INSPECTION CIRCLE, JABALPUR

TEST SCHEDULE SMPS POWER PLANT

Document No No of Pages. Issue No. Issued By: Approved By: Date of Issue: TD/SW-3512 /TS/SMPS 5 II T&D Circle, Jabalpur CGM T&D Circle 12.06.2008

Amendment No (If Any) 01 Document No No of Pages: Issued by: Date of Issue: TD/CFA/TS-INFRA/PH-VII/02 05 Inspection Circle Jabalpur 02/11/2012

Restricted use by BSNL Employees only

FIX IT RIGHT AT THE FIRST INSTANCE

INSPECTION CIRCLE JABALPUR

SMPS POWER PLANT TEST SCHEDULE

TEST SCHEDULE FOR SMPS BASED POWER PLANTS

S. No. 1. 2. 3. 4. 5. 6. NAME OF TEST LAR Cabling, termination- check. Operation & maintenance manuals check. Equipment Configuration Earth Insulation Test (To be taken before heat run test ) As per purchase order. Earth resistance should be Less than or equal to 0.5 Ohms. With 500V DC Meggar . AC Input & Earth- > 2 M . DC Out put & Earth- > 1 M . AC Input & DC out put- > 5 M 7. Load limiting (Voltage droop) EFFICIENCY Voltage drooping should occur on load 100%+5% at the O/P voltage range 44.4 to 56 volts. . At nominal input, output and full rated load: for single phase AC better that 85% and for three phase AC better than 90%. . For other specified input, output conditions and load between 50% to 100% should be better than 85% for single phase AC and better than 87% for three phase AC. The prescribed float voltage settings are. -54Volts for VRLA Battery . -52.8 Volts for conventional Bty . Normally 2.3 V/cell till changeover to float mode. . Voltage 55.2 Volts If power factor meter is not available, the reading may be taken from panel meter.
AMMENDMENT-1, ISSUE-II

REFERENCE

REMARK Location: As per approved lay out plan. Physical check for proper gauge of lead & proper termination.

8.

9.

Voltage Stability: (a) Auto Float mode (Range -48V to 56 V) (b)Auto Charge Mode (-do-) (c)Manual Boast mode (Range 56 v to 65V)

10.

Power Factor

TD/CFA/TS-INFRA/PH-VII/02

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INSPECTION CIRCLE JABALPUR

SMPS POWER PLANT TEST SCHEDULE

11.

Voltage Regulation Test

The DC output voltage shall be maintained within +/-1% of the half load preset voltage in the range 25% load to full load when measured at the output terminals over the full specified input range. Reading may be recorded for individual modules as well as whole in both modes. . FR/FC Over voltage, under voltage or output fail. . FR/FC over load (voltage drop) . Fan fail (due to any reason) . Load voltage high (above 56V)/Low(above 45.6V) . FR/FC fail (any failure condition as per clause 11.) . Mains out of range. . System over load. .Mains ON/Battery Discharge .Fan fail (in case fan provided at rack level) .Temp. Compensation fail. .Battery fail or no battery (separate for each battery) .Battery isolated from the load. a) Mains available* b) FR/FC on auto float. c) FR/FC on auto charge. * The indication a) shall be provided on both DSA and FR/FC/BC module while B&C may be provided either on DSA on both FR/FC and DSA. There shall be an arrangement for automatic switching-OFF of fans during AC input failure/Fan failure with raising of alarm.

12.

Alarm indication on FR/FC :

13.

Alarm indication on DSA

14.

Functional indications on FR/FC & DSA

15. 15.1

Protection Fan fail

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INSPECTION CIRCLE JABALPUR

SMPS POWER PLANT TEST SCHEDULE

15.2

DC Over voltage protection

Each rectifier module shall be fitted with an internal over-voltage Protection circuit In case output DC voltage exceeds 56V with tolerance of +_ 0.25 V the over voltage protection circuit shall operate & shut off the faulty module. Shutting-off of faulty FR/FC module shall not affect the operation of other FR/FC operating in the rack. The circuit design shall ensure protection against the discharge of the Battery through the FR/FC module in any case. FR/FC module should be fully protected against short circuit. Fuses or circuit breakers shall be provided for each FR/FC module as follows: Live AC input line Negative D C output Against failure of Control sensing circuit. All fuses/circuit breaker used shall be suitably fault rated. Percentage variation should be less than +_10% of average current per rectifier module while loaded between 50 to 100% of its rated capacity. Accuracy +_1.5% of the range

15.3

Fuse/Circuit Breakers

16.

Load Sharing

17. 18. 18.1

Meter and their calibrations Battery Monitoring Battery under voltage isolation

The operate and release voltages for the above conditions shall be as follows: Cut-Off :1.85V/cell(44.4+0.25V) shall be settable between 1.85V & 1.9V/ell) Reconnect: When the FR/FC voltage has built-up fully. Shall be settable/between 2.25V to 2.3V/cell).
AMMENDMENT-1, ISSUE-II

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INSPECTION CIRCLE JABALPUR

SMPS POWER PLANT TEST SCHEDULE

18.2

Battery Health Monitoring in Auto Mode

18.3

Battery Current Limiting Circuit

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 battery condition (depth of discharge) sensed, 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. In Auto Mode to ensure the availability of required exchange load and safely of the battery, the current in each battery path shall be settable as per the battery capacity so that the battery path current is kept to 10% of battery AH capacity. There shall be provision for monitoring the temperature of battery and consequent arrangement for Automatic temperature compensation of the FR/FC output voltage to match the battery temperature dependant change characteristics. The output voltage of the rectifier in Float/Change operation shall decreases 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 to 2.2V/cell. The increase in output voltage due to decrease in compensation has been taken care of by the tripping of the unit due to output voltage high 0.56V) protection A tolerance of +/-5mV may be acceptable over the specified rate of 72mV/degC. The nominal distance between the battery & power plant may be 20 meters failure of temperature compensation circuit including sensors shall create an alarm and shall not lead to abnormal change in output voltage.
AMMENDMENT-1, ISSUE-II

18.4

Temperature Compensation for Battery

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INSPECTION CIRCLE JABALPUR

SMPS POWER PLANT TEST SCHEDULE

19.

Heat Run test (Temperature rise test of component may be taken if possible)

8 hours at full load Transformer and Chokes 70C Transistor/diode/FET etc. 60 C. In vigorous at atmosphere condition if room ambient temperature reaches to 50 C, then rack shell be capable of withstanding at room ambient temperature of 50 C measured at a distance of 1 foot from the equipment.

20. 21.

Check of operation of SMPS with E/A set. General inspection:QA Approval, Sign writing, lighting protection, wiring neatly secured in position, adequate supports, spare components etc. - Availability of cabling diagram, placed in the inside of the front door or any other convenient place for ready reference of the maintenance staff. - Details of the fuse rating and type. In case of fuses on PCBs, the rating shall be either on the fuse or PCB. - All non current carrying metal parts shall be bonded together and Earthed with suitable marking. - A name plate shall be suitably fixed on each rack/module and contain following information: Specification Number: 1 Type of the Unit: 2 Manufacturers name and identification: 3 Model No.: 4 Unit Serial No.: 5 Input voltage and phase : 6 Output Voltage and Current: 7 Year of manufacture: 9. Suitable for battery capacity:

TD/CFA/TS-INFRA/PH-VII/02

AMMENDMENT-1, ISSUE-II

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