of
the battery cell will be faster (and the lifetime of the battery
shorter), unless the charging voltage is decreased
 Density and Performance

Cable resistance
-Since all\

The chemical reaction in the battery cell is determined

by the density of the acid. If the density is high the
chemical reaction is fast and if it is low the reaction is
slow
Float Voltage and performance

Using low or high float voltage would lead to sulfation or

corrosion respectively
 Battery Capacity

Capacity means the amount of energy that a battery or an accumulator

can give off without having to be recharged.
The capacity is stated in ampere-hours (Ah) and it is the product of the
discharge current in amperes and discharge time in hours.
Discharge Current x Discharge Time = Capacity
For accumulators the discharge current decides the ampere-hours that
can be taken out from it. C10 = 350 Ah means that the discharge current
of the accumulator is approximately 35 A if the discharge time is 10 hours.
5 hours (350 Ah / 70 A)
 Valve Regulated batteries

The VR-batteries have one-way venting

valves that let out gas (hydrogen and
oxygen) during normal operation. There are • There
two ways of keeping the acid in place in a
valve-regulated battery, by gelling the
electrolyte or by absorbing it into non-woven
glass fiber material
 Freely Vented

In freely vented batteries the electrolyte is in liquid form. These

batteries are “open” and therefore the electrolyte density increases
when the distillated water of the electrolyte dissipates
Issues with batteries
Battery Maintenance

• There
 Module 3.4-
Rectifiers common Models

Some common models of rectifier

deployed on various sites
 Introduction of Rectifier (Grintek)

Grintek FP412 System Grintek GT305plus System

 Introduction of Rectifier
(Battery Technologies)

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

Understanding of the fundamentals of

dimensioning capacity requirement of
rectifier
 Step 1- Survey required
Gather all information that would help to dimension your
system:
• Total load capacity to support KW
• Voltage rating (+24V or -48V)
• Request battery autonomy
• Note if there are AC equipment(this would require an
Inverter)
• Proposed installation placement
• Determine your cable run length (AC&DC)
i.E AC –from the AC DB to rectifier, DC from rectifier to
battery and also load

• Confirm the cooling(shelter or outdoor) –influences

battery choise
• Request the growth pattern (20%, 30%, 4kW extra etc)
.
 Step 2- Required system rating
and battery capacity
From the survey gathering total system rating can be
extracted:

e.g Load to support

Base station cabinet(radio&TX) (MTN) 3kW
Base station cabinet EMTS (radio&TX) 1.5kW
Voltage -48V DC
Assuming no other load(lighting, socket all negligible)

Battery Autonomy-6 hours

Growth projection- 20%

.
 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

Required current = P/V = 5625/48 = 117A

For 6 hour support =117AX6h= 702 Ah

@80% DoD = 702/0.8= 877Ah

Required capacity to charge battery @ C10 assuming float @ 54V

=87X 54= 4752W

Total required system capacity is 5625+4752= 10377W

So approximately a 10-12kW capacity is adequate for the proposed

system
 Step 3- Estimate modular
structure
Rectifiers are protected against failure in an N+1
configuration
i.e when ordering the system N+1 rectifier module is
required
Where N= total number of modules to support the system
dimensioning
And +1 for a fail proof protection
E.G for our 12 kW load if each module is 2kW then N+1 is
6+1=7 nos 2kW module

(Note: its not compulsory but this is standard design for

fail proof and maintenance requirement)
.
 Step 4- Estimate required
battery breaker capacity
DC Side Breaker
Battery breaker is determined by the highest
drawn current from the battery either the
load requirement or C10 charging
For our example load =117A and C10-88Ah

Hence the minimum requirement would

consider 117Ah

A breaker rating of 120A is adequate

.
 Step 4- Estimate required
battery breaker capacity
DC Load Side
For the DC load assuming just 2 connection point for the two system
I.e MTN with 3kW would require 3000/48=62.5A
So A 63A DC breaker is adequate for MTN

For EMTS with 1.5kW would require 1500/48= 31.5

So a 32 A DC breaker is adequate for EMTS

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

If the site is a DC generator you can load up to 90%

Hence in this example 11-12kW is adequate to allow for a bit of
peak traffic
 Question
1. A site with 5kW Rectifier and 200Ah battery @-48V
Question
(a) Calculate the maximum DC load the rectifier can support
assuming charging at float voltage
(b) Calculate the required Generator capacity assuming a PF
of 0.8
(c) Calculate the required load breaker on ATS assuming zero
losses and site have an inductive load
(d) Calculate the wire diameter required to power the load at
a distance of 60meters and Aluminum cable with
resistivity of 2.65X10-8ohm/m
 Module 3.6-
Rectifier Installation

Standard installation procedure of the

rectifier and components
 Procedure
• Installation preparative
– Prepare the tools
– Safety
• Installation process
• Installing equipment
• Connecting the system cables
 Installing Preparative
•Prepare the tools before the installation ：
Flat – Phillips Hydraulic Hydraulic Percussion drill Drill bit(φ4、 Pincer pliers Step ladder
Screwdriver(3*100 screwdrivers(3*100m pliers pliers φ12、φ16 (2m)
mm,6*200mm) m,6*200mm)

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.

• Multiple disconnectors-If more than one mains

disconnector is connected to the system, they shall be
placed next to each other.

• No easy access to disconnector-The mains and the

battery disconnectors, if any, shall be lockable or placed
within sight of the power cabinets
Safety
 Installation process
Install Power and Install Connect system Test and
battery cabinet Batteries cables commission

1.Installing power and

battery cabinet
A.)Installing power and
battery cabinet
Place power and battery
cabinet on the base . Take
horizontal adjustment and
fix it with expanding bolt
Note ：At least 4 persons
are required in the
transport of power and
battery cabinet
 Installing battery cabinet

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.

4.2.Instal batteries to rack

specified in the manual

Page 264
 Installing battery cabinet

Installing temp
sensor
Installing the
temperature sensor
on the battery shelf
by bundling tapes

Page 265
 Installing battery cabinet

Connect the cables

between batteries.
Connect cables
between batteries and
cables between battery
and bar bus

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

AC mains protective earth

DC system earth
Bonding to the main earth terminal
Battery Connection
Battery Connection

The battery cables shall be strapped

together in a maximum of two layers
on acable rack or cable chute
Battery Connection
Connection of a cable to distribution
unit
1. Make sure that the circuit breaker is in the “OFF” position

2. Cut the positive and negative cables to length (enough to

connect into the correct positive clamp and negative CB).

3. Strip 15 mm of the insulation of the cables.

4. Insert the cables in their terminals, be careful not to damage

the conductor strands. Check that an alarm detection cable lug
is connected to each CB terminal.

Note: If an alarm detection cable is not to be connected, its cable

lug must be insulated to avoid false alarms.
External signaling cable to CU
Connector Board
External signalling cable to CU
 Connecting Temperature sensor
Two temperature sensors KET 103 06/1 can be connected. Their functions
are configured through the ACU display interface.
1. Battery: Mount the temperature sensor as close as possible to the
centre of a battery cell or block at the top shelf of the battery cabinet. Do
not mount it where it will be affected by airflow from fans etc.
Clean thoroughly the surface where the sensor is to be placed.

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.

4. Connect the temperature sensor plug(s) to the terminal(s) on the

connector board.
 Module 3.7-
Rectifier Configuration

Some basic configuration steps of the

rectifier controller
 Battery Technologies rectifier system
• Configuration Requirements：
Cable：A cross-over (Null-Modem) DB-9 female-to-female serial port
cable;

PC: A PC with RS-232C

Software： DCTools-1.10.0

• 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

• Configure the total rated

capacity of battery Modify this
parameter
according to the
actual total battery
capacity

Step 2

Configure the charging

float voltage
Modify this
parameter to
Enable
Modify this
parameter
to 56.5V

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

of the LLDV (Load Modify this

parameter
to 44V
low voltage
disconnect ) to 44V
Modify this
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

• Configure the quantity of

battery strings according to ENT

the actual battery strings.

• Configure the total rated

capacity of battery ENT ENT

according to the actual

capacity of every battery
string
ENT ENT
Modify this
parameter
according to the
actual quantity of
the battery
strings

NOTE: The password is “2” by default Modify this parameter

according to the actual
capacity of every
battery string

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 Emerson rectifier system
( Actura 48 701)
Enter the
Press Enter
Password 1

Press Enter
and

NOTE: The password is

“1” by default Press

Press Enter Press Enter

and or and or
Modify the battery Modify the battery
capacity of every blocks and then
block and then Press Enter to save
Press Enter to save the parameter
the parameter

• 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:

F2 6 Initialization PWD PWD RESET£ ºNO

SYS INFO MAIN PASSWORD Initialization
MENU type
SYS INIT£ ºNO
F2 F2 F2

Press and keys to select between password initialization and system

initialization, then press and keys to select between "YES" and "NO".
After selecting "YES" for "SYS INIT" and pressing the enter key, the system is
initialized.

Page 285
 Module 3.8-
Commissioning

Commissioning steps and key notes during

rectifier commissioning and integration
Start Up and Test Installation
Test Equipment Proper
• Test load . inspection
• Multimeter.

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

Overview of monitoring the rectifier

remotely
System architecture-using DPU

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

Some common faults and recommended

steps to repair and clear faults on rectifier
system
 Rectifier fail alarm
Fault: Rectifier fail alarm

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