RESTRICTED

THE INFORMATION GIVEN IN THIS DOCUMENT IS NOT TO BE PUBLISHED OR COMMUNICATED EITHER DIRECTLY OR INDIRECTLY TO THE PRESS OR ANY PERSON NOT AUTHORISED TO RECEIVE IT.

USER HAND BOOK/ OPERATORS MANUAL FOR LOW LEVEL TRANSPOTABLE OPS (LLTR) ENERGY SUBSYSTEM THALES

SUPPLIED BY BHARAT ELECTRONICS LIMITED L1, MIDC, TALOJA, NAVI MUMBAI 410208

JULY ,2012

USER HAND BOOK BEL P|N:9170 001 050 10

ISSUE NO. 00 01 CHANGE NO --07.06.2012 05.04.2013 -As per M/s TIPL Feedback DATE CHANGE APPROVED BY SCS SCS

CONTENTS
S.NO. DISCRIPTION PAGE NO. 14 14 15 16 19 21 21 21 21 22 22 23 24 24 24 24 24 25 25

CHAPTER- I LEADING PARTICULARS AND GENERAL DATA

1.0 2.0 3.0 4.0 5.0 5.1. 5.2. 5.3. 5.4. 5.4.1. 5.4.2. 5.4.3 5.4.4. 5.5 5.5.1 5.5.2 5.6. 5.7 INTRODUCTION CONTENTS OF OPS ENERGY SUBSYSTEM OPS ENERGY SUBSYSTEM SUBSYSTEM CONFIGURATION TECHNICAL SPECIFICATION OPERATING CONDITIONS SHELTER CONFIGURATION TECHNICAL SPECIFICATION OF SHELTER INTERFACE CONNECTOR PANEL CONNECTOR PANEL-1 POWER PANEL CONNECTOR PANEL-2 ACU PANEL CONNECTOR PANEL-3 GLAND PLATE 1 CONNECTOR PANEL-4 GLAND PLATE 2 SHELTER DOORS STORAGE COMPARTMENT DOOR DG COMPARTMENT DOORS FLOORING ACCESSORIES

5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.7.7 5.7.8 5.8. 5.9. 5.10. 5.11. 5.12 5.13 5.14 5.14.1 5.14.2 5.15

LIGHTINGS EMERGENCY BREAKER SMOKE, HUMIDITY AND TEMPERATURE SENSORS LIFTING JACKS CABLE DRUM HAMMER FIRST AID BOX FIRE EXTINGUISHER POWER SPECIFICATION OF SUBSYSTEM DESCRIPTION OF DG SET DESCRIPTION OF UPS ISOLATION TRANSFORMER UNIT (ITU) EMI FILTER DESCRIPTION OF AIR CONDITIONER UNIT CONTROL PANEL UNIT SENSORS BIT PANEL DESCRIPTION OF JACKS

25 25 25 26 26 26 26 26 27 27 29 32 34 35 36 36 37 38 40 40 40 41

CHAPTER- II UNPACKING AND REMOVAL OF PRESERVATIVES

1.0. 2.0. GENERAL INITIAL CHECK

CHAPTER- III PREPARATION FOR USE AND INSTALLATION SPECIFICATIONS

1.0. 2.0. 3.0. 3.1. 3.2.

GENERAL LIGHTINING ARRESTOR AND EARTHING/GROUNDING SUBSYSTEM POWER ON SAFETY MEASURES POWER THROUGH MAINS/ DG SET

41 43 43 43 44
48 48 48 49 51 51 53 53 55 56 58 59 59 60 61

CHAPTER- IV OPERATING INSTRUCTIONS

1.0. 2.0. 2.1 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.2.10 GENERAL CONTROL PANEL UNIT CONTROL PANEL USER INTERFACE DETAILS OPERATING PROCEDURE CONTROL PANEL DETAILS OF COMPONENTS OF CONTROL PANEL CONTROLLER DISPLAY AND ITS FUNCTIONS STARTING PROCEDURE FOR THE CONTROL PANEL AUTO MODE OF OPERATION MANUAL MODE OF OPERATION PARAMETERS MONITERING PROCEDURE ABNORMAL VIBRATION OF DG (STABILITY OF DG) COLD START OF DG TEMPERATURE AND HUMIDITY CONTROLLER POWER RESTORATION PROCEDURE AFTER EMERGENCY STOP BUTTON IS PRESSED. POWER RESTORATION PROCEDURE AFTER SENSOR TRIP SIGNAL UPS SUBSYSTEM STARTING OF 60KVA UPS

2.2.11 3.0 3.1

62

3.2 3.3 4.0 4.1

SHUTTING DOWN UPS BATTERY BANK LIFTING OF JACK SUBSYSTEM ASSEMBLY OF SUBSYSTEM (NO. OF TRAINED OPERATORS REQUIRED2) DE-ASSEMBLY OF SUBSYSTEM (NO. OF TRAINED OPERATORS REQUIRED-2) RAISING OF THE SHELTER (NO. OF TRAINED OPERATORS REQUIRED-4) SAFETY FEATURES AIR-CONDITIONER OPERATION CONTROLLER UNIT OF ACU OPERATION 74 74

4.2

4.3 4.4 5.0 5.1

CHAPTER- V USERS/OPERATORS SERVICING AND MAINTENANCE INSTRUCTIONS

1.0. 2.0 2.1 2.2 2.3 2.4 2.4.1 2.4.2 3.0 GENERAL PREVENTIVE MAINTAINANCE DAILY MAINTAINANCE WEEKLY MAINTAINANCE FUEL CLEANING/MAINTENANCE PROCEDURE 30KVA GENSET BATTERY RACK PROCEDURE FOR REMOVING BATTERIES FROM BATTERY RACK PROCEDURE FOR INSTALLATION OF BATTERIES IN BATTERY RACK DOS AND DONTS 75 75 76 77 79 79 79 81

CHAPTER- VI IL76 LOADING AND UNLOADING OF THE ENERGY SHELTER

CHAPTER- VII MISCELLANEOUS

1.0 2.0 3.0 STATION LISTS O-LEVEL SPARES DRAWINGS

89 89 93 93

FIRST AID IN CASE OF ELECTRIC SHOCK

1.

SWITCH OFF. If this is not possible PROTECT YOURSELF with dry insulating material and pull the victim clear of the conductor. DO NOT TOUCH THE VICTIM WITH YOUR BARE HANDS until he is clear of the conductor. But DO NOT WASTE TIME a) Place the victim in the supine position. b) Keep the air passages clear by turning the head to one side, opening the patients mouth and clearing it of water, saline, mucus or blood, a lot of which might have accumulated in the

Fig: 1 2.

back of the throat (Fig. 1)

If the jaw is rigid try to force the mouth open by pressure on the gun behind the last molar tooth of the lower jaw. When the upper air passages are thus cleared, tilt the head backward and force the jaw forward, from the angles of the jaw in front of the ears. This would prevent mechanical obstructions to the upper air passages.(Fig. 2 - 3)

Fig: 2 3. a) Then hold the chin up and forward with one hand and pinch the nostrils of the victim with the other (Fig. 4) b) Take a very deeps breath and apply your mouth to

that of the victim and blow into his mouth until the chest of the victim moves up indicating filling of the lungs. (NEVER Fig: 3 4. ALLOW THE CHIN TO SAG) (Fig. 4) When the chest has moved up, withdraw your mouth and allow the chest to slink back very three to four REPEAT this process seconds until the victim begins to

breathe again or until he is taken over by a medical attendant. This method can be continued in an ambulance during transit of the patient from the site of accident to the nearest medical centre Fig: 4 NOTE : HAVE SOMEONE ELSE SEND FOR A DOCTOR. KEEP PATIENT WARM AND

LOOSEN HIS CLOTHING. DO NOT GIVE LIQUID UNTIL THE PATIENT IS CONSCIOUS

DO NOTs AND Dos

DO NOTs:
1. DO NOT OPERATE THE SUBSYSTEM IN CONFINED SPACE. 2. DO NOT USE ENGINE BEYOND ITS RATED CAPACITY OR RATED STROKE. 3. DO NOT REPAIR ANY PART WHEN THE SET IS RUNNING. 4. NEVER OPERATE THE ENGINE WITH ANY PORTION OF DUCTING REMOVED. 5. DO NOT FILL THE FUEL WHEN THE SET IS RUNNING. 6. DO NOT FILL THE FUEL WITHOUT STRAINER. 7. DO NOT USE COTTON WASTE FOR CLEANING PURPOSE. USE SOFT CLOTH. 8. DO NOT BRING THE NAKED FLAME NEAR BATTERY WHEN IT IS BEING CHARGED. 9. DO NOT PRESS THE START BUTTON WHEN THE ENGINE IS RUNNING, OTHERWISE SERIOUS DAMAGE TO STARTER MOTOR GEAR MAY RESULT. 10. DO NOT ALLOW THE ENGINE TO RUN FOR LONG PERIOD ON NO LOAD OR LOW LOAD. ( LESS THAN 25% OF RATED CAPACITY ) 11. DO NOT DISCONNECT THE BATTERY WHEN THE SET IS RUNNING. 12. DO NOT STOP THE ENGINE ON 'FULL LOAD', RUN IT ON 'NO LOAD' FOR A WHILE TO PERMIT TEMPERATURE BALANCE.

DOs:
1. FIRST STUDY 'USER HAND BOOK' IN DETAIL. 2. KEEP THE GENSET ENCLOSURE VENTILATION ARRANGEMENT

( LOUVERS FOR FRESH AIR INTAKE & HOTAIR OUTLET ) CLEAN FOR PROPER AND ADEQUATE AIR CIRCULATION 3. USE PROPER TOOLS AND GENUINE SPARES TO SUIT THE JOB AND UNNECESSARY DAMAGES TO THE SUBSYSTEM. 4. ENSURE THAT ALL NUTS, BOLTS, SCREWS, PIPE CONNECTIONS ARE PROPERLY TIGHTENED. 5. CHECK THAT ALL GUARDS ARE PROPERLY FITTED. 6. ENSURE THAT ALL THE FILTER ELEMENTS ARE CLEANED AS PER MAINTENANCE SCHEDULE. 7. USE CORRECT GRADE OF LUBRICATION OIL & FUEL AND ALSO ENSURE CHANGE OF LUBRICATION OIL AS PER RECOMMENDED SCHEDULE

10

8. OBSERVE PROPER POLARITY BEFORE CONNECTING THE BATTERY 9. APPLY LOAD TO THE GENSET GRADUALLY 10. ENSURE THAT ALL THE CONNECTIONS ARE PROPERLY MADE AND CHECKED BEFORE STARTING THE SET. 11. BE ALERT FOR ANY UNUSUAL SOUND OF THE ENGINE AND FIND CAUSE WITHOUT DELAY. 12. MAINTAIN A LOG BOOK FOR RUNNING RECORD AND MAINTENANCE SCHEDULE.

WARNING
1. MAKE SURE THAT THERE IS SUFFICIENT VENTILATION AND ENGINE EXHAUST IS TAKEN OUT PROPERLY, IF THE SET IS TO RUN IN A CONFINED PLACE. 2. DO NOT DISMANTLE ANY PART OF THE SUBSYSTEM WITHOUT POSITIVE EVIDENCE THAT IT IS FAULTY. 3. 4. DO NOT LOAD THE SET BEYOND ITS RATED CAPACITY. DO NOT STOP THE ENGINE SUDDENLY FROM FULL LOAD BUT RUN IT ON NO LOAD FOR A WHILE TO PERMIT TEMPERATURE BALANCE. 5. BEFORE STARTING THE SET, ENSURE THAT ALL THE CONNECTIONS ARE PROPERLY MADE AND CHECKED. ENGINE OIL LEVEL IS CHECKED. 6. USE CORRECT GRADE OF LUB. OIL AND FUEL DEPENDING UPON THE AMBIENT CONDITIONS.

IMPORTANT POINTS
This handbook has been provided to assist the operator to understand the set thoroughly so that he may use it efficiently and service it correctly. This book should be read by the operator before the set is run for the first time and thereafter it should be readily available for reference whenever required.

I]

BEFORE STARTING THE SET

1. Check level of oil and fuel in Engine Compartment and add if necessary.

11

2. 3. 4.

Check that all plugs and sockets are secured. Check that the set is clear off the tools, loose nuts & bolts etc. Check that the battery is fully charged and that all the connections are securely and correctly made. the set is running in a confined place.

5. Make sure that there is sufficient ventilation and the engine exhaust is taken out,if

6. Check that the battery is fully charged and all the connections are made securely and correctly. 7. Do not run the set unprotected during dust storm. If dust or water enter in the Enclosure of the set, clean it immediately.

II]

CARE SHALL BE TAKEN DURING

a. Starting of Set under cold conditions If the ambient temperature is below zero degrees centigrade, use heaters (glow plugs) provided with the engine. Use proper grade of lub. oil and fuel suitable for sub zero temperature application. b. Normal running of Set Run the engine for few minutes on No Load in order to 'WARM UP' before applying the load. The load should be applied gradually whenever possible. c. Stopping of Set Load shall be put off before stopping the genset. Genset shall be run for few minutes on NO LOAD before switching off.

SAFETY PRECAUTIONS AND SAFETY MEASURES

I]

BEFORE STARTING
Before starting the set, check the oil level in oil sump with the help of dipstick provided on the crankcase. See whether the ventilation subsystem is perfect without any obstructions particularly on fan end side, ducting side and exhaust.

12

Ensure that the air inlets are not near any heating source. Make sure that there is no air bubble or water in the fuel subsystem; if so prime the subsystem with clean fuel.

Do not allow the set to run on an inclined ground more than 1 in 4 inclinations. Select fairly levelled ground to run the set.

Check that the fuel and lubrication oil used to operate the engine are of the correct grade and viscosity and does not contain any foreign particles.

If any fault is traced, do not attempt to start the engine unless fault is rectified. Ensure that all nuts, bolts, screws, pipe connections and covers, guards, etc. are properly tightened.

Ensure that all filter elements on filler subsystem, strainers are clean. Check that the battery is fully charged and that all connections are securely and correctly made.

II]

AFTER STARTING
Do not fill the fuel tank by hand filling spout while the engine is running. Avoid spilling of fuel on a hot engine when the engine is running. Top up the fuel oil after every recommended operating time period. Do not allow the tank level to reach the bottom during operation. The engine should never be operated with any portion of the fan casing or ducting removed as overheating and possible seizure will result. Never allow the engine to start when the load is ON Never make any clamping or unclamping of nuts, bolts or any parts when the engine is running. Never stop the engine when the load is ON, first shut the load OFF and then stop the engine.

III]

AT SHUTDOWN
Add the makeup lubricating oil at the end of each shift to the required level indicated. Clean the engine while warm.

13

IV]

OCCASIONALLY
Lubricate the links and check connections of all external controls. Check the tightness bolts, nuts and screws of any sub assemblies.

DEMOLITION OF MATERIAL TO PREVENT ENEMY USE

I]

GENERAL The demolition procedure outlined below will be used to prevent enemies from using or salvaging this equipment. DEMOLITION OF THE EQUIPMENT WILL BE DONE ONLY ON ORDER OF THE COMMANDER

II)

METHODS OF DESTRUCTION Use any or all of the following methods to destroy the equipment. 1. Smash: Smash all controls, switches, switch gears, components etc. In the control panel; starter, pump, filters etc. of Engine; Output terminals, RRA, AVR etc. in Alternator. Use sledges, Hammers, pickaxes, crowbars or heavy tools. 2. 3. Cut: Cut the cords, fuel pipe line and wiring. Use axes, hand axes Or hatchets. Burn: Burn the cords, control wiring, components etc., Technical Manuals. 4. 5. 6. Use gasoline, kerosene oil, flame throwers, Or incendiary grenades. Bend: Bend the panels, cabinet and chassis. Explosives: If explosives are necessary, use fire arms, grenades TNT Disposal: Bury or scatter the destroyed parts in slit trenches, fox holes or other holes, or throws them into streams.

14

Chapter I Leading Particulars and General Data

1.0 INTRODUCTION

The OPS Energy Subsystem (30kVA) is designed to provide power to the OPS Subsystem of Low Level Transportable Radar (LLTR). In operation, the Energy Shelter is designed to provide power of 30kVA to the load without any disturbance when a power source is selected (either DG or Commercial Mains) and during the switching from one power source to another. The mission is to provide uninterrupted power to the OPS Subsystem for load of 30kVA as per operational requirements and environmental constraints. Final delivered 30kVA OPS Energy System is identified with BEL Part No 1768 802 072 27.

15

2.0

CONTENTS OF OPS ENERGY SUBSYSTEM

Bare Shelter 1 No DG Set 60kVA : 1 No 60kVA UPS Subsystem with Battery bank -1 No 30kVA Isolation Transformer Unit (ITU) -1 No 3-Phase, 4-Wire, 100Amps EMI Filter 2Nos 2Ton Air Conditioner Unit (ACU) with respective Auto Controller - 2No Auto controller ACU 2 Nos Connector Panel-1 (Power Entry Panel on UPS compartment Wall, below EMI Connector Panel-2 (ACU Connector Panel on UPS Compartment Wall, Near Connector Panel-3 (Gland Plate on UPS Compartment Wall, Near ITU) Connector Panel-4 (Gland Plate on wall between DG and storage

Filters ) Battery Bank)

compartments) Control Panel Unit: It comprising of BIT information Panel, Breakers, ATS, Distribution Box, Indicators, Meters, Relays, Alarm and Emergency stop Power etc. Lighting subsystem Safety devices and alarms Smoke detectors External Horn Alarm Temperature and Humidity sensors with Controller Earthing Rods (Pegs) Earthing cables Fire Extinguisher operated manually

Cable drum with cable 16

Ladder / stairs Two Set (4 Nos each) of jacks to load and unload the shelter from the vehicle Hammer

3.0

OPS ENERGY SUBSYSTEM

The OPS ENERGY SUBSYSTEM consists of total four compartments, one compartment for the DG Set, one compartment for UPS, one compartment for Storage and one compartment for Silencer.

17

Figure 1 & 2 Photos of OPS Energy Shelter When the commercial mains are available on site, the load will be supplied through the UPS. In normal conditions, the role of the UPS is to avoid short breakdown of supply if occurred. The UPS ensures power supply to the load between the duration when Mains have failed and DG set (either one) starts up to supply full power. When one DG Set fails the second one starts automatically to supply full power. If the Mains become normal (available) again, the DG Set will be stopped automatically and the load will be supplied by Mains. When the external temperature is high, the commercial mains power will fed to Energy System through Power Cable (Not a supply part of the system) at connector Panel-1 (J1) in order to supply the air conditioning unit and to keep the temperature at +24C 4C inside the UPS compartment.

18

BLOCK DIAGRAM

The block diagram of 30 kVA OPS Energy Subsystem is shown below. It describes the flow of power inside the shelter within the no. of equipments is connected to the subsystem.

19

Figure 3 Block Diagram of OPS Energy Subsystem Control Panel is receiving power from Commercial Mains and/or DG Set. Commercial Mains is the preferred source of power. If it is not available then DG power is selected automatically. Power to OPS load is routed through UPS and Isolation transformer. One EMI Filter is used for Commercial Mains input and other used in Output Line to OPS Load. 20

Two Air conditioners, Switch Boards and all Lights are connected to Control Panel. Temperature, Humidity and Smoke Detectors are integrated with control panel. Based on the alarm raised by sensors power MCCBs shall be tripped manually.

4.0

SUBSYSTEM CONFIGURATION

The overall size of Bare Shelter in accordance with the standard ISO 8323 is a 20 feet ISO shelter. The Length, Width and Height of the Bare Shelter are mentioned below. Width Length Height : : : 2438 mm; 6058 mm; 2438 mm.

The Bare Shelter is made up of aluminium-foam sandwich panels in structural framework. The Energy Shelter is provided with ISO corners in accordance with ISO 1161, at the eight corners for locking and securing during road transportation and for lifting and handling. Two nos of air-conditioners of 2 TR capacity is fitted on the wall of ACU compartment of the shelter. Lightning Arrestors are mounted on the external top end of the cabin for providing protection to the cabin and its equipments from lightning. It also includes the 4 no. of earthing rods (pegs), lead and hammer. During transportation mode of the Energy shelter is locked on to the vehicle platform using ISO corner Twist locks. Exhaust from the DG set is taken through an insulated piping and is attached to the shelter wall. Ladders are provided under the vehicle platform of the shelter.

21

 Remember to un-lock four twist locks and four tie-down slings and free the shelter from the vehicle platform before lifting the vehicle platform. Otherwise it will damage the shelter. Do not touch the dg set exhaust piping when the DG is running; otherwise person may get burn injury.

Do not operate the OPS Energy Shelter while it is on Lifting Jack. Do not operate the OPS Energy Shelter DG Set while louvers for fresh air intake and hot air outlet are close. Do not operate the OPS Energy Shelter ACU while louvers and dust covers for air circulations are close.

22

5.0

TECHNICAL SPECIFICATIONS

5.1 OPERATING CONDITIONS

Temperature

: :

-35C to + 55C Operations -40C to + 70C Storage 95 % at 40C 3500Meters above MSL 4500Meters above MSL

Relative Humidity Altitude Operational Storage

: : :

5.2 SHELTER CONFIGURATION

The aluminium-skinned shelter is fully enclosed & thermally insulated to house equipments and accessories of OPS ENERGY SHELTER. All panels are of sandwich construction, where rigid polyurethane foam slab is sandwiched between aluminium alloy sheets. The aluminium alloy sheet is flat and continuous without any joint and is not affected by natural causes like humidity, rain, and dust. The bonding of sheets with solid polyurethane foam is carried out using state-of-the-art Hot Press Bonding machines.

5.3 TECHNICAL SPECIFICATION OF THE SHELTER

External Dimensions of 30kVA OPS Energy Shelter with projection Width Length Height : : : 2725 mm; 6533 mm; 2438 mm.

Weight Centre of gravity (x-3012mm,y-837mm,z-1113mm)

23

The centre of gravity of Energy Shelter Length Width Height : 3012mm : 1113mm : 837mm

Location of C.G is 3012 (along longitudinal direction), 1113(along lateral direction) and 837(along vertical direction). Reference point (0,0,0), for estimation was taken at the outer most tip of the bottom ISO corner of silencer end, towards the UPS compartment door side of the 30kVA Energy Shelter. Shelter is fitted with Standard aluminium ISO corners four at top & four at bottom. All doors fitted with locking mechanism Foot step for climbing up the shelter Stand for cable drum Lightning arrestors Ladder and Cable Drum
5.4 INTERFACE CONNECTORS PANELS

Three Interface Connectors Panels are installed in the shelter , the connector panels is used for connecting of power lines, data and communication lines between the shelter internal equipment and elements outside the shelter. Details are as under. The three Interface connector panel are
5.4.1 CONNECTOR PANEL-1 POWER PANEL

Specification of the POWER I/O panel is as per plate-1, mentioned in the drawings sections of this manual. Power I/O panel is having following connectors fixed on to it: COMMERCIAL MAINS (J1) OPS ENERGY LOAD (J2)

24

DG CONTROL (J3) LOAD (UPS) ETHERNET (J4) J1 J2 J3 J4

Figure 4 Power Entry Panel

5.4.2 CONNECTOR PANEL- 2: ACU PANEL

Specification of the ACU-2 panel is as per plate-2, mentioned in the drawings sections of this manual. ACU panel is having following connectors fixed on to it: ACU-1 POWER (JI) ACU-1 CONTROL (J2) ACU-2 POWER (J3) ACU-2 CONTROL (J4) J1 J2 J3 J4

25

Figure 5 ACU Panel

5.4.3 CONNECTOR PANEL- 3: GLAND PLATE1

This plate is placed on the wall between the UPS compartment and Storage compartment. It is used to take DG Power, DG Control, Sensors Cables and Lights etc. cables to UPS Compartment.
5.4.4 CONNECTOR PANEL- 4: GLAND PLATE2

This plate is placed on the wall between the DG compartment and Storage Compartment. It is used to take DG Power, DG Control, Sensors Cables and Lights etc. cables to UPS Compartment.

5.5

SHELTER DOORS

The Energy shelter has total six no. doors for exit from the compartment. Two no. doors are for DG Set Compartment, one door is for ACU compartment, one door is for Storage compartment one door is for UPS compartment and one door is for Silencer Compartment. The location of the door is as following:
5.5.1 STORAGE COMPARTMENT DOOR

Door Located on the left side wall of the shelter. The door is having three points lock latching mechanism and safety lock.
5.5.2 DG COMPARTMENT DOORS

There are total 2 Nos. of Door for DG Set Compartment .The locations of these Doors are such that one door is on the left side wall and second door is on the right side wall of the shelter. These doors are used to enter inside the DG compartment for maintenance activities of DG set.`

26

5.6 FLOORING

The floor surface of the UPS Cabin is covered with an anti-static mat in UPS Compartment of Blue colour. .
5.7 ACCESSORIES 5.7.1 LIGHTINGS

Four numbers Square CFL lights are provided in UPS compartment. Two numbers of CFL Bulkhead Lights are provided in DG Compartment. Two numbers CFL Bulkhead lights are provided in silencer compartment are provided. Two numbers CFL lights are provided in storage compartment are provided.

5.7.2

EMERGENCY BREAKER

Emergency breakers are used to stop all electric power inside the shelter. When the Emergency breaker operates then the input of commercial mains, output of DG Set, and the output of UPS goes off. The energy shelter will restart only when the operator releases the Emergency breaker/ switch. The Energy Shelter Emergency Breakers are located as follows: inside the shelter, one in UPS compartment on Control Panel outside the shelter, close to the door external inside the shelter, one in DG compartment on wall

These emergency breakers will stop all electrical power inside and outside the Energy Shelter (input of commercial mains; output of DG set(s); output of the UPS).
5.7.3
SMOKE, HUMIDITY AND TEMPERATURE SENSORS

In UPS and DG compartment of energy shelter Smoke detector, Humidity and Temperature sensor are installed. If any presence of smoke is detected by the smoke detector then the smoke detector is activated and suddenly stops all the electric power. The energy shelter shall restart only when the operator request.

27

There is external horn alarm. The external horn alarm is activated manually in case of any failure to alert personnel up to 100m from the energy shelter. It is switched ON/OFF by the operator.
5.7.4 LIFTING JACKS

Lifting Jacks are stored in Storage Compartments. Total eight numbers of lifting jacks are supplied with OPS Energy shelter. Four are for OPS Energy Shelter and four are for Radar Energy Shelter. During the transportation of the shelters all eight Lifting Jacks are stored in OPS Energy Shelter.
5.7.5 CABLE DRUM

There is 25m cable is provided with Cable Drum to connect the load. This cable is plugs with cap. Cable drum is stored in ACU compartment.
5.7.6 HAMMER

A hammer is placed inside the shelter.

5.7.7 FIRST AID BOX

Medical emergency kit (first aid kit) is provided inside UPS compartment of OPS Energy Shelter.
5.7.8 FIRE EXTINGUISHER

Fire Extinguisher unit (Co2 type), two numbers, operated manually, including mounting bracket is provided inside the Energy shelter. One is installed in DG compartment Other is installed in UPS compartment

28

5.8 POWER SPECIFICATION OF SUBSYSTEM

Commercial mains Input: Three phase Voltage Frequency Subsystem grounding

5.9
DESCRIPTION

: : :

400V 15% 50 Hz 2% resistance<5 ohms

OF DG SET

The DG Set(s) System shall be capable to provide a power output of 30kVA at 0.8 pf and at NTP. The DG Set shall be capable to provide power to an external load of 30 kVA. DG Compartment is provided with acoustic insulation to reduce effect of noise in the UPS compartment, when generator is working. Controlling of the DG sets is done through a control panel placed in the operator compartment.

Figure 6 DG Photo Refer manufacturer Technical manual for detailed operation procedures.

29

Do not operate the OPS Energy Shelter while it is on Lifting Jack. Do not operate the OPS Energy Shelter DG Set while louvers for fresh air intake and hot air outlet are close.

DG ENGINE Engine Make Engine Model 206HP Engine Rating Speed DG ALTERNATOR Alternator Make Alternator Model Alternator Rating Efficiency Governor type Voltage Phase Frequency : : : : : : : : STAMFORD Make UCI224 F 72 KVA 92.5% Electronic Type 400 15 V Three phase 50 Hz : : 56kW/ 72.5HP at NTP 1500 RPM : : Deutz make DEUTZ BF4M2011C, 1500 RPM, 50Hz,

ELECTRICAL STARTIING SUBSYSTEM Rating BATTERIES Make Type Quantity Rating Fuel tank capacity : : : : : Cummins Pulselite make SMF Dry type 2 No. 12V, 65Ah 499 liters : 24V DC

30

5.10 DESCRIPTION OF UPS

An ON LINE UPS, 60kVA, 3Ph 4 Wire, 400V, 50Hz AC is provided to power the load with 30kVA for a maximum duration of 10 minutes. The UPS has user friendly man machine interface which is a menu based screen panel to display the status of the UPS. The operator can easily understand and monitor all the commands and control provided by the UPS. UPS battery bank is provided inside the operator compartment. It consists of 32 numbers of 12V, 65AH batteries. The UPS controls are: Display the operating status (inverter load, mains load.) Display the storing of status event history log Built in test result ON/OFF audio warning device etc.

Figure 7 UPS Photo

31

The detailed specifications are . Sl No 1.0 2.0 3.0 Description Type Model Make kVA rating Input Voltage Admissible Tolerance Frequency Waveform Crest Factor 5.0 : Rectifier, Inverter, Automatic emergency UPS include By- Pass( standard/ emergency), Battery Set, with protection. 6.0 7.0 8.0 Overall efficiency Battery Minimum Battery : Better than 90% backup : 10 Minutes : : : : : Voltage : 15% : 50Hz Tolerance: 0.2% : Sinusodial : 3 with THDU<3%with THDI<5% Double conversion On-line MGETM GALAXY TM 500060kVA APC 60kVA 3ph 4 wire 415V

time required at full load 9.0 rating (0.8 Power Factor) Type of battery/Model : SMF lead acid type of Global and Yuasa make : ESC120-12 : 70 % IN 2 HOURS 80 % IN 4 HOURS 100 % IN 9 HOURS : 12V,65AH each battery

10.0

Recovery Time

11.0

AH rating of each battery

All operations concerning system start-up and compliance with standards and regulations, including those related to the battery cabinet, must be carried out by trained and certified personnel before using the UPS. Control Panel of UPS

32

Figure 8 UPS Control Panel Display and Keys Refer manufacturer user manual for detailed specification / operation / maintenance procedures.

5.11 ISOLATION TRANSFORMER UNIT (ITU)

ISOLATION TRANSFORMER UNIT is used to provide isolation between Energy System and load. 33

It is suitable for operation at suitable to jerk, bumps & vibrations unconditionally throughout its life.

Figure 9 Isolation Transformer Dimensions

TECHNICAL DATA:

Transformer rating : 36kVA Primary Voltage : 400 V 5%, 3 phase, 3 wires, DELTA connected.

Secondary Voltage : 400 V 5%, 3 phase, 4 wires, STAR connected. Frequency tolerance: 50 Hz 2Hz Insulation class Protection factor Cooling : H Class, Non-Bygroscopic, Non-flamable and fire retardant : IP 215 : Air Cooled.

INPUT POWER FROM CONTROL PANEL

OUTPUT POWER TO CONTROL PANEL

34

EARTHING WIRE

Figure 10 ISOLATION TRANSFORMER

5.12 EMI FILTER

EMI filter is capable to provide a output free from harmonics and unwanted signal. In 30kVA Subsystem, there are two 100Amps filters. One is for Commercial Mains input and other is for OPS Load output. 35

MAINS INPUT POWER TO CONTROL PANEL

POWER FROM CONTROL PANEL

MAINS INPUT POWER FROM OUTSIDE SHELTER Figure 11 EMI Filters

TECHNICAL DATA:

OUTPUT POWER FROM SHELTER (OPS LAOD)

3 phase 4wire : Rated current : Short circuit intensity : Shape wave : Rise time 10%-90% : Duration at half height : Residual in common mode : Residual in differential mode: Attenuation of filter : Overload current Leakage current Temperature range Operation Storage : : : :

100A 415V 50Hz 100A 20 kA Bi-exponential 10 s 1000 s < 1 kV (wave 1.2/50 s) < 500 V (wave 1.2/50 s) 20 dB at 10 kHz 60 dB from 100 kHz to 100 MHz 6 times of rated current for 8second < 60 mA -20 C to 50 C -30 C to 65 C

5.13 DESCRIPTION OF AIR CONDITIONER UNIT

Two numbers MIL Grade, vertical slip on type, TAT make, air-conditioners of capacity 2Ton, are mounted on the shelter. Air conditioner unit is designed to maintain the environment conditions compatible with the temperature inside the shelter. 36

A thermal warning report is transmitted to the Built in test unit and will indicate when the internal temperature is outside the temperature range.
TECHNICAL DATA:

Total cooling capacity (Outdoor +35C, Indoor 26 C, 50%RH) Heating capacity Power Supply Maximum starting current Weight Refrigerant Operating temperature, Cooling Operating temperature, Heating Storage temperature range

: : : : : : : : :

23900TU/H 3kW 3Ph, +G +N, 380VAC, 50Hz 6.9A per phase 34A 96Kg R407C; Charge-3700gr -10 C to +55 C From -20 C -30 C to +65 C

Maximum current consumption-Cooling :

Figure 12 and 13 ACU Indicators and Remote Control Refer manufacturer Technical manual for detailed specification / operation / maintenance procedures. Do not operate the OPS Energy Shelter ACU while louvers and dust covers for air circulations are close.
5.14 CONTROL PANEL UNIT

37

Control panel unit is consists of BIT Panel, Automatic transfer switch unit (ATU), Power distribution unit (PDU). The Control panel requires good healthy DG batteries, to operate properly. When the power supply is connected either mains or DG Set supply, respective indication of phases(R, Y, B) comes on the indicators of control panel.

Figure 13 Control Panel

5.14.1 SENSORS:

Each compartment (DG Set and UPS) of energy shelter is provided with one Temperature, Smoke and Humidity Sensors. These are integrated inside the control panel. If alarm is generated by any sensors then output power will be tripped. Upon perceiving the temperature of more than 60C the temperature sensor (first setting) will initiate a warning in the form of a conspicuously visual light located on the Control panel. Upon sensing a temperature in excess of 80 C the temperature sensor (second setting) will give a trip message to trip the Mains Power or DG Set Power. Upon perceiving the Humidity of more than 90% the humidity sensor (first setting) will initiate a warning in the form of a conspicuously visual light located on the Control panel. Upon sensing humidity in excess of 95% the humidity sensor (second setting) will give a trip message to trip the Mains Power or DG Set Power. 38

Upon detection of smoke, Smoke Detector will give an alarm message to trip the Mains Power or DG Set Power. After the trip message operator has to see the cause and operate Emergency Stop Button to trip output power of OPS Energy Shelter.

Temperature and Humidity Sensors Figure 14

5.14.2 BIT PANEL:

Smoke Detector Figure 15

The BIT Panel Unit shows the status of circuit breakers, temperature range, bit information of air conditioning, level of hygrometry inside the shelter.

Refer manufacturer Technical manual for detailed specification / operation / maintenance procedures.

39

5.15 DESCRIPTION OF JACKS

The removable jacks are for raising and lowering shelters of 12 TON (max.) up to a height of 1650mm (max.) from ground level and are manually operated. The removable jacks (LH) & (RH) are designed to be operated manually by operators 4 Nos, one for each jack. The jacks are to be fixed when required on the side face of ISO Corners as shown in fig. 16. The jacks are to be removed and stored until the time they are required next. Technical Specifications 1) 2) 3) 4) Lifting capacity (SWL) of individual jack Lifting capacity (SWL) for one set of 4 Nos. Individual Jack structurally tested for Weight of each Jack a) Top Bracket b) Bottom Bracket c) Main leg. d) Foot rest Total 5) 6) 7) 8) 9) 10) 11) Number of mounting points Effort for lifting per stroke Total length of jack retracted Total extended length of Jack Stroke of Jack Height gain or retraction per one complete rotation of rachet Admit between Jacks 8 mm 3230 mm 17 Kg. 14 Kg. 84 Kg. 3 Kg. 118 Kg. 2 Nos. for each jack 8 Kg-m (max.) 2275 mm 4062mm 1650 mm (max.) 5 TON load capacity. 12 TONS 3 TONS

----------------------------------------------------

40

Figure 16 Refer manufacturer Technical manual for detailed specification / operation / maintenance procedures. Do not operate the OPS Energy Shelter while it is on Lifting Jack.

41

Chapter II UNPACKING AND REMOVAL PRESERVATIVES

1.0 GENERAL The OPS Energy is a mobile subsystem and hence is always transported on its dedicated prime mover, military a truck on road. No special preservatives are used.

OF

2.0 INITIAL CHECKS

Carry out the following initial checks immediately after unpacking: Inspect the OPS Energy Subsystems for any external damages such as bends, cracks, dents and any other abnormalities. Inspect all external fittings for their loose condition, misplacement, missing parts and damages. Inspect the equipment and accessories for any external damages such as bends, cracks, dents and any other abnormalities. Inspect all controls, connectors and external fittings for their loose condition, misplacement, missing parts and damages. Operate all the knobs, controls and switches and check for their smooth operation without applying excessive force. Check that the subsystems are properly secured in shelter. Do not operate the OPS Energy Shelter while it is on Lifting Jack. Lifting Jack is used only for the removing the OPS shelter from the platform of the vehicle.

42

Chapter III PREPARATION FOR USE AND INSTALLATION SPECIFICATIONS

1.0

GENERAL

The OPS Energy Shelter is to be operated on ground. For transportation the OPS Energy Shelter is locked on to the truck using the four ISO corner twist locks. Various other subsystems are mounted inside the shelter. Check for the availability of crucial items as mentioned in chapter II. Unload the subsystem as follows 1. Unload the subsystem from the trailer with the help of Lifting Jack or Craine. Keep Energy Subsystem on 6 square blocks, which are stored in storage compartment of OPS Energy subsystem shelter. 2. 3. 4. Open the doors locks with the keys. Lock the doors with door stoppers. Open the dust cover of lovers and lock them with stopper. Check following items visual inspection. a. DG set i. Careful observation should be maintained over the whole engine for fuel and oil leaks and any leaks discovered should be rectified at the earliest opportunity. Leaks are more easily located on a clean engine than a dirty one. Fuel or lubricating oil should never be allowed to drip.

43

Figure 17 .Engine Fuel System (Representative Schematic) ii. Check the level and condition of the lube oil; if needed top up to the MAX level or change it if due.

44

Figure 18. Engine Operation Side iii. Check the supply and level of fuel in the tank & top up if found necessary;. iv. Drain the water or sediments from pre filter. v. Check for any abnormality visually & if any to be rectified. b. Shelter external and internal for damage or loose items. i. ii. iii. Air Conditioner Input / Output Connector Panels Shelter Lightings, Switch Boards

c. UPS Subsystems: Check the UPS visually and rectify the damages before starting UPS sub system d. Control Panel: Check the Control Panel visually and rectify the damages before starting OPS Energy Shelter. 2.0

LIGHTNING ARRESTOR EARTHING/GROUNDING

AND

45

Lightening arrestor rod is fixed on the side of the shelter. The level of the rod projection from this arrestor can be adjusted. When the shelter is on the move the rod has to be brought down to a level below the shelter top by loosening the two screws and re-fixing them. When the shelter is positioned for operation, the rod has to be raised to the maximum level above the shelter top. Raise the level of lightning rod up to the maximum level. Connect it to the earthing pin with a earthing cable provided. The earthing pin has to be driven into the earth by a sledge hammer provided. Earth pins are provided on Silencer Compartment and near airconditioning units. Refer Drawing 1768 802 071 30 Sheet Number 04 for grounding/earthing purpose. 3.0

SUBSYSTEM POWER ON

3.1 SAFETY MEASURES

The following Safety measures should be followed and verified before electrical power is connected to the subsystem. a. OPS Energy Subsystem is grounded properly b. 30kVA System Gen set is grounded properly c. Isolation Transformer is properly grounded d. Lightning rod is erected and is grounded properly e. Verify main power source selector is in OFF position f. Check all circuit breakers on the control panel are in OFF position, if not set it in OFF position g. Check that the UPS is in OFF position h. Installed all earthing pin along with the earthing wire. i. If subsystem is not in use for more than 15 days then check for DG batteries health. Charge the battery if it is below the 11V. j. If subsystem is not in use for more than 15 days then operate priming pump in DG compartment. 46

Figure 19 Priming Pump

3.2 POWER THROUGH MAINS /DG SET

1. Check the health of the DG set batteries using multi-meter. The battery voltage observed shall be 10.8V to 13.5V. If it is less than 12V, charge the batteries before operating the DG set. 2. If DG subsystem is not used in more than 15 days Operate the priming pump provided with DG before the starting of DG 3. Refer drawing number 1768 802 072 27 Sheet No 6 for external Electrical Connections or figure give at the end of this chapter. 4. Refer figure given at the end of this chapter for the locations of the MCBs and MCCBs 5. Connect External commercial Mains to the Energy subsystem at J1 of Power Entry Panel using cable 3W16 supplied with subsystem.

J1

Figure 20 Power Entry Panel

47

5.

Switch on Control MCBs as mentioned in Operating Procedure of Control Panel. Check the health of the DG set batteries on DG controller.

6.

Connect Load to the OPS Energy Shelter at J2 of Power Entry Panel using cables PWR CA TO OPS supplied with the subsystem.

J3

Figure 21Power Entry Panel 7. If Mains is not available then start DG set in Auto/Manual Mode as mentioned in the operating procedure. 8. Switch on CB9 and CB11 for Switch Board 1A and Switch Board 2. Switch On Lights. 9. Switch on CB12 for DG AC Battery Charger.

10. After starting the DG set or if Commercial Mains available, Switch On the Air Conditioner by Switching on respective MCBs (CB7 and CB8) and Remote Control. 11. Switch on the UPS input power by operating MCCB (CB4). Switch ON UPS Subsystem as described below. 12. After switching on the UPS Power Output, Switch ON CB10 (Switch Board -1 UPS) and MCCB (CB5). Input power is given to Isolation transformer by operating MCCB(CB5) 13. Switch on MCCB (CB3) to give Output Power to OPS Subsystem. 14. Performed the operation in reverse order to shut down the OPS Energy Shelter.

Control CB13 to CB22 48

CB1

CB2

ATS

CB7 to CB12

Load Distribution Bus Bar

CB4

CB5

CB3

Figure 22 Control Panel Layout

49

Figure 23 External Connection Diagram Read this user manual before starting deployment and operation of OPS Energy Shelter

50

Do not operate the OPS Energy Shelter while it is on Lifting Jack.

Do not operate the OPS Energy Shelter DG Set while louvers for fresh air intake and hot air outlet are close. Do not operate the OPS Energy Shelter ACU while louvers and dust covers for air circulations are close.

CHAPTER IV OPERATING INSTRUCTIONS

1.0

GENERAL

For setting up the Energy shelter for operations, the vehicle needs to be positioned at a given place and properly grounded subsystem using Earth Pins and Earth Wires. Check the DG set Subsystem, UPS and Shelter for any problem, damage etc. a) If a commercial power supply is available, connect the commercial mains supply to the power entry panel mains socket. If commercial power supply is not available, start the DG set in Manual Mode or Auto Mode as per the procedure mentioned below. b) Switch ON Lights, Air-conditioner depending on the requirement. c) Switch ON the input UPS MCCB. d) Switch ON UPS as per the procedure mentioned below e) Switch ON MCCBs Of Isolation Transformer and OPS Load. Connect the Load with the help of Cable. Switch ON the Load. f) After use of the energy subsystems switch off all the MCCBs and MCBs in the reverse order. 51

g) Refer SD Text Plate of 30kVA Subsystem pasted in UPS Compartment 2.0

CONTROL PANEL UNIT

Control panel unit is provided inside the energy shelter to distribute the incoming power to various switch boards through the UPS, to the Air-conditioning units etc. The Control panel unit is having automatic transfer switch to change over power from Commercial Mains to DG set. In case of phase failure (single and reverse phase) mains power will not be transferred to the load.
2.1 CONTROL PANEL USER INTERFACE DETAILS

52

1 4 3

6 7 8 9 10 11 12 13 14

Figure 24 Door of Control Panel

1. 2. 3. 4. 5.

DG indication lamps Mains indication lamp DSE controller 7310 module Controller ACU1 Controller ACU2

53

6. 7. 8. 9.

Mains Monitor Load Monitor ATS Controller Temperature and Humidity Controller

10. Hooter for Alarm 11. External Siren Switch 12. Emergency Stop Button 13. Glow Plug for Cold Start 14. BIT Information

2.2 OPERATING PROCEDURE CONTROL PANEL 2.2.1 DETAILS OF COMPONENTS OF CONTROL PANEL

Control CB13 to CB22

LVM

Relay R1 to R7

54

Relay Card and CB1 Power Supply

2310 Controlle r ATS

CB2

CB7 to CB12

Load Distribution Bus Bar

CB4

CB5

CB3

Figure 25 Control Panel inside Layout CB1: IS FOR MAINS. CB2: IS FOR DG. CB3: IS FOR LOAD OPS (SWITCH ON WHEN YOU NEED THE OPS LOAD). CB4: IS FOR UPS INPUT (SWITCH ON IN CASE WHEN YOU WANT THE UPS TO BE ON). CB5: IS FOR UPS O/P (ITU I/P). CB6: IS FOR THE UPS BATTERY (Mounted on Battery Rack) CB7: ACU-1(SWITCH ON IN CASE WHEN YOU WANT THE AC TO BE ON). 55

CB8: ACU-2(SWITCH ON WHEN YOU WANT THE SECOND AC TO BE ON). CB9: IS FOR SWITCH BOARD 2. CB10: IS FOR SWITCH BOARD 1. CB11: IS FOR SWITCH BOARD 1A. CB12: IS FOR MAINS BATTERY CHARGER (ON IN CASE WHEN THE MAINS FAILS). CB13: IS FOR THE CONTROLLER 7310 DSE MODULE. CB14: IS FOR CRANKING AND EMERGENCY STOP. CB15: IS FOR FUEL SOLENOID. CB16: IS FOR THE 2310 MODULE. CB17, CB18 AND CB19: IS FOR THE MAINS VOLTAGE SENSING(R-PH, S-PH, T-PH). CB20, CB21 AND CB22: IS FOR THE DG VOLTAGE SENSING (U-PH, VPH, W-PH). Relays R1:Remote start relay, R2:start relay(solenoid), R3: Strt relay(Crank relay) R4: Relay for hooter, R5: Smoke detector relay, R6: Emg stop(control panel), R7: Emergency Stop (control panel)

LVM : For Commercial Mains monitor, Reverse Phase Protection Controller Expansion Module 2310: For Temperature and Humidity Control Signal Relay Card and Power Supply: For Temperature and Humidity Sensors Generation of Alarm and Trip Signals and Communication with Controller. Power Supply is converting 24DC to 12VDC

2.2.2

CONTROLLER DISPLAY AND ITS FUNCTIONS

56

Figure 26 Deep Sea Controller Push Buttons

2.2.3 STARTING PROCEDURE FOR THE CONTROL PANEL

a) Check the healthy condition of Genset Batteries. If require charge the batteries. b) Check if Batteries of DG Set are connected to Engine (DG Compartment). If not then connect these batteries. c) Ensure that ATS is in Auto Mode.

57

ATS Auto Mode

Figure 27 ATS Controller d) Check the all connectors tightness in control panel. e) Switch ON all the control MCBs in control panel.(CB13 TO CB23) f) Ensure all the Ventilation Louvers of DG Compartment, ACU compartment and Silencer Compartment are open.

Figure 28 and Figure 29 Louvers with Dust Covers g) Switch ON the power MCCBs for DG1 (CB2) and MAINS (CB1). h) To ensure the readiness of the gensetss. Controller displays show Generator at Rest.

58

2.2.4

AUTO MODE OF OPERATION

a) Ensure Commercial Mains is available. b) Ensure that Controller is in AUTO mode. Press Auto Button for selecting AUTO mode of operation

Controller Auto Mode Figure 30 Auto Mode Operation c) Switch on UPS MCCB (CB4) and UPS (refer user manual of OEM) d) Switch On the all the load MCBs and MCCBs. e) Connect OPS load to subsystem through the connector panel 1 (J2) with power cable. f) When Commercial MAINS fails then DG will start automatically with following Sequence and power to load will be given through UPS till the starting of DG. Start Delay: Start Delay is of 5Secaonds. Crank Delay: Cranking will initiate in this timer. If Cranking is successful then Safety on Delay. This timer is for 10Seconds.

59

After this Load On or Generator Available will be displayed on controller display.

g) If Commercial Mains resumes then DG will Shutdown with following Sequence Return Delay. In this delay power to load will be taken from Commercial MAINS. Cooling Time Stopping DG Generator at Rest

h) Switch OFF UPS, all MCBs and MCCBs in distribution area if not required. i) If the external temperature is cold, use the glow plug before starting the DG as explained in the chapter 2.2.8
2.2.5 MANUAL MODE OPERATION

a) If the external temperature is cold, use the glow plug before starting the DG as explained in the chapter 2.2.8 b) Use this mode when commercial Mains is not available. c) Press Manual Mode operation Button. d) Press Start Button as shown in the figure below.

Figure 31Manual Mode operation 60

e) DG will be switched on with following Sequence f) Crank Delay Safety On Delay Generator will be available for load and Indicating Lights (R Y B) will glow on the control Panel. Switch on UPS MCCB (CB4) and UPS (refer user manual of OEM) g) Switch On the all the load MCBs and MCCBs. h) Connect OPS load to subsystem through the connector panel 1 (J2) with power cable. i) j) Switch OFF UPS, all MCBs and MCCBs in distribution area if power is not required. Press Stop button to switch of the DG. DG will Shutdown with following Sequence Stopping DG Generator at Rest

61

Figure 32 DG Stop Operation After starting the DG set or if Commercial Mains is available, Switch on the Air Conditioner by Switching on respective MCBs (CB7 and CB8) and using Remote Control.

Switch ON MCBs (CB9, CB10, and CB11) for Lights and Socket Outlet Power. Switch ON MCB (CB12) for charging the Batteries of DG Set. Switch on the UPS input power by operating MCCB (CB4). Switch ON UPS Subsystem as described below.

2.2.6

PARAMETERS MONITORING PROCEDURE

Page order:Status, Engine, Generator, Alarms and Event log,

62

Figure 33 Engine Parameters Instruction Page Content Engine In this we can see the parameters like Engine Speed, Engine Battery Volts, Run Time, Fuel Temperature, etc. Generator In this we can see the parameters like Generator Voltage (ph-N), Generator Voltage (ph-ph), Generator Frequency, Generator Current, etc.

2.2.7

ABNORMAL VIBRATION OF DG (STABILITY OF DG)

After the staring of the DG set if abnormal vibrations of DG is observed then open the cover of electronic governor and then adjust the GAIN pot as shown in below figure

63

Gain Pot

Figure 34 Engine Governer

2.2.8 COLD START OF DG

Electrically operated GLOW PLUG is fitted on the engine. GLOW PLUG is an aid to start the engine; when engine has to start in the specific low temperature condition (below 0C). The glow plug is mounted on air intake manifold.

Glow Plug

Glow Plug

Figure 35 Engine Glow Plugs Operation of Glow Plug a) Push the 'GLOW PLUG ' push button switch on the control Panel. b) Press and hold the 'GLOW PLUG ON ' switch on the control Panel for 30 Sec. c) Hold the above push button pressed or both the push buttons pressed simultaneously. Keep both the keys pressed until the DG starts. d) Release the Glow Plug switch after the DG starts. 64

2.2.9

TEMPERATURE AND HUMIDITY CONTROLLER

a) Controller has inbuilt program for detection of T1 and T2 : Pre-Alarm Set point and High Level Temperature H1 and H2: Pre Alarm Set point and High Level Humidity

b) To edit set points press Prog key and Ent, it will asked for password, then password and set points can be increased or decrease with the help of INC or DEC key. c) Password for Controller is 9995 d) After entering password select the any of the following parameters and with the help of INC or DEC key, press Ent to modify set points. Temp1 HighSetPt Temp1 AlamSetpt Temp2 HighSetPt Temp2 AlamSetpt Hum1 HighSetpt Hum1 AlamSetPt Hum2 HighSetpt Hum2 AlamSetPt

e) After selection of parameter press INC or DEC key to set the desired values, press Ent key to save the value and come out. f) In normal Run mode Condition LCD flashes every second following windows. LCD can be hold by pressing Dec Key & unhold by same key or automatically it goes to run mode after one minute. T1:54.2 No Faults H1:54.2 No Faults 65 H2:56.1 T2:56.1

g) If any fault occurs, that will flash in second line. h) If multiple faults occurs at a time that can be seen one by one in scrolling pattern or can view one by one by Inc key & automatically goes to scroll after three minutes H1:54.2 H2:56.1

Hum 2 High H1:54.2 H2:56.1

Hum 2 Alarm
2.2.10 POWER RESTORATION PROCEDURE AFTER EMERGENCY STOP BUTTON IS PRESSED

a) When these EMG.STOP1 or EMG.STOP2 or EMG.STOP3 button is pressed then CB1, CB2, CB3, CB4, CB5, CB6, CB7 circuit breaker will get tripped with an alarm indication b) Silent the hooter by pushing Acknowledge button provided on the respective hooter c) Solve the reason for pressing EMG STOP button. d) Release the pressed Emergency Stop button. e) Reset the controller by pressing the STOP button f) Switch on MCCB CB1, CB2 and Switch ON the subsystem as mentioned in above.
2.2.11 POWER RESTORATION PROCEDURE FOR SENSORS TRIP SIGNAL

a) If Temperature or Humidity beyond Higher Level then Sensor Controller Generates trip signal for Power MCCBs. DG controller will display the respective sensor name on the display.

66

b) If Smoke Detector detects smoke, then control panels generates trip signal Power MCCBs DG controller will display the respective sensor name on the display. c) CB1, CB2, CB3, CB4, CB5 will be tripped in both above conditions. Please press any EMG Stop Button to Shutdown UPS. d) Silent the hooter by pushing Acknowledge button provided on the respective hooter e) Solve the reason for respective sensor trip signal. f) Release the pressed Emergency Stop button. g) Reset the controller by pressing the STOP button h) Switch MCCB CB1, CB2 and Switch ON the subsystem as mentioned in above.

3.0

UPS SUBSYSTEM

All operations concerning UPS start-up and maintenance with standards and regulations, including those related to the battery cabinet, must be carried out by trained and certified personnel before using the UPS. Ensure that DG or Commercial Mains is available in control panel. Switch ON the UPS input power by operating MCCB CB3 67

Control Panel of UPS

Figure 36 UPS Control Panel Display and Key

3.1 STARTING OF 60KVA UPS

3.1.1 Ensure Commercial Mains or DG Power is available. 3.1.2 Switch ON CB3 in control input power to UPS 3.1.3 Set Bypass Switch (Q9) ON in UPS subsystem. (or Refer OEM manual)

Figure 37, 38 & 39 UPS MCBs 3.1.4 Set the Normal AC source input switch Q1 (8) to the ON position. 3.1.5 Wait until the end of the start sequence.

68

3.1.6 Set the battery circuit breakers in the auxiliary cabinet installed above battery bank to the ON position. 3.1.7 Press the ON button (37) The UPS unit starts automatically. LED (31) is ON. If LED (31) remains OFF, press the ON button (37) If LED (31) still remains OFF and either of LEDs (32) or (33) is ON, a fault has occurred (see OEM User Manual).
3.2 SHUTTING DOWN

The UPS remains energized unless it is shut down.

Figure 40, 41 & 42 UPS MCBs 3.2.1 Press a button to exit sleep mode. 3.2.2 Confirm by pressing the function key (38) for 3 seconds. The load is no longer protected by the UPS. It is supplied via the bypass. 3.2.3 Set the battery circuit-breaker battery circuit-breakers of the auxiliary cabinet installed above the battery bank to OFF. 3.2.4 Set the input circuit-breaker Q1 B (8) to OFF. The charger no longer operates to keep the batteries fully charged. 3.2.5 Open the upstream circuit-breakers of the Normal AC source and Bypass AC source to completely power off the UPS.

69

3.3

UPS BATTERY BANK

Though the UPS provided is true on-line, it will give back up power for 10-minutes, when its input power is failed / tripped. UPS battery bank is provided as per 10-minutes back up time. To enable the UPS to give backup power during its input failure, its batteries must be regularly monitored for their charge level. In view of this when UPS is not in use more than 15 days then charge the UPS batteries for about 24 hours. When the UPS batteries are fully charged, battery charge level will be indicated as 100%.

Refer manufacturer user manual for detailed specification / operation / maintenance procedures. After switching on the UPS Power Output, Switch ON CB10 ( Switch Board -1 UPS). UPS Output power is given to Isolation transformer by switching ON MCCB (CB5). Switch on MCCB (CB3) to give Output Power to OPS Subsystem.

LIFTING JACK SYSTEM

4.1 ASSEMBLY OF SUBSYSTEM (NO. OF TRAINED OPERATORS REQUIREDTWO)

70

Figure 43 & 44 Lifting Jack Bracket Step 1: The top brackets are fixed on to the top ISO Corners of the Shelter with help of mounting bolts and nuts. The profiled washer is provided to avoid excessive shear load on the bolt and is placed in between the nut & mounting bolt head in the ISO Corner slot. Step 2 : Fix the Bottom brackets of the jacks in similar fashion as the top brackets with bolts & Nuts provided. Step 3 : Lay out the main legs of the individual jacks as shown above

71

Figure 45 Jack Connection With Bracket

72

Figure 46 Brackets with Winch Step 4: Mount the winch subsystem provided on to the bottom Bracket of the jack to be assembled first as shown above Step 5 : Unwind the winch drum and route the wire rope round the pulley and now fix the pulley on to the top Bracket.

73

Figure 47 Lifting Jack and Winch Step 6 : Extend the wire rope (hook end) up to the main jack leg (laid on the Ground) and engage the hook with the lifting lug provided.

74

Figure 48 Jack and Winch Step 7 : Now as the winch is rotated the wire rope winds on to the winch drum and the main jack leg gets lifted from one side. As one operator winds the winch, the other operator can guide the main jack leg to fit onto the top and bottom brackets and finally the lock pins can be inserted into the holes of mounting bracket to complete the assembly of the jack the nuts of the pins can be tighten and secured. The winch and pulley can now be removed and mounted on to the next jack brackets, which are to be assembled. This process is repeated for all the 4 Jacks on the shelter.

75

4.2

DE-ASSEMBLY OF SUBSYSTEM (NO. OF TRAINED OPERATORS REQUIREDTWO)

Step 1: Lower the shelter and make sure that there is no load on the jacks. Step 2: For the winch and pulley subsystem on to the lower mounting bracket and upper mounting bracket respectively. Step 3: Fix the wire rope hook on to the lifting leg and keep the wire rope taunt. Step 4: Loosen the nuts of the mounting bracket pins (all four) and now slowly unwind the winch to loosen the wire rope. Remove the lock pins and disengage the main jack leg by pulling it away from the brackets and lower it slowly to the ground. Step 5: Once on the ground the hook is removed from the lifting lug and wire rope wound back on to the winch drum. Step 6: Remove the winch and pulley subsystem and mount it onto the other jacks to be de-assembled. Step 7: Lastly the top and bottom mounting brackets can be removed from the ISO corners by loosening the nut and removing the ISO corner mounting bolt.
4.3 RAISING OF THE SHELTER (NO. OF TRAINED OPERATORS REQUIRED FOUR)

76

Figure 49 Photo of Lifting Jack (1) (2) (3) Assemble the jacks on to the shelter as explained in earlier chapter. Rotate the gear box with help of rachet to lower the inner pipe until the ball end is in touch with the foot rest cavity (provided at centre) The operators should start to raise the shelter together and should keep pace with one another and should ensure that the level of shelter should be within 3 degrees (i.e. maximum slope of about 150mm (6 inches). A spirit level can also be used to keep track of the level of shelter. (4) Once the desired height is achieved the operation of gear box can be stopped. The level of the jacks will not be disturbed by itself as the design is self locking type. (5) A red marking is provided on the inner pipe to mark end of stroke of 1600mm. In case the shelter is to be lifted further than a packing under the footrest should be provided before raising operation. 77

4.4

SAFETY FEATURES

Following safety provisions to be incorporated in the jack: Red marking on jack legs to be provided to warn operator about Maximum lift (at a distance of 100mm below it maximum lift) position of the jack. Engraved safety precaution text plates to be provided. Refer manufacturer Technical manual for detailed specification / operation / maintenance procedures.

78

AIRCONDITIONER OPERATION
5.1 CONTROLER UNIT OF ACU OPERATION:

Cooling: Before pressing on/off button control panel make setting for cooling. Move right cursor to cool position and Lift Cursor to Medium / High or Low Position before starting of Air Conditioner. Temperature can be set to desired level by pressing + and buttons on the remote control. The unit will now operate automatically at the selected temperature.

ACU1 REMOTE

ACU2 REMOTE

Figure 50 ACU Remotes and Indicting Lamps Heating: Before pressing ON/OFF button control panel make setting for Heating. Move right cursor to heater position and Lift Cursor to Medium / High or Low Position before starting of Air Conditioner. Temperature can be set to desired level by pressing + and buttons on the remote control. The unit will now operate automatically at the selected temperature. Ventilation: If the cursor is set to FAN, then ACU operate for ventilation Mode.

79

 Refer manufacturer Technical manual for detailed specification / operation / maintenance procedures.

80

CHAPTER V USERS/OPERATORS SERVICING AND MAINTENANCE INSTRUCTIONS

1.0

GENERAL
The

Users / operators servicing and maintenance instructions are given below. maintenance is broadly categorized as follows: a) Preventive maintenance. b) Battery maintenance. c) Fault finding procedure.

2.0

PREVENTIVE MAINTENANCE

2.1 DAILY MAINTENANCE:

a) Wipe dust and dampness from the control panel, DG Set, Light board etc. b) Check and maintain earthing as recommended. c) Ensure all cables are engaged properly. d) Switch ON the power supply through AC mains and check that the units are functioning properly at least once. e) Run the subsystem for at least two or three hours on mains or DG Set to charge the UPS batteries. f) Switch OFF the AC power supply and check for the functionality of the subsystem through UPS supply. g) Close all the doors properly when the subsystem is not in use to avoid dust entering the shelter. 81

h) Close all the external connectors with dust caps, when they are not in use.

2.2 WEEKLY MAINTENANCE:

This is required when the subsystems are not in use. a) Check all the screws after every transportation and tighten it properly if found any loose fitting. b) Check all the wiring or presence of any loose connection inside the shelter. c) The UPS has to be switched ON using either commercial Mains or generator supply for at least 5 hrs in a week. d) Switch OFF the AC power supply and check the functionality of the subsystem through UPS supply. e) Check the functionalities of ACUs. Do the ACU maintenance as per the manufacturer recommended maintenance procedures. f) Check the functioning of Mechanical jacks. Switch ON the power supply through generator and check that the units are functioning properly.

In addition to the general maintenance details given above, each equipment like UPS, DG set, Air-Conditioners, Mechanical jacks etc are to be maintained as per the OEM recommended maintenance procedures.

82

2.3 FUEL CLEANING/ MAINTENANCE PROCEDURE 30KVA GENSET

a) First Remove Battery Cables from Battery Terminals. b) Remove cable from Fuel Sensors.

Remove Sensor Cables

Figure 51 Fuel Tank Inlet Plate with Sensors c) Remove Plate from the fuel tank as shown in the figure

Remove plate

Figure 52 Sensor Plate d) Remove Fuel Inlet from corner of fuel Tank.

After removing Fuel Inlet

Figure 53 Fuel Inlet

83

e) Remove all the screws from the Fuel tank cover

Remove Screws (x6 nos.)

Figure 54 & Figure 55 Cover Plate f) Pull out fuel tank slightly and remove fuel from tank by opening the pipe. Collect fuel in can or barrel.

Fuel Outlets

Figure 56 Fuel Outlet g) Clean the fuel tank and connect all the removed parts for assembling the fuel tank.

While performing any sort of welding job make sure that the fuel is drained out completely & keep the man hole & breather open while performing the welding job.

84

2.4 BATTERY RACK: 2.4.1. PROCEDURE FOR REMOVING BATTERIES FROM BATTERY RACK

1.0 Switch-off the UPS as per UPS switching-off procedure as per User Manual. 2.0 Wear electrically insulated rubber hand gloves to remove the DC cable from battery string. 2.1 Slide off the terminal shroud and remove input +ve DC cable connected at the +ve terminal of 32nd battery. Cover the cable terminal with electrically insulated tape. (Refer drawing of battery bank) 2.2 Slide off the terminal shroud and remove input ve DC cable connected at the ve terminal of 1st battery. (Refer drawing of battery bank) 2.3 Slide off the terminal shroud and disconnect interconnecting cable links between battery number 32 to battery number 1. Remove one by one the battery number 32 to 1; from the battery bank.. +ve
32 17 31 18 30 19 29 20 28 21 27 22 26 23 25 24

-ve

16 1

15 2

14 3

13 4

12 5

11 6

10 7

9 8

Interconnecting cables
2.4.2 PROCEDURE FOR INSTALLATION OF BATTERIES IN BATTERY RACK

1.0 Ensure that UPS is in Switch-off mode. 2.0 Wear electrically insulated rubber hand gloves to remove the DC cable from battery string.

85

2.1Install the battery number 1 to 32 one by one; in the battery bank (Refer drawing of battery bank). 2.2 Connect interconnecting cable links, along with terminal shrouds, between battery number 1 to battery number 32 (Refer drawing of battery bank). Slide on the shrouds over the battery terminals. 2.3 Connect input +ve DC cable, along with terminal shroud, at the +ve terminal of 32nd battery, slide-on shroud over battery terminal. (Refer drawing of battery bank) Connect input ve DC cable, along with terminal shroud, at the ve terminal of 1st battery, slide-on the shroud over the battery terminal. (Refer drawing of battery bank) +ve 32 17 -ve 16 1 31 18 15 2 30 19 14 3 29 20 13 4 28 21 12 5 27 22 11 6 26 23 10 7 25 24 9 8

Interconnecting cables

Safety Note Ensure that battery circuit MCCB, CB8 is in OFF CONDITION before opening the battery rack cover.

The 32 Nos of batteries are to be connected in series; Total nominal voltage is 384 V DC. Never touch the +ve & -ve terminals of the string of batteries simultaneously. Doing so would cause serious electric shock.

86

3.0 DOS AND DONTS

Following instructions are to be followed: 1) All personnel must remain clear of truck while the OPS shelter is being lowered into place on the truck platform 2) Do not jerk, bounce the OPS shelter when lifting. Avoid swinging shelter from side to side. Do not attempt to push the shelter in place with forklift 3) To prevent injuries to personnel, do not stand near the truck stabilising legs other than the hydraulic subsystem operating personnel. 4) To avoid injury or death to personnel due to falling from shelter roof always wear personnel safety harness hooked in the positions on the roof, before starting any work on shelter roof. 5) On actuation of smoke alarm, do the following: If the personnel is inside the shelter Take the rechargeable lamp and switch on. Push the emergency stop provided on power operation panel.

If the personnel is outside the shelter 6) Switch off the mains and DG supply. Open the shelter door and inspect the cause of smoke alarm.

Ensure air conditioners are switched on and temperature inside the shelter is maintained as per user manual before switching on UPS.

7) Ensure air conditioner filter cover and all connector plates are tightened properly after any maintenance activity. 8) Do secure the crane before transport.

87

9) Secure the crane before start of operations by fully tightening of swing bolts 10) Rotate the crane with hand and always hold the handle during rotation to safe guard the load from overshooting the desired location
DOS FOR 30KVA DG SET:

1) First study User Hand Book in detail. 2) Keep the Gen Set enclosure ventilation arrangement (Louvers for fresh air intake & hot air outlet) clean for proper and adequate air circulation. 3) Use proper tools and genuine spares to suit the job and unnecessary damages to the subsystem. 4) Ensure that all nuts, bolts, screws, pipe connections are properly tightened. 5) Check that all guards are properly fitted. 6) Ensure that all the filter elements are cleaned as per maintenance schedule. 7) Use correct grade of lubrication oil and fuel and also ensure change of lubrication oil as per recommended schedule. 8) Observe proper polarity before connecting the battery. 9) Apply load to the Gen Set gradually. 10) Ensure that all the connections are properly made and checked before starting the set. 11) Be alert for any unusual sound of the engine and find cause without delay. 12) Maintain a log book for running record and maintenance schedule.
DO NOTS FOR 30KVA DG SET:

1) Do not operate the subsystem in confined space. 2) Do not use Gen set beyond its rate capacity. 3) Do not repair any part when the set is running.

88

4) Never operate the Gen Set with any portion of ducting removed. 5) Do not fill the fuel when the set is running. 6) Do not fill the fuel without strainer. 7) Do not use cotton waste for cleaning purpose. Use soft cloth. 8) Do not bring the naked flame near battery. 9) Do not press the start button when the engine is running. Otherwise serious damage to starter motor gear may result. 10)Do not allow the engine to run for long period on no load or low load. (Less than 25% of rated capacity) 11)Do not disconnect the battery when the set is running. 12)Do not stop the engine on Full Load, run it on No Load for a while to permit temperature balance.

DOS FOR LIFTING JACKS

1) DO read the manual thoroughly before start of operation. 2) DO keep the inner pipe clean & it regularly to keep friction low. 3) DO inspect the equipment regularly for any defects such as cracks, abnormal deflection, bend and damage. 4) In such case do not use the equipment unless it is certified fit or damaged part replaced. 5) DO store the components of each jack along with main jacks leg eg. Top & bottom brackets should be stored together. 6) The components are marked accordingly for operator convince. 7) DO operate the jacks simultaneously to raise / lower the shelter in level manner.

89

DO NOTS FOR LIFTING JACKS

1) DO NOT operate subsystem without properly securing the jacks on to the ISO corners with help of ISO bolts provided. 2) DO NOT operate subsystem unless and until the lock pins 2 Nos. for top bracket and 2 Nos. of bottom bracket are properly locked by tightening the nuts. 3) DO NOT handle the jacks in rough manner. Avoid sudden jacks, impacts and drops while handling and storage. 4) DO NOT leave the shelter raised up on these jacks for prolonged periods specially if the shelter is prone to vibration (In case of D.G. set shelter) 5) DO NOT raise / lower the shelter unevenly. The level out should not be more than 150mm (6). 6) DO NOT raise the jack beyond the horizontal red mark on the inner tube. That indicates the maximum stroke.

FAULT FINDING AND RECTIFICATION

Fault finding and rectification is given below:

Fault Finding and Rectification UNIT 30kVA Energy Subsystem FAULT Not powering ON REASON a) Power may not be available RECTIFICATION a) Check for availability of power at power source b) Check for the Emergency stop Button.

90

b) Control MCBs may be in OFF position

c) Check the position and if found in OFF position, change it to ON d) Check the Position of ATS Switch and RESET it if required. e) Check MCB and if found tripped, RESET f) Check individual circuit MCB and if found tripped, RESET

c) ATS Switch may be OFF

d) Load MCCB might have tripped

e) Individual circuit MCCB might have tripped f) Sensors May be giving the Alarm to Control Panel

g) If the Sensors are giving tripping signal then, please rectify the corresponding problem and then switch on the subsystem

UPS Air-conditioners DG sets PDB

Refer OEM Manual Refer OEM Manual Refer OEM Manual Refer OEM Manual

91

CHAPTER VI
IL

76

LOADING AND UNLOADING OF THE ENERGY SHELTER

The Energy Shelter for LLTR project designed as per required overall dimensions and weight. It is possible to transport the shelter by C130/ IL76 aircrafts. Tie-down provision is as per 20ft ISO container provision using the ISO corners are provided on the shelter. Shelter External Dimensions of 30kVA Radar ENERGY SHELTER with projection Width Length Height : : : 2738 mm; 6320 mm; 2441 mm;

Weight Centre of gravity (x-3012mm,y-837mm,z-1113mm) Comparison of the dimensions of the energy subsystems and aircrafts with ENERGY SUBSYSTEM 6.058 m 2.438 m 2.438 m

C 130 Cabin length Max. Width Max. Height 12.19 m 3.12 m 2.74 m

IL-76 20.00 m 3.40 m 3.46 m

During Air transportability some essential parameters need to be checked : S.NO. 1. 2. 3. 4. Type of Check Lashing Points CG Point Weight Ease of alignment with IL-76 using HMV 92

5. 6.

Ease of Telpher operation Clearance space along width and height of IL-76

It can be loaded directly into IL-76 Aircraft by using aircraft telphers (quantity =4), Inbuilt crane inside IL-76 which is capable of lifting a payload around 10 ton directly from the vehicle were utilized Internal space available for cargo transportation is 18.5m (L) x 3.0m (W) x 3.1m (H). The overall dimensions of OPS shelter with all its projections are 6.5m (L) x 2.8 m (W) x 2.5 m (H). While loading OPS Energy Shelter into IL-76 Aircraft, Aircraft is divided into following sections.

Figure 57 Loading of Energy Subsystem Shelter Procedure to be followed: 1. If weight of the subsystem is more than desired level then Batteries from the Battery Rack can be removed as mentioned in Chapter No. V (Para 2.4). These batteries shall be transported separately. 2. Put the shelter on the vehicle bed in such a way that its air conditioners are towards the cabin side of the vehicle. 3. Park the vehicle with its back side towards aircraft ramp as close as possible.

93

4. Now both ends of the shelter are in permissible lifting range of cranes. 5. Engage chains with the lower ISO corners of shelter (ramp side) and telpher beam. Now connect hooks of crane with telpher beam. 6. Position ramp side crane in section 1, so that chain is slightly tilted when tiught as shown in fig. 7. At other end (cabin side), engage upper and lower ISO corners of shelter with chain. Position crane such that chain, hook of crane & vertical pillars of the shelter in the same vertical plane. Connect hooks of the crane with the chain directly (without telpher beam). 8. Put some soft material between steel rope and shelter(particularly on cabin side) so that shelter is not damaged during lifting when steel chains are taut and press against shelter. 9. Lift the shelter slowly up to the suitable height and move both the cranes inside IL-76 and put the shelter on desired place 10.Disengage chain and hooks of telpher beam from the shelter

94

CHAPTER VII MISCELLANEOUS

1.0 STATION LISTS
Main Sl. No. 1 Sub. Sl. No. Basic Equipment 30kVA Energy Subsystem 1.00 BARE SHELTER ASSLY-30KVA 1768 802 072 27 1768 802 745 45 1768 802 765 82 1 No 001 Description BE Part No. Qty MPN / S. No. (If any) Remark

1.01

DG SET ASSY-30KVA a) Engine, Deutz make BF4M2011C b) Alternator, STAMFORD make, UC 1224F

1 NO

01 10839337

06082158 1768 803 431 24 1768 802 773 58 1 NO 01

1.02

30 KVA DG SET CONTROL PANEL

1.03

UPS 60KVA ASSY a) UPS b) Battery Bank (32 x 65 AH)

1 NO

3A5M3507 40

1.04

MANUAL JACK (RH)

1768 802 771 64

4 NO

2 FOR OPS, 2 FOR RADAR --DO--

1.05

MANUAL JACK (LH)

1768 802 772 61 1768 802 752 24 4766 764

4 NO

1.06

CABLE & DRUM ASSY-1 30KVA PWR25M

1 NO

1.07

AIR CONDITIONER 2 TR, TYPE

2 NO

T0082,

95

Main Sl. No.

Sub. Sl. No.

Description

BE Part No.

Qty

MPN / S. No. (If any) T0083

Remark

EAC-24-3RSF-V 1.08 ACU CONTROLLER

201 06 4766 779 601 75 3840 760 101 12 1762 300 020 65 3840 761 201 10 1763 500 029 96 4504 760 001 72 4579 153 401 91 4950 761 001 37 4576 760 102 48 4530 760 402 61 4571 761 902 97 2 NO

1.09

FIRE EXTINGUISHER - 2 KG.CO2 TYPE )

2 NO

41- 2011, 43 - 2011 -

1.10 CLUB HAMMER 1.5 KG 1.11 FIRST AID KIT

1 NO

1 NO

1.12

EARTH PIN ASSEMBLY

4 NO

1.13

SIREN

1 NO

EXTERNAL

1.14 RECHARGEABLE LANTERN 1.15 ISOLATION TRANSFORMER 3PH 36kVA 1.16 SMOKE DETECTOR SERIES65 & RELAY BASE 1.17 EMI FILTER 3PH 4W

1 NO

1 NO

01

2 NO

2 NO

01, 02

1.18

LUMINAIRE SURFACEMOUNT FCS31/211,2x11W

6 NO

4NO-UPS COMP. & 2NO- DG COMP. SHELTER OUTSIDE

1.19

LUMINAIRE BULKHEAD FXC101(GREY)CLEAR

4571 761 105 63

2 NO

96

Main Sl. No.

Sub. Sl. No. 1.20

Description

BE Part No.

Qty

MPN / S. No. (If any) -

Remark

LAMP CFL PL-S 9W CAP BASE G23

4569 760 301 18 4754 119 001 70

2 NO

SHELTER OUTSIDE 2 NO SILENCER COMP & 2 NO DG COMP. - DO -

1.21

EH LAMP HLDR OFF-WHITE

4 NO

1.22

LAMP

4571 103 201 19 1768 804 136 43 4745 760 501 03 1768 803 813 42 1768 803 813 42 1768 803 548 61 1768 803 832 82 1768 803 833 79 1768 803 355 58 1768 803 684 41

4 NO

1.23

LIGHTENING ARRESTER

1 NO

1.24

FUEL TRANSFER PUMP (MANUALLY OPERATED)

1 NO

1.25

SWITCH BOARD 1 (LIGHTING UPS)

1 NO

1.26

SWITCH BOARD 1 A (LIGHTING MAINS/DG)

1 NO

1.27

SWITCH BOARD 2 (SOCKET OUTLETS)

1 NO

1.28

EARTHING CABLE 25SQ MM

3 NO

1.29 EARTHING CABLE 50 SQ MM 1.30 CABLE ASSLY POWER 3W 16 (OPS) 1.31 CA ASSY ETH 4W12 (OPS)

1 NO

1NO

1 NO

97

Main Sl. No.

Sub. Sl. No. 1.32

Description

BE Part No.

Qty

MPN / S. No. (If any) -

Remark

SPARES FOR 30 KVA EDG SET AND CONTROL PANEL

1768 803 432 21

1 SET

LOOSE ITEM

User Hand Book / Operating Instruction A User Hand Book 30kVA Energy Shelter B C Mechanical Jack APS UPS 60KVA Installation and Operation Manual D DG Set User Hand Book 1 NO OEM 9170 001 050 10 1 No BEL

1 No 1 No

OEM OEM

2.0 O-LEVEL SPARE LIST For every shelter following O-level Spares will be supplied. Sl NO. Description Part No. Qty.

98

A) a b c d e f B) a b c d e f g

SPARES FOR 60kVA UPS FUSE-INPUT FOR UPS (125A) ALLEN KEY SET HARDWARE KIT BATTERY INTERLINK CABLE 120AH LUGS METER SPARES FOR 30 KVA DG SET & CONTROL PANEL O-SEAL P/N.01180693 SPIN-ON OIL FILTER P/N 01174416 SPIN-ON FUEL FILT. P/N 01182242 AVR MX321 P/N E000-23212 TERMINALS P/N CTS4U INDICATION LAMP P/N SSD-3-22-5 CONTROL RELAYS P/N RXM4LB2BD

1768 804 735 89 4567 761 201 02 3131 760 301 96 3131 760 401 87 4867 761 902 80 4758 760 602 05 4730 760 601 45 1768 803 432 21 3650 860 201 88 3820 763 001 13 3820 763 101 04 4694 760 101 96 4757 760 501 01 4571 764 801 33 4692 101 64

1 2 1 1 4 8 1 1 2 1 1 1 10 5 2

Refer Radar Energy Shelter Manual for Shelter O-Level spares. 3.0 DRAWINGS

99