Smps

ENGINEERING INSTRUCTION
SMPS POWER PLANT

(Model RMPS N X 100A / D) ITI 600 Amp
No. SMPS/ D - 004

No of Pages. 11
Issue No. 01
Issued By: T&D, Circle
Approved By: CGM T&D Circle
Date of Issue 19-03-2005
Amendment No (If Any) NIL
No of Pages
Issued by:
Approved By:
Date of Issue
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BHARAT SANCHAR NIGAM LIMITED
(A Govt. of India Enterprise)
All efforts have been made to incorporate all relevant up to date information
available, any discrepancies or need for addition or deletion is felt necessarily may
please be intimated to this office for further improvement, on E-Mail Id
singhai_sc2@rediffmail.com.
TECHNICAL & DEVELOPMENT CIRCLE,

SANCHAR VIKAS BHAWAN, RESIDENCY ROAD,
JABALPUR, MP-482001
1
Power Plants & Batteries
ENGINEERING INSTRUCTIONS SMPS / D– 004
SMPS POWER PLANT

(Model RMPS N X 100A / D) ITI 600 Amp
1.0 SCOPE
This EI describes in general the salient features of SMPS power plants and in particular ITI
600Amp.Capicity RMPS N X 100 A/D Model.
2.0 Introduction:
The System shall be capable of meeting the load requirements for various telecom equipment in Rural
areas or Urban areas. The systems should be expandable at rack level itself or by additional rack using the basic
FR/FC modules of the same rating. The prescribed FR/FC ratings are 6.25A,12.5A,25A,50A,100A,200A.
• Rural System: These type of systems are for smaller loads, which are normally installed in
rented buildings where the roof height is not as per standard equipment room. These systems are
normally required to work at unattended stations. The systems using basic modules of rating up
to 50A are envisaged for this application.
• Urban systems: These type of systems are to cater for the needs of larger loads. The systems
using the basic modules of rating 50A, 100A,and 200A are envisaged for this application.
System shall consist of a Distribution/Switching/alarm arrangement (DSA) & Float Rectifier-cum-
Chargers (FR/FCs) in a rack.
• It shall employ menu driven Micro Processor Controlled Techniques for DSA as well as module
for control, monitoring & alarms to achieve better reliability of the system.
• To cater for higher load requirements, same type of FR/FCs mounted in the same rack or
different racks shall be capable of working in parallel load sharing arrangement.
• Depending on the system requirements and manufacturer design one or all power plant racks
shall be provided with a DSA for the ultimate system capacity. However, DSA shall preferably
be provided either in the first rack or in a separate rack.
• The DSA shall provide for the following:
(a) Termination for the batteries
(b) Termination for the exchange load
(c) Interconnecting arrangement for power equipment.
(d) Battery switching arrangement
(e) Termination for AC input to the rack shall be finger touch proof, flame retardant, insulated.
Use of bus bars for the purpose is precluded.
(f) Termination for AC and DC to FR/FC modules.
(g) Circuit/ Breakers/fuses etc.
2.1 Principle of Operation
Input:
400Vac, 3-Phase
+10%,-15% Uncontrolled High Rectifier
3-Φ,3wire I/P Full Wave Frequency & Output
48V/100A
50Hz,+/-2Hz Choke Rectifier, Isolation L-C DC Output
PFC and Transforme Filter
Half-Bridge rs
Resonant
Inverter Bl
Diagram
A three phase uncontrolled full wave rectifier converts the three phase AC into DC. The rectified DC is
converted into AC by resonant inverter which is a zero current switching type control having switching frequency
above 20 KHz. This resonant inverter section consists of two IGBTs connected in a half bridge configuration.
A Govt of India Enterprises Page 2 of 11
Restricted to Telecom Staff Issue 1
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An LC resonance tank forces a quasi-sinusoidal current, which sinusoid ally increases with time as the
IGBT conducts and linearly decreases down to zero. At this point the IGBT is turned off, thus facilitating a zero
current switching.
The output of the high frequency Transformers is rectified using fast recovery diode and is passed via an
output filter ensuring lower output noise and ripple.
The input power factor is ensured always better than 0.98 for rated load and better than 0.95 for all other
input & output conditions.
2.2 General Requirements

SMPS is intended to be used in Auto Float-cum-charge mode as a regulated DC power Source.The single
phase module capacity ranging from 6..25A to 25.0A and its ultimate capacity ranging from 25A to 300A. For 3
phase module these datas are corresponding to 50A to 200A and its ultimate capacity ranging from 800A to
4800A. All factories wiring for the rack shall be for the ultimate capacity so that only plugging-in of FR/FC
module shall enhance the DC power output.
2.3 Rack configuration

Rack is composed for the following units preferably accommodated in 19’’ sub rack.
(a) Float rectifier-cum-charger (FR/FC) modules
(b) Distribution, switching, control, Alarm & Monitoring (DSA) unit.
2.4 Operational Requirements

2.4.1 Temperature Limit:
The temperature rise of the heat dissipating components above the ambient measured directly or at heat
sink in the first eight hours of the test shall not be more than
(a) Transformers and Chokes: 70 deg C for Grade B insulation. For higher grade of insulation, it is at least
20 deg C below the permissible limit for the grade of insulation used. The temperature rise shall be at
least 30 deg C below curie temperature of the magnetic material.
(b) Semiconductor Devices: 60 deg C or as per component Specification.
2.4.2 Insulation Resistance Tests:

The insulation resistance of a fully wired FR/FC when tested with a 500V Dc megger shall be as given
below:
(a) AC Input & Earth- Greater than 2 meg Ohm
(b) DC Output & Earth- Greater than 1 meg Ohm.
(c) AC Input & DC Output- Greater than 5 meg Ohm
2.4.3 Lightning & Surge Protection:
A two-stage protection in TT configuration shall be provided.
Stage-1 Protection: This protection against Lightning Electromagnetic Impulse (LEMP) & other high surges
shall be provided at the distribution panel, for the following value of currents.
Between Requirement
R,Y,B &N Greter than or equal to: Iimp:50KA, 10/350µS for each phase.
N & PE Greter than or equal to: Iimp:100KA, 10/350µS
Where Iimp : value of lightning impulse current 10/350µS.
Stage-2 Protection: This protection against low voltage surges shall be provided at the power plant level. This
protection shall be equipped with thermal disconnection and potential free contact for arrestors connected between
live and neutral.
Between Protection Requirement
R,Y,B &N Greter than or equal to: In: 10KA, 8/20µS for each phase.
N & PE Greter than or equal to: Iimp: 20KA, 8/20µS
Where In : value of Nominal discharge current 8/20µS.
It must be insured that both protection devices are sourced from the same manufacture to ensure perfect
co-ordination between the two stages.
Response time of the stage 1 protective devices shall be =< 100 neno seconds and that of stage 2 devices
shall be =<25 neno seconds.
The vendor must give installation procedure very clearly in installation manual.
The protection devices of the above two stages shall be tested to work in tandem and in perfect co-
ordination to given complete protection to the power plant against lightning and surges and also to ensure that the
voltage to the power plant equipment is kept below 800V.To cater for this requirement it is imperative that these
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devices should be tested simultaneously to ensure perfect synchronization. These protection devices shall be duly
approved by CACT. CACT will accept an International Test Certification provided the protective devices of both
the stages are tested in the same Lab as per testing procedure given in Standard VDE0675.
Coordination between the two stages:
a) For smaller Power Plants (upto 25A basic module) the necessary coordination inductance shall be
provided by the SDP Manufacturer in Stage-1 device, either inside the enclosure or in a separate
enclosure.
b) For high rating Power Plants (above 25A basic module) SDP Manufacturer will specify the minimum
coordination cable length in his technical catalogue. It shall be included in the instruction Manual and
also screen printed on the enclosure of stage-1 device.
The cross-sectional area of the conductor required for stage 1 protection shall not be less than 6 mm2 and for
second stage shall not be less than 2.5mm2.
The failure of stage-II protection device shall create and extend visual as well as audio alarm.
The power plant shall also be fully protected against the low voltage surges of the amplitude of 5th harmonics of
durations up to 500ms.
The manufacturer will clearly given earthling guidelines required for the purpose.
2.4.4 Radio Frequency Interference Suppression:

The module shall be designed to minimize the level of Electromagnetic interference (EMI), both
conducted & radiated, detected in its vicinity & generated by Switch Mode Power conversion equipment
operating within the rack.
2.4.5 Noise and vibration:

The fully equipped rack at full load shall not contribute more than 15db to the ambient noise level taken
as 45 dbA. It shall be measured at a distance of 1 meter from the unit & 1.25m above the floor level in the
Acoustic Range.
2.5 Alarm Indications:
A. On FR/FC :
• FR/FC over voltage, under voltage or output fail
• FR/FC over load (Voltage Droop)
• Fan Fail (Due to any Reason)
B. On DSA
• Load voltage high (Above 56V)/ Low (Below 45.6V)
• FR/FC fail
• Mains out of range
• System over load
• Mains “On” / battery Discharge
• Fan fail ( in case fan provided at rack level)
• Temperature compensation fail
• Battery fail or no battery
• Battery isolated from the load
All alarm circuits shall be provided with suitable delay to ensure that they do not operate to transients.
All the protections/alarms shall be within tolerance of 0.25V in case of DC voltage and 1% in case of
current. For AC voltage it shall be +/- 5V.
3.0 RMPS NX100A/D (ITI make)

It is a power system of ultimate capacity of 600A and suitable for VRLA batteries. The power system is
intended primarily to provide uninterrupted DC power to the telecommunication equipments and current for
charging the batteries. The system works from commercial AC mains supply (three phase, 4-wire, 50 Hz) which is
rectified and regulated to –54V DC and is fed to the equipment (exchange). The system has provision to connect
three sets of VRLA batteries and charge them simultaneously and charge them simultaneously to ensure
uninterrupted DC power to the equipment.
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The power system –48V/600A has the following features:
1. Multi rack configuration having one main, and two-extension rack.

2. Facility to parallel a maximum of 06 nos. of 48V/100A (5600W) rectifier modules operating from
three phase AC (400V phase to phase, 50 Hz).
3. Termination for three/four sets of VRLA batteries and equipment.
The power system has a single bus called auto float/charge bus. Depending upon the status of the
batteries, the output DC voltage is maintained at 54.0 + 0.5V under auto float condition. During auto charge
condition, the maximum DC voltage reached across the bus is 55.2 volts. The equipment, battery and rectifier
modules are connected in parallel.
The system employs natural convection cooling and has AC input distribution, DC output distribution,
protection and alarm circuitry for rectifiers, battery and equipment.
3.1 Technical Specification
Input Voltage Nominal(Vrms) 230
(Single phase AC) Range (Vrms) 165 – 260
(3phase 4Wire)
Frequency Range (Hz) 45-65Hz (Normally48-
52 Hz)
Power factor 50% to 100% load at >0.98
nominal input
Output Voltage Float Nominal (V) 54.0 + 0.5
Range (V) 48.0 to 56.0
Charge Maximum (V) 55.2
Current Maximum (A) 100 Amp
Psophometeric Without battery floated (mV) <4 mV
Noise With battery floated (mV) <2 mV
Efficiency At full load and nominal input
>90%
Protection Short circuit protection

Input over/under voltage protection
Output over voltage protection
Constant current features settable from 50 – 100A in auto
float/charge mode.
Alarms and indicating lamps Auto – Float/charge Green LED
Over voltage Red LED
Alarm (DC output fail/under voltage) Red LED
Overload (voltage droop) Amber/Yellow LED
Mains OK Green LED
3.2 For System

Input Voltage Nominal(V RMS) 230
(3 phase AC)
Range (V RMS) 165 -260 (3 phase 4 wire)
Frequency Range (Hz) 45-65Hz (Normally48-52
Hz)
Power factor 50% to 100% load at >0.98
nominal input
Output Voltage Float Nominal (V) 54.0 + 0.5
Charge Maximum (V) 55.2

Current Equipment + batteries 600A (Max)
Protection Short Circuit/Overload protection

Input over/under voltage protection
Battery over/under voltage protection
Alarms & Indicating Mains Available Green LED
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Lamps. Mains Out of Range Red LED

FR/FC Fail Red LED
Battery isolated Red LED
Load Voltage Low Red LED
Load Voltage High Red LED
Mains ON/Bty Discharge Red LED
System Overload Red LED
TEMCO Fail Red LED
FR/FC in Float Green LED
FR/FC in Charge Yellow/Amber LED
Battery Fail/No Battery Red LED
Voltage Droop Red LED
4.0 Functional Description of Power System
The 48V/600A Power system is multi rack configuration consists of the following:
• One main and two-extension rack.
• AC distribution arrangement in each rack
• Rectifier modules (06 nos. max.)
• DC distribution arrangement in main rack
• Power system controller unit.
4.1 Standalone Rack
The rack is made of mild steel profiles with hinged front door. The rack is convection cooled and has
ventilator slots in the front and at the top. The rear panel is screwed type and can be dismantled. The rack
accommodates 19 sub systems. Air baffles are provided for better heat transfer. Depending upon the load
requirement (Exchange and Battery), additional modules (up to a max. no. of 06 modules) can be added. The AC
and DC power termination and distribution is done at the top.
4.2 AC Distribution
The AC input cable for each rack is terminated at the top on screw type terminal blocks. The three
phases, neutral and earth wires and terminated on tag blocks. From the tag block four pole AC circuit breakers are
provided for each module. The line, neutral and earth from cabinet are terminated on modules socket which is
fixed to the respective plugs on the rectifier modules.
4.3 Rectifier Modules
The SMPS rectifier module –48/5600W works on 400 AC input and provides –48V DC for system. The
input is fed through 9 pin AC socket and the DC output is available on terminal blocks. The status and fault
indication are available on the front panel of the module. Two test jacks Vout and 1out are also provided on the front
panel of the module to monitor its voltage and current. The control signals coming from power system controller
on a 8-pin flat cable are also terminated on a 8-pin telephone jack available on front panel.
The rectifier modules are convection cooled and can be jacked in and out of the cabinet easily. Three
modules can be accommodated in each sub-rack in the extension rack and two modules can be accommodated in
each sub-rack in the main rack. The DC output from the module is terminated on the respective DC circuit breaker
mounted on the DC distribution panel.
4.4 DC Distribution Arrangement

It is provided at the top of the rack, having following facilities.
• Termination for the out put of individual rectifier modules.
• DC shunts to monitor current in various paths.
• Termination for positive and negative battery 1,2 & 3.
• Termination for equipment positive and negative cables.
• LVDs for battery paths 1,2, and3 for automatic disconnection and manual isolation of batteries.
4.5 Power System Controller (PSC) (Also termed as DAS)

The power system controller is a micro controller based unit to control the complete functioning of the
power system. It consist of the following:
Controller Card is the main CPU of the unit measurement section of this card is responsible for all
AC/DC voltage & current measurement
TEMCO card is responsible for temperature compensation for battery Voltage,

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LCD Module is used to display various measurement results & error messages and Keypad is used for
man machine communication
Beside above it also provides 13 LEDs on front panel to indicate various status and error conditions as detailed in
sec 3.2 (Alarms & Indicating Lamps).
Requirement of Cables between Lightning Protection Box Stage1and SMPS Power Plant Rack
Input Cable size

Sl. Nos of
System current for line & Colour
No. modules
Per Phase neutral
1. 100 Amp 04 40 Amp. 10 sq.mm Red for line,
black for
2. 150 Amp. 06 25 Amp. 60 Amp. 16 sq.mm
neutral. Earth
3. 200 Amp. 08 Single phase 70 Amp. 25 sq.mm Cable (Note 2)
module
4. 300 Amp. 12 120 Amp. 35 sq.mm
5. 600 Amp. 06 80 Amp. 25 sq.mm Red for L1,

yellow for L2,
6. 1000 Amp. 10 125 Amp. 35 sq.mm Blue for L3,
Black for N
Earth
7. 1500 Amp. 15 200 Amp. 100 sq.mm cable(Note3)
100 Amp.
Three Phase
8. 2000 Amp. 20 Module 250 Amp. 120 sq.mm
9. 2500 Amp. 25 325 Amp. 185 sq.mm
10 3000 Amp. 30 400 Amp. 240 sq.mm
(1) Cable from Stage –1 lightning protection box to SMPS power plant should be
at least 1.5 meters.
(2) For NX25 AMP system, earth cable should be 16 sq.mm (green).
(3) For NX1000 AMP system, earth cable should be 35 sq.mm (green).
(4) For systems 1500 AMP to 300 AMP. Connection 3 phase 4 wire cable from stage –1 lightning
protection box to AC distribution rack and connect AC cables 3 phase 4 wire from AC
distribution rack to different main, Aux., and extension rack.
(5) Proper earthing should be provided to all racks by earth cable.
5.0 System programming

After the testing of the rectifiers, system is required to be programmed for proper functioning of the
system. For this press SYSTEM VALUE key on the keypad. The system will display /edit system of values in the
following order.
5.1 ENTER PASSWORD will be displayed. Unless the user gives the correct password, system will not
allow the user to change any system parameters. Enter the password. The default password is 12345 followed by
enter.
5.2 Password Change will be displayed. If the user desired to change the password, press SYSTEM VALUE
KEY. New password will be asked. Once the user enters a password, system will ask once again to confirm the
password by typing it again.
If both the entries are found same, system will update the password. Once the password is changed, factory set
password is not valid. If the user loses hid password there is now ay to change the password in the field.
Considering this, it is advisable to keep you’re the password cautiously. If factory set password is OK, press
ENTER key.
5.3 No. of rectifiers installed in the system will be displayed. The default value is 8. If it is not OK press
SYSTEM VALUE KEY, system will ask for new value. Enter the value through suitable numeric key. If the
default value is OK, press ENTER key.

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5.4 The maximum system current value will be displayed. This value is not user programmable. From the no.
of rectifiers given, system will derive value for maximum system current.
5.5 The number of battery paths supported by the system will be displayed. The default value is 3. If it is no
OK press SYSTEM VALUE KEY, system will ask for new value. Enter the value through suitable numeric key.
If the default value is OK, press ENTER key.
5.6 The battery path 1 current limit value will be displayed. The default value is 200A. If it is not OK press
SYSTEM VALUEKEY, system will ask for new value. Enter the value through suitable numeric key. If the
SYSTEM VLAUE KEY, system will ask for new value. Enter the value through suitable numeric key. If the
5.9 The charge mode current value will be displayed. The default value is 20A. If it is not OK press
5.10 The float mode current value will be displayed. The default value is 10A. If it is not OK press SYSTEM
VALUE KEY, system will ask for new value. Enter the value through suitable numeric key. If the default value is
OK, press ENTER key.
5.11 The AC available value will be displayed. The default value is 50V. If it is not OK press SYSEM
5.12 The AC low value will be displayed. The default value is 165V. If it is not OK press SYSEM VALUE
KEY, system will ask for new value. Enter the value through suitable numeric key. If the default value is OK,
press ENTER key.
5.13 The AC high value will be displayed. The default value is 260V. If it is not OK press SYSEM VALUE
KEY, system will ask for new value. Enter the value through suitable numeric key. If the default value is OK,
press ENTER key.
5.14 The low voltage battery disconnect value will be displayed. The default value is 44 V. If it is not OK
press SYSTEM VALUE KEY, system will ask for new value. Enter the value through suitable numeric key. If the
5.15 The load voltage low value will be displayed. The default value is 45.5V. If it is not OK press SYSEM
5.16 The load voltage high value will be displayed. The default value is 56.2V. If it is not OK press SYSEM
5.17 Battery temperature high value will be displayed. This is required to set TEMCO FAIL on the higher
side. The default value is 50C. If it is not OK press SYSEM VALUE KEY, system will ask for new value. Enter
the value through suitable numeric key. If the default value is OK, press ENTER key.
5.18 Battery temperature low will be displayed. This is required to set TEMCO FAIL on the lower side. The
default value is 5C. If it is not OK press SYSEM VALUE KEY, system will ask for new value. Enter the value
through suitable numeric key. If the default value is OK, press ENTER key.
This completes the system programming.

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6.0 Salient provisions made in New GR No GR/SMP-01/ 05. JAN 2005

(New power plants may pl be tested confirming new GR 2005)
SMPS is intended to be used in Auto Flat-cum-Charge mode as a regulated D.C. Power Source.
Switching frequencies of these power plants shall be 20 KHz and above. The system shall only be based on menu
driven Micro Processor Controlled Technique (both DSCA as well as FR/FC, FR/BC module) for control,
monitoring & alarms. DSCA shall display the software version and checksum number for both DSCA and FR/FC,
FR/BC. Setting of all the parameters shall be through menu-driven microprocessor control only. The failure of
Micro processor or DSCA shall not affect the setting of individual FR/FC, FR/BC. No parameter of FR/FC,
FR/BC modules shall take care of the load on default settings and share the load collectively. Only the setting of
new parameters from DSCA, shall be affected. In case of failure of microprocessor of FR/FC, FR/BC module its
last settings shall not be affected.
The system shall be RS 485 compatible. It shall be feasible to set any monitoring control parameter from
a remote site through RS 485. All the information regarding Control and monitoring of Power Plant data shall be
accessible on demand from the remote site. The exchange of information and protocol format shall be as given in
the Annexure – 1.
The DSCA shall be provided for the ultimate capacity of the Power Plant. However, it shall preferably be
provided either in the first rack or in a separate rack. The DSCA, in addition to control, monitoring and alarms,
shall provide for the following:
a) Termination for the batteries.
b) Termination for the exchange load.
c) Interconnecting arrangement for power equipment.
d) Battery Switching arrangement (Connection to/isolation from system).
e) Termination for AC input to the rack shall be finger touch proof, flame retardant, insulated.
Use of bus-bars for the purpose is precluded.
f) Termination for AC and DC to FR/FC modules.
g) Circuit Breakers/fuses etc.
The capacity and number of batteries shall be as per order. For the purpose of Type approval, it shall be taken as
three batteries.
Only CACT approved ‘Handled enclosed Knife fuse assembly’ or ‘MCBs (which do not produce spark while
cutting in or out) for manual isolation and reconnection of the battery. Tripping the contractor through an external
switch does not permit the manual isolation/reconnection of the battery by tripping the contractor through an
external switch.
Note – 1: For AC input supply, AC contactor with AC Coil shall preferably be used. AC Contactor with DC coil
(if used) shall have its own power supply and shall not be fed from exchange battery.
Note – 2: Battery shall be protected against the short circuit from any source, including switching equipment such
as contractor, MCB coil and their control and sensing circuitry.
Note - 3: Solid state switching device may preferably be used. Relays, if used, shall be UL or CE compliant.
6.1 Interlocking of batteries: Necessary interlocking arrangement for batteries shall be provided so as to ensure
that atleast one battery remains floated across the load under all working conditions.
Starting of Power plant without battery supply: There shall be provision to start the power plant without
battery supply.
6.2 Power Plant compatibility with Engine alternator: The power plant system (including FR/FCs, FR/BCs and
DSCA), shall be suitable for operation from A.C mains or a DG set (of capacity 1.25 times AC load of power
plant).
6.3 Load sharing (parallel operation): FR/FC modules shall be suitable for operating in parallel with one or
more modules of similar type, make and rating, other output conditions remaining within specified limits.
The current sharing shall be within +/-10% of the average current per rectifier module in the system
(mounted in the same or different racks), when loaded between 50 to 100% of its rated capacity for all working
conditions.
In the event of failure of DSCA, FR/FC, FR/BC modules’ parameters shall not be disturbed. All the
FR/FC, FR/BC modules shall take care of the load on default settings and share the load collectively.
6.4 Battery Monitoring:

Battery Under Voltage Isolation: There shall be a provision for Automatic isolation/reconnection of
each battery from the load. The DC contactor used for the purpose shall be of single pole only. The operate and
release voltages for the above conditions shall be as follows:
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Cut off : 1.85V/cell (44.4V + 0.25V) shall be settable

between 1.85V and 1.9V cell)
Reconnect : When the FR/FC, voltage has built up fully. Shall
Be settable between 2.15V to 2.3V/cell)
6.5 Battery Health Monitoring in Auto Mode: To keep the battery in healthy state, the battery condition shall be
continuously monitored. On restoration of AC mains after an interruption, depending on the sensed battery
condition (depth of discharge), the system shall change over to auto charge mode to charge the battery at higher
voltage of 55.2V till the battery is fully recouped.
Battery Health Check: There shall be a provision of monitoring the voltage, current, trickle current,
conductance and temperature (programmable) of the batteries associated with the power plant at a set periodicity.
There shall also be a provision of monitoring of each cells of the battery bank for voltage and temperature.
The provision for conducting a partial discharge (about 20%) test, of a pre-determined duration and
frequency, shall be made available in the power plant (Frequency and duration of partial discharge test shall be
programmable). During this test, the current and voltage of the battery as well as each individual cell shall be
recorded. It shall also record the conductance and temperature of each cell.
Conductance measurements/observations shall be off-line to prevent noise interference. First
observations of conductance, recorded by the power plant system, for the battery shall form the base values for
future comparison.
The provision of partial test discharge shall be implemented in such a way that at a time only one battery
is put to discharge, so as to ensure that necessary battery reserve is available in case of power failure during or
immediately after the test discharge. Provision shall be made for observing the state of charge of battery before
commencing this test. In case the battery is not fully charged this test may be deferred till the battery is fully
recouped.
Initiating an alarm shall highlight any abnormality observed during above observations. All the above
information shall be made available to the remote site through RS 485 (Refer Annexure 1 for specified protocol).
6.6 Battery path Current Limiting Circuit: In Auto mode the current in each battery path shall be settable as
per the battery capacity so that the battery path current is kept at 10% of battery AH capacity. Tendering Authority
will give the capacity of the battery to be used for this purpose. For the type approval the manufacturer shall
demonstrate the facility and undertake to make provision as per order.
6.7 Temperature compensation for battery: In auto float/charge, mode there shall be provision for monitoring
the temperature of battery and consequent arrangement for Automatic temperature compensation of the FR/FC,
FR/BC output voltage to match the battery temperature dependant charge characteristics. The output voltage of
the rectifier in float/charge operation shall decrease or increase at the rate of 72mV (3mV/cell, 24 cell battery) per
degree increase or decrease in temperature over the set voltage. The output voltage shall decrease till the open
circuit voltage of the battery is reached. The open circuit voltage range shall be settable between 2.1V/cell to
2.2V/cell. At this voltage, the power plant voltage gets locked and further increase in temperature shall not
decrease the voltage any further. This voltage shall also remain locked till the temperature falls below the value
corresponding to set value. When the output voltage reaches 55.8V, due to increase in the output voltage owing to
decrease in temperature shall not lead to further rise in the output voltage of the power plant. This voltage shall
also remain locked till the temperature rises above the value corresponding to set value. A tolerance +/- 5 mV may
be acceptable over the specified rate of 72mV/degree C. The nominal distance between the battery & power plant
may be 20 meters. The manufacturer shall provide the necessary sensor and cord for the purpose with the power
plant. Failure of temperature compensation circuit including sensors (including the open or short circuit) shall
create an alarm and shall not lead to abnormal change in output voltage. Proper sign-writing shall be made in
DSCA and both ends of temperature compensation cord for its easy termination.
6.8 Protections: Failure of control and sensing circuitry shall not cause any hazard. The voltages of the system
shall not abnormally increase to endanger the load.
AC input: There shall be an automatic arrangement to provide galvanic isolation at the AC input of the
FR/BC module whenever the input voltage is beyond the specified operating range (90V to 300V for single phase
and 320V to 480V for three phase systems). Suitable alarm indication shall also be provided. The FR/FC module
shall resume normal working automatically when the input is restored within the working limits. Hysteresis within
specified working limits shall prevent shutting down of the FR/FC. A tolerance of +/-5V is acceptable for
protection & alarm operation. Reconnection shall occur at a voltage, 10V lower than the set voltage for high
isolation limit and 10V higher than the lower set limit, to avoid hunting. The circuitry used for sensing the voltage
for operation of isolation/reconnection device shall be able to withstand a voltage 15% higher than the specified
extreme limit of isolation.
The module shall be isolated (if required for the protection of the unit) in the event of unbalance beyond
10% and shall restore when the input is within limits.
Date
D.C.Over voltage: Each rectifier module shall be fitted with an internal over voltage protection circuit.
In case ouput DC voltage exceeds –56V, the over voltage protection circuit shall operate and shut-
off the faulty module. A tolerance of +/-0.25V is permitted in this case. Restoration of the module shall be
through a res4et switch/push button.
Shutting off of faulty FR/FC module shall not affect the operation of other FR/FC operating in the rack.
Operation of over-voltage shut down shall be suitably indicated on the module and also extended
monitoring/control unit.
The circuit design shall ensure protection against the discharge of the battery through the FR/FC module
in any case.
The over voltage protection circuit failure shall not cause any safety hazard.
Fuse/Circuit breakers: Fuses or circuit breakers shall be provided for each FR/FC, FR/BC module as
follows:
1. Live AC input line (MCB)
2. Negative D.C. output (handled enclosed ultra-fats fuse assembly or DC-circuit-
breaker.
3. Against failure of control sensing circuit.
All fuses/circuit breaker used shall be suitably fault rated.
Over Load/Short Circuit: The FR/FC shall be protected for over load/short circuit. Monitoring alarms and
indicating lamps: Visual indications/display shall be provided by means of bright LCDs on each FR/FC module
and DSCA to indicate.
Functional indications: The following functional indications shall be provided on FR/FC & DSCA:
a) Mains available
b) FR/FC, FR/BC on auto flot
c) FR/FC, FR/BC on auto charge.
Note: The functional indication a) shall be provided on both DSCA & FR/FC/BC module, while b) and c) may
be provided either on DSCA or on both FR/FC and DSCA.
References:
• Generic Requirements no. GR /SMP-01/04, FEB 2001.
• Instruction and Maintenance Manual of ITI Ltd for SMPS Model no. RMPS N X 100 A/D of Ultimate
Capacity 600Amp.
• GR/SMP - 01/05, JAN’ 2005

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ENGINEERING INSTRUCTION

SMPS POWER PLANT

No. SMPS/ D - 004

Restricted use by BSNL Employees

TECHNICAL & DEVELOPMENT CIRCLE,

SMPS POWER PLANT

2.1 Principle of Operation

2.2 General Requirements

2.3 Rack configuration

2.4 Operational Requirements

2.4.2 Insulation Resistance Tests:

Coordination between the two stages:

2.4.4 Radio Frequency Interference Suppression:

2.4.5 Noise and vibration:

3.0 RMPS NX100A/D (ITI make)

The power system –48V/600A has the following features:

1. Multi rack configuration having one main, and two-extension rack.

Protection Short circuit protection

3.2 For System

Charge Maximum (V) 55.2

Protection Short Circuit/Overload protection

Lamps. Mains Out of Range Red LED

4.4 DC Distribution Arrangement

4.5 Power System Controller (PSC) (Also termed as DAS)

BHARAT SANCHAR NIGAM LIMITED

Input Cable size

5. 600 Amp. 06 80 Amp. 25 sq.mm Red for L1,

9. 2500 Amp. 25 325 Amp. 185 sq.mm

10 3000 Amp. 30 400 Amp. 240 sq.mm

5.0 System programming

BHARAT SANCHAR NIGAM LIMITED

BHARAT SANCHAR NIGAM LIMITED

6.0 Salient provisions made in New GR No GR/SMP-01/ 05. JAN 2005

6.4 Battery Monitoring:

Cut off : 1.85V/cell (44.4V + 0.25V) shall be settable

BHARAT SANCHAR NIGAM LIMITED

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