USER MANUAL

INTEGRATED POWER SYSTEM

315IPS-ODU
DS210R00

WARNING AND SAFETY PRECAUTIONS

Danger and Warning
High voltages can be present inside the unit at the AC Inlet/Outlet and
cable terminals.
The Equipment must be properly grounded.
Do not touch Electronic Circuit when system is turned on.

Safety Precautions
Install the unit in an area with adequate Air Flow.
Avoid blocking the Ventilation openings of the System
Do not place the System near Heat-Emitting Appliances such as Radiators or
Stoves.
If Installed near Generator then the unit should be at least one meter apart from
Generator.
The unit should be kept away from Generator / HVAC / Air Conditioners Exhaust and hot air flow.
Installation should be carried out by Trained Staff.

Note: Failure to undertake safety precautions and warnings under consideration can result in damage to
equipment and injury to people.

II

Table of Contents
WARNING AND SAFETY PRECAUTIONS ............................................................................................. I
Table of Contents .................................................................................................................................... II
Chapter 1 General Information................................................................................................................ 4
1.1 Introduction ................................................................................................................................... 4
1.2 Snap Shots .................................................................................................................................... 4
1.3 Product Features ........................................................................................................................... 5
1.4 Line Diagram ................................................................................................................................. 6
1.5 Physical Layout ............................................................................................................................. 7
Chapter 2 Functional description .......................................................................................................... 12
2.1 Power Measurement and Management ...................................................................................... 12
2.1.1 Over Voltage Isolator ............................................................................................................ 12
2.1.2 OVI Bypass ........................................................................................................................... 12
2.1.3 Auto Mains Fail (AMF) .......................................................................................................... 12
2.1.4 Bypass (AMF) ....................................................................................................................... 13
2.1.5 Power Measuring Module (PMM) ......................................................................................... 13
2.2 Generator Management (GEM3) ................................................................................................ 14
2.3 DC Tower Light (TLC) ................................................................................................................. 14
Chapter 3 Operation and Configuration ................................................................................................ 15
3.1 Operation .................................................................................................................................... 15
3.1.1 Turning-on IPS ...................................................................................................................... 15
3.1.2 Emergency Stop ................................................................................................................... 16
3.1.3 LCD Displays ........................................................................................................................ 17
3.2 Configuration ............................................................................................................................... 20
3.3 Alarms ......................................................................................................................................... 22
3.4 References .................................................................................................................................. 23
Chapter 4 Technical Datasheet ............................................................................................................. 24
Chapter 5 Warranty ............................................................................................................................... 25
Chapter 6 Appendix ............................................................................................................................... 26
Appendix A: Schematic ..................................................................................................................... 26
Appendix B: Bill of Quantity (BOQ) ................................................................................................... 27

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Chapter 1 General Information

1.1 Introduction
Integrated Power System (IPS) is a High tech power solution specially designed for BTS Sites. It
incorporates all Power Protection and Management devices into a single cabinet. The one unit
solution is easy to install, efficient, cost effective and easily manageable.
IPS is state of the art power conditioning and monitoring platform for BTS sites. Power fluctuations,
phase failure, phase reversal are detected by the unit and immediately corrected to provide smooth
operation for the BTS site.
This single cabinet solution is composed of the following devices integrated together in a modular
form:
Generator Manager (GEM3)
Auto Mains Fail(AMF)
Power Measuring Module(PMM)

Over Voltage Isolator (OVI)

DC Tower Light (DCTLC)

IPS is specially designed to be installed at outdoor locations, and hence its cabinet is IP55 rated and
constructed with stainless steel, dual coated with epoxy based zinc additive and polyester based
powder paint, to ensure long life. Front mounted dual DC operated cooling fans provide forced cooling
to support high power applications and maintain tolerable temperature for sensitive ancillary electronic
equipment. The front and rear door are also equipped with locks for vandal protection. The equipment
is designed to cater for the safety of the user, equipment and the environment, which includes
compliance with IEC60950 Safety standard for telecom equipment.

1.2 Snap Shots

Front Door Open

Front View

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Rear Door Open

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Rear View

1.3 Product Features

IPS provides:
Digital (LCD) Metering of Input & Output Voltages, and Load Current
Extremely fast (<80mS) Over Voltage Isolator (OVI)
Under/Over voltage protection with instantaneous power cut-off
Over load protection (MCB)
Automatic Genset start and stop
Automatic Load Transfer to Mains/ Genset
Battery bank monitoring and management for efficient use of batteries and Genset, capable of
reducing Genset fuel consumption up to 50% or more (requires optional GEM3)

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1.4 Line Diagram

The basic functional overview and power flow of IPS is depicted in Figure 1 Integrated Power Solution
Line Diagram

Figure 1 Integrated Power Solution Line Diagram

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1.5 Physical Layout

Front View A (Front Door Closed)

A. Front Door 1

B. Front Door Lock

C. Vents

Front View B (Front Door 1 Open)

Front Door - 2

A. Output Power
Indicators
B. PMM Display

C. Auto Mains Fail(AMF)

D. ATS By Pass Selector
Switch
E. OVI By Pass Selector
Switch
F. Source Selector
Switch

Table 1 Front Door

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Front View C (Inside Front Door 1)

A. Document Pocket
B. Dual DC Operated
Cooling Fans

C. Air inlets with Air

filters

Front View D (Panel inside Door - 2)

A. GEM3 Module
B. DC-TLC
C. DC-DC Power Supply
UnitA
D. AC Distribution
BreakerS Terminal
Module
E. Power Measuring
Module(PMM)

F. AC-DC Power Supply

Unit

G. AMF Contactor

E
G
F

Table 2 Front View

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Rear View A

A. Hazard warning
B. Door Lock
C

C. Access to
Industrial Socket

Rear View B (Panel inside Rare Door)

A. Input MCB for

Mains power input
B. Genset Input
Terminals
C. AC Distribution
Terminal
D. DIN rail terminals
and Fuses

E
D

E. SPDs
F. Utility Socket

A
B

Table 3 Rear View

Note: For detailed view of front and rear side terminals placement, refer to Table 4 Detailed View

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Detailed View
GENSET BATTERY CHARGER AND AMF FUSES

DIN RAIL TERMINALS AND FUSES

BYPASS SELECTORS (Front View B)

ATS BYPASS (S3)

POWER SOURCE (S1)

OVI BYPASS (S1)

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GENSET INPUT TERMINALS

AC DISTRIBUTION

Table 4 Detailed View

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Chapter 2 Functional description

IPS can be functionally classified into 2 distinct categories, namely Power Management and
measurement and Generator Management. Details pertaining to each category are provided in
subsequent sections.

2.1 Power Measurement and Management

The Raw Mains input to IPS is first conditioned and controlled by Over Voltage Isolator. High voltage
surges are suppressed by Input Class B&C surge protectors. A bypass selector is provided to facilitate
on-site maintenance. Next, the Conditioned Mains and Genset Lines are fed to the ATS Panel, which
performs automatic load transfer between Conditioned Mains and Genset. Finally, the output of the
ATS is distributed via numerous breakers in the AC Distribution. PMM provides IPS output voltages
and load current measurement, along with energy and power consumption for performance analysis.

2.1.1 Over Voltage Isolator

Over Voltage Isolator is a protective device for AC system that
shuts down the output power in case of under or over voltage.
Its a Micro-controller based intelligent system that protects
against an accidental phase-neutral reversal, or neutral failure in
the incoming power lines by isolating complete power to the
equipment and automatically restores the power to the load
upon restoration of safe input voltage. It has the capability to
respond to input AC voltage variation within 3 to 4 cycles
(<80ms) and protects the equipment from chronic brownouts
and high voltages.

2.1.2 OVI Bypass

The bypass selector allows connection of ATS input to either
OVI output or the raw mains, to facilitate maintenance and
unexpected condition handling.

Over Voltage Isolator

2.1.3 Auto Mains Fail (AMF)

Auto Mains Fail (AMF) is a low price / high-efficiency
micro-controller device designed to operate the (Genset)
automatically. The primary function of AMF is to ensure
that load is powered up by either one of the power
sources, Mains OR Genset, Mains being the preferred
source and alert in case no source is available.
AMF performs multiple functions which includes efficient
power monitoring and control, Auto / Manual Emergency
Stop, AUTO Start / Stop and engine monitoring in a user
friendly environment, comprising of 128 x 64 Graphical
Liquid Crystal Display (LCD) with back-light and 8 x Push
Buttons for menu settings / navigation.
AMF incorporates the following key features:
Three Modes Of Operation
1) AUTO
2) MANUAL
3) STOP

AMF Module

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AUTO Mode: AMF monitors Mains voltages and controls the Genset Automatic Start and Stop and
Transfers load to the Generator in case of either single Phase, double Phase or total Mains Failure.
Unhealthy Mains voltages are also considered as Mains Fail (Under or Over Voltage).
MANUAL Mode: Facilitates manually generator start and stop, even if Mains is present.
STOP Mode: Used for emergency stop of the generator in both, MANUAL and AUTO modes.
Automatic Shutdown on fault condition
Once the generator is running, AMF monitors the internal protection and external faults inputs. The
external fault inputs are listed below.
1)
2)
3)
4)
5)

Low fuel
Low Oil Pressure
High Engine Temperature
Genset Over/Under Speed
Genset Over/Under Voltage

In case of any fault condition, the module shuts down the engine automatically and indicates the
source of failure on the GLCD, activating the ALARM LED.
AMF as an Automatic Load Transfer Switch (ATS)
The AMF automatically transfers the Load to Genset, in case of Mains failure and transfers the Load
back to Mains on Mains restoration. AMF performs this operation by controlling the MAINS and
GENSET contactor.
Configurable Timers and Alarms
AMF has a unique Timer and Alarm configuration mode. This feature enables AMF compatibility with
different types of engine controller, and allows it to cater to different BTS site conditions.

2.1.4 Bypass (AMF)

The two bypass selectors allow connection of Distribution input to either AMF output, mains, or
directly to genset. This facilitates on-site AMF maintenance, without hampering the power flow to the
IPS Load.

2.1.5 Power Measuring Module (PMM)

Power Measuring Module (SP305PMM) is a sophisticated
micro-controller based Energy Monitoring device. It takes
energy metering to a step further by introducing digital
power-measurement techniques that are not only limited
to monitoring Voltages and Currents but also Apparent
and Real Power, Power Factor and Energy.
PMM measures the following parameters:
RMS AC Voltage
PMM measures RMS AC voltage within the range of 0400V with an accuracy of 1%.
RMS AC Current
PMM measures RMS AC current within the range of 0100A with an accuracy of 1%.

PMM Module

Apparent Power, Real Power and Power Factor

PMM measures Apparent Power, Real Power and Power Factor within the range of 0- 20kVA, 030kW and 0-1 respectively with an accuracy of 2%.
Frequency and Energy
PMM measures the Frequency and Energy of the power source with an accuracy of 10% and 2%
respectively.

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2.2 Generator Management (GEM3)

Advanced Generator Manager (GEM3) is a micro-controller
based, add-on module to the existing conventional AMF/ATS
of standby Genset, used in the present telecom applications
such as BTS & BSC sites of wireless operators. GEM3
controls the Genset switching by enabling or disabling
(overriding Genset startup) the AMF on the basis of BTS
system battery voltage and temperature of the room. The
intelligence minimizes the Genset running hours, which leads
towards the saving of fuel and subsequent wear and tear of
Genset.
GEM3 has the following key features:
Genset Fuel Saving

GEM3 Module

GEM3 can monitor two battery banks of either 48V or 24V DC simultaneously. It disables Genset
auto-start and allows BTS load to run on the battery bank power, until the battery bank is discharged
to 30% of its total capacity, and starts Genset immediately afterwards.
GEM3 monitors the temperature of the BTS room as well, because during the Genset off period, airconditioners are off. If room temperature rises, (and the MAINS is still absent) GEM3 starts the
Genset so that air-conditioners can cool the room.
Genset Testing Capability in GEM3
GEM3 has Genset testing capability to ensure Gensets operational readiness so that alarm can be
sent to remote user in advance, in the case of malfunction. This reduces excessive downtime which
could result if battery is fully discharged.
In case of a mains failure, generator must first be tested for its operational readiness before GEM3
can resume its normal operation so that any malfunction in Genset can be reported in advance. But
constant start and stop of Genset on every mains fail can cause wear and tear of Genset. Hence,
GEM3 is designed to trigger a Genset Test after a pre determined interval after first instant of mains
failure.
GEM3 as Dual Genset Duty Cycle Controller
At Remote sites that do not have access to a mains supply, BTS load is run on two generators that
work in tandem with each other. Effective management of these internal combustion generators is a
tedious and expensive task. The GEM3 monitors and manages all parameters of these generators in
a robust, accurate and efficient manner.
Genset Failure Sensing
GEM3 intelligently deals with critical errors namely if one Genset fails (Low battery condition persists
for 5 minutes despite of enabling Genset). In such case, GEM3 passes control to next Genset, and
escalates a Genset Fail Alarm. Second generator handles the load extensively stopping only for the
minimum rest time and during its rest time, BTS load is shifted to battery bank. In case battery levels
also drop low, the GEM3 automatically shifts whole BTS load on to the generator, halting its rest time.

2.3 DC Tower Light (TLC)

DC Tower light controller (TLC) is a module designed to control
the tower light. A light detector mounted with the tower light
enables the system to differentiate between day and night.
This signal is used to switch the tower light on at night and
blink during day time.

DCTLC

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Chapter 3 Operation and Configuration

3.1 Operation
3.1.1 Turning-on IPS
Instruction

Snapshot
MAINS

Switch On the Mains Breaker

located at the Rear side of IPS
(Refer Table 3 Marker A)

OVI BY PASS
MAINS

OFF

OVI

Move OVI Bypass Selector Switch to

OVI(Refer Table 1 Marker E)

POWER SOURCE
GENSET

OFF

MAINS

Move POWER SOURCE Selector

Switch to MAINS(Refer Table 1
Marker F)

ATS BYPASS
MANUAL

Move ATS BYPASS to AUTO(Refer

Table 1 Marker D)

Table 5 Turning on IPS

OFF

AUTO

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3.1.2 Emergency Stop

Instruction

Snapshot
ATS BYPASS
MANUAL

OFF

AUTO

Move ATS BYPASS to OFF(Refer

Table 1 Marker D)

POWER SOURCE
GENSET

OFF

MAINS

Move POWER SOURCE Selector

Switch to OFF(Refer Table 1 Marker
F)

OVI BY PASS
MAINS

OFF

Move System Bypass Selector to Zero

Position i.e. disconnecting the
Load(Refer Table 1 Marker E)

MAINS

Turn off the MAINS MCB located at

the Rear Side(Refer Table 3 Marker A)

Table 6 Emergency Stop

OVI

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3.1.3 LCD Displays

The real time data pertaining to IPS operations is displayed over different LCDs within IPS. Detailed
information regarding data enquiry of different parameters related to IPS is provided in Table 7 Data
Query.
Parameter

Instruction

Snapshot

PMM LCD

Load Status Summary

Default PMM screen

1
2
3

P1
49.5 Hz
kW
00.5
0.000005kVA
00000000kWh

P2
49.5 Hz
kW
00.5
0.000005kVA
00000000kWh

P3
49.5 Hz
kW
00.5
0.000005kVA
00000000kWh

227
002.4

Phase ONE Load Status

pf

0.89

Phase Two Load Status

Press the RIGHT OR LEFT key to view

these screens

227
002.4

pf

0.89

227
002.4

Phase Three Load Status

pf

0.89
AMF LCD

Load Connected to
MAINS

Transfer of Load between

MAINS and GENSET

Load Connected to
GENSET

Default AMF screen

228
02.4
v
v
228
02.4
v
v
228
02.4
000000000KWh

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GEM3 LCD
If Single battery is connected

B1:51.0V 22.1C

Rectifier Battery 1 Voltage

AMF DS
B1:Lo Hi
Rectifier Battery 2 Voltage
Default GEM3 screen (Press Cancel key
to activate default screen if its not
visible)
Ambient temperature

AMF DS
If two batteries are connected

B1:51.0V 22.1C
B2:53.5V AMF DS
B1:Hi Hi

AMF Status
EN=Enable; DS=Disable

B2:Lo AMF DS

Battery and Genset status

summary
[ - ] : Discharging
[ + ] : Charging
[ X ] : Disabled
[ E ] : Enabled
[ 1 ] : Running
[ 1 ] : Stopped

BT1 BT2 GN1 GN2

[+] [+] [0] [0]
Press the DOWN key on default
screen

Rectifier Battery 1 current

Press the DOWN key twice on default

screen

B1 CURRENT
0150.0 A

Press the DOWN key thrice on default

screen

T2 16.2C

T2 Temperature

DG Battery Current

Press the DOWN key four times on

default screen

B3
00.2V

Table 7 Data Query

BT1
[+]

BT2
[+]

GN1
[0]

GN2
[0]

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Other advanced parameters that can be monitored via GEM3 LCD are described along with their
definitions in Table 8 Advanced GEM3 Parameters

Parameter

Description

Battery 1 cycles

Total charging cycles of Battery 1

Battery 1 low count

Battery 1 shift time
Battery 1 total time

The number of times battery 1 is drained to low threshold

value
Time for which the BTS(load) has been shifted on battery
(HH:MM Format)
Total Time for which battery 1 supply power to the load with
AMF Disabled

Battery 1 last charging

Battery 1 voltage prior to most recent charging

Over-temperature count

The number of times ambient temperature crossed high

threshold value of temperature

Table 8 Advanced GEM3 Parameters

Note: All parameters mentioned in Table 8 for battery 1 are also available for battery 2

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3.2 Configuration
To configure the parameters indicated below, refer to instructions provided in Table 10 AMF
Configuration Procedure.
Parameter

Definition

REM Start
REM Stop

It allows the user to Enable/Disable Remote Start Function

It allows the user to Enable/Disable Remote Stop Function
It determines the type of signal(Hi/Low) being generated by the
Sensors for Monitoring Genset Temperature, Genset Oil and
Genset Fuel
Displays total Running Hours for the Genset
Displays Last / Current Running hours of the Genset
It determines how long the Genset has been kept off when Mains
was absent
Five Different Alarms can be activated. On the basis of the
occurrence of any activated Alarm Gensets operation will be
hindered until the fault condition is restored to normal condition
Time to Pre-Heat the fuel before starting the Genset
Time of Crank to the Genset
Time for Genset to warm-up before taking the load
Time for Genset to keep on running after the load has been
shifted
The time for Genset to stop after the Low Fuel Alarm has been
generated
Time to tolerate Overvoltage(Genset)
Time to tolerate Under Voltage(Genset)
Time to tolerate Overvoltage(Mains)

Hi TEMP,LO OIL ,LO FUEL

Life Count
Shift Time
Stop Life
Over Speed, Under Speed, Start
Fail, Emergency Stop, Low
Battery
Pre Heat
Start
Warm Up
Cooling
Low Fuel
Over Volts(Genset)
UnderVolts(Genset)
Over Volts(Mains)
UnderVolts(Mains)
Genset
Battery
Frequency
Under Voltage(Genset)
Over Voltage(Genset)
Critical Phase(Mains)

Time to tolerate Under Voltage(Mains)

Output Voltage of the Genset acceptable to the Load
Genset Battery Output Voltage acceptable for Genset operation
Genset Output Frequency that is acceptable to the Load
It is the Minimum Voltage generated by the Genset that is
acceptable to the Load
It is the Maximum Voltage generated by the Genset that is
acceptable to the Load.
The phase whose absence will cause the AMF to switch load from
MAINS to Genset is called Critical Phase. One, Two ,Three Phase
can be configured as Critical Phase

Table 9 AMF Configurable Parameters

Instructions
Press the DOWNWARD Key (AMF will go to SYSTEM
CONFIG MENU)
Press ENTER Key to configure value
Use LEFT and RIGHT Key to change the
parameter value
Use UP and DOWN Key to chose another
parameter
Press SAVE Key to save and exit
Table 10 AMF Configuration Procedure

AMF LCD Display

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To configure the parameters indicated below, refer to instructions provided in Table 12 GEM3
Configuration Procedure
Parameters

Definition

Base voltage B1
Gensets Mode
settings

Voltage of Battery 1 string (24V/48V)

Mode 1: Single Genset
Mode 2: Dual Genset
Battery 1 Low and High voltage thresholds configuration which are used to
decide battery health
Battery 2 Low and High voltage thresholds configuration which are used to
decide battery health
[EN] / [DS] : Enable/Disable temperature based action of GEM3
If Enabled, set the High and low temperature thresholds
B3 [EN] / [DS] : Enable/Disable Battery 3 monitoring
T2 [EN] / [DS] : Enable/Disable Temperature 2 monitoring
Time for which AMF is kept enabled after the restoration of battery voltage or
temperature. Both parameters are separately enabled/disabled and configured

Battery 1 settings
Battery 2 settings
Temperature
settings
Optional Settings
Extended Runtime settings
Battery Calibration
settings
Temperature
Calibration
CT Zero Adjust
CT Range
CT Zero current
Limit
Reset B1/B2
Factory reset

Allows calibration of battery 1 or 2 or 3 voltages

Allows calibration of temperature sensor 1 or 2
Used to calibrate DC CT at the time of calibration
Maximum current that needs to be measured using DC CT
Current that is considered insignificant for the decision of charging/discharging
state
Reset all counters related to Battery 1 or 2
Restores default factory settings of all parameters

Table 11 GEM3 Configurable Parameters

Instructions

GEM3 LCD Display

Press ENTER on GEM3 Module

(GEM3 will go to the setting mode)

SETTING MODE

Use arrow keys to Change value

Press Enter to select next digit
(Enter the Password)

SETTING MODE

PSWD: [0]0 0 0

Access Granted

Use arrow keys to select the parameter that needs

configuration (e.g. Base voltage)

BASE VOLTAGE

Press Enter
Use Up or Down keys to change configuration

BASE VOLTAGE

Press Enter to save and exit

Table 12 GEM3 Configuration Procedure

B1

[48V]

BASE VOLTAGE
[ENTER] to Save

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3.3 Alarms
Alarm/Indicator

Description

AMF Module
Power
Available
MAINS
On Load
Available
Genset
On Load
Auto
Alarm

On : AMF is powered up
Off : AMF is not powered
On : MAINS is present
Off : MAINS is absent
On : Load on MAINS
Off : Load not on MAINS
On : Genset is running
Off : Genset is not running
On : Load on GENSET
Off : Load not on GENSET
On : AMF in AUTO MODE
Off : AMF in MANUAL MODE
On : In case of fault condition
Off : Normal behavior

GEM Module
Power LED
Active LED
Alarm LED

On : GEM is powered up
Off : GEM is not powered
On : Site is powered by battery bank
(AMF Disabled
On : Alarming condition(GEM Critical
alarm)

DCTLC
Power
Lamp Fail
Sensor Fail

On: DCTLC is on
Off: DCTLC is off
On: Tower Light is not working
Off: Normal Behavior
On: Solar sensor is not working
Off: Normal Behavior

External Alarms for NOC

GEM Active
GEM Critical
GEM Fail
AMF Low Fuel Out
AMF Genset Fail
ATS Mains Fail
ATS Genset Running
Table 13 IPS Alarms/Indicators

Site is powered by battery bank

Battery bank voltage is below
threshold and GENSET failed to start
in predefined time
GEM Failure
Genset Fuel is Low
Genset has Failed to Start
Mains has Failed
Genset is running

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3.4 References
For further details on operations and configuration of different modules of IPS, refer to the following
manuals:
Doc# DS142 : GEM3 User Manual
Doc# DS205 : AMF User Manual
Doc# DS150 : PMM User Manual

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Chapter 4 Technical Datasheet

315IPS-ODU
Utility Input Phases Supply

3+N

Utility Input Phases Utilized

3+N

Power Rating
Input Voltage Range
Input Current
Input Over Current Protection
Surge Protection
OVI (Independent for Each Phase)
Rotary OVI Bypass Switch: Mains OVI
Rotary ATS Bypass Switch: Auto - Manual
- Source Selector Switch (G-M) when ATS Manual
AMF + Automatic Transfer Switch
- Number of Gensets Direct Control
Mobile Genset Support (Manual Selector + Socket)
AC DISTRIBUTION (ACDB)
BTS/ Rectifier MCBs
Spare MCBs
SP MCBs for Guard Light
ELCB for Utility socket
OTHER FEATURES
Power Measurement Module (For IPS Load)
DC Tower Light Controller (48VDC)
Genset Battery Charger (SMPS)
BTS Battery - Genset Cycling controller (GEM3)
MECHANICAL / ENVIRONMENT
Dimensions (Outdoor Cabinet)
Weight (Net, Estimated)
Ingress Protection
Cooling System
Operating Temperature / Relative Humidity

15KVA
175-255 VAC
18A per phase
Yes (MCB)
Class C
3
Yes
Yes
Yes
Yes ( Single Genset + Mains)
1
Yes

Cabinet Construction

SAFETY
Designed to IEC60950 Electrical Safety Standard

25A TP x 2
6A SP x 2; 25A TP x 1
6A SP x 1
25A DP 30mA; 6A SP x 1
Yes
Yes
Yes
Yes
1579H x 735W x 562D
125kg
IP55
DC Fan Cooled
0 to 55C, 10 to 90 %RH
iioMS CRC Sheet, thickness: Main Pillars 2 mm,
Side angles 1.6mm, Wall 1.2mm, C-channel
base 4mm. Dual Coated (Undercoat: Epoxy
based Zinc additive, Overcoat: Polyester based
Powder paint RAL7035)
Yes

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Chapter 5 Warranty
The Integrated Power System is warranted free from defects in materials and workmanship for period
specified at sale, starting on receipt. This warranty is limited to repairing or replacing, at companys
option, any defective component, circuit board, or module contained within the product only when it is
returned to company or to a company-designated repair facility. In all cases, the customer is
responsible for shipping charges to and from company or the company-designated repair facility.

Limitations of Warranty
This limited warranty does not cover any losses or damage resulting from shipment to or from the
customer, or from improper installation, inappropriate environment, abuse, modifications, adjustments,
or unauthorized repair.

Life Support Policy

As a general policy, company does not recommend the use of any of its products in life support
applications where failure or malfunction of the company product can be reasonably expected to
cause failure of the life support device or to significantly affect its safety or effectiveness. Company
does not recommend the use of any of its products in direct patient care. Company will not knowingly
sell its products for use in such applications unless it receives in writing assurances satisfactory to
company that (a) the risks of injury or damage have been minimized, (b) the customer assumes all
such risks, and (c) the liability of company is adequately protected under the circumstances.

GEN.BATT.POS
GEN.BATT. NEG

76
74

Wire f lexible 4mm sq(Y ellow)

Wire f lexible 6mm sq(Black)

Batt. Pos
Batt. Neg

74 4

76 3

15

14

13

F10

F9

F8

102 94

101

101 94

2 23

1 24

21

16

17

17

20

18

12

23

19

MAINS INTAKE

L3

L2

MCB4
20A SP

MCB2 MCB3
32A SP 32A SP

11

12

page 2/4

11

F5

.
99

TB8
99

94

11

12

TB67

COM

94

25

25

29

CLASS C N
SPD(Class C)
SPD3
CLASS C N
SPD(Class C)

SPD1

31

(X0)

28

28

L3

27

30

L2

26

27

26

STANDBY GENSET

L1

CLASS C N
SPD(Class C)
SPD2

23

22

10

OVI
BYPASS
TO
MAINS

21

page 3/4

AMF/ATS

20

MCB
63A 4P

19

10

10

100 94

18

3 PHASE OVI

22

100 94

GF COM M.F COM

BATTERY CHARGER -12VDC

GND

VDC+

PSU1

102 94

16

L1

MCB1
32A SP

S1
32A 1-0-2 /4P

FUEL SOLENOID

CRANK SOLENOID

LOW OIL PRESSURE

HIGH ENGINE TEMPERATURE

LOW FUEL IN

REMOTE START NO
COM

Green Y ellow Red

I3
I2
I1

Wire f lexible 6mm sq(Black)

Wire f lexible 4mm sq(Blue)

Wire f lexible 4mm sq(Y ellow)

Wire f lexible 4mm sq(Red)

108

107

106

105

104

97
103

104 103 97

Wire f lexible 4mm sq(Red)

76

TB68

FUEL SOLENOID

TB31

CRANK

TB29

TB40

LOW OIL PRESSURE

TB30

LOW FUEL IN

HIGH ENGINE TEMPERATURE

Wire f lexible 4mm sq(Blue)

BATT. NEG

1.5mm sq wire flexible

74

BATT. POS

2.5mm sq wire flexible

TB1

TB2

COM

.
TB17
L1 Gen1

LFO COM G.R

32

12VDC
B
A
GND

27

13

36

35

34

33

MCB11
6A SP

S2
32A 1-0-2 /4P
MAINS OR GENSET
SELECTOR

28

23
14
15
16

10
11
12

22

26

6
7
8

2
3
4

21

25

20

46

RCCB 1

MCB10
6A SP

MANUAL

AUTO

36

32

35

31

34

30

SECURITY
LIGHT

48

25A DP 30mA

90

29
33

13

47

98

88

48

89

6A SP

UTILITY
SOCKET

MCB9
6A SP

From Rectifier
Battery

Pow er Input

-48V

91

GND

78

L2
R1

S2

42

L3
T3

43

96

47

87

48

48V DC LAMP

10

48

47

46

45

93

MCB7

45

84

84

85

46

47

79

78

L2

L3

Tow er Light
Fail OR
Sensor Fail

TL NO TL COM

49
50
51
48

L1

L2

Cabinet 1

L3

CT1

45

53
54
55
56
57
58

CT2

46

47

82

L3
81

L2

CT3

80

25A 3P L1

MCB6

48

PMM.CT1+
PMM.CT1PMM.CT2+
PMM.CT2PMM.CT3+
PMM.CT3-

F2 F3 F4

77

25A 3P L1

85

PMM.V1_sense
PMM.V2_sense
PMM.V3_sense
PMM.N_sense

MAINS DISTRIBUTION(X1)

SPARE

86

48

DC TLC (X6)

46

78

TL +

POWER OUTPUT

TL -

12

44

S4
32A 1-0-2 /4P
POWER BYPASS
TO MOBILE GENSET

9
11

43
40

6
8

38
42

41

39

37

DC
POWER
INPUT
SENSOR
NC
FAIL
COM
ALARM NO
NC
TL
COM
FAIL
NO
ALARM
TOWER
LIGHT
OUTPUT

1SUNLIGHT
2
3 SENSOR

DTLC1

48

MCB8
6A SP

SUNLIGHT
SENSOR

SENSE NEG

SPARE

52

52

90

E10mm

6mm

44

INDUSTRIAL SOCKET1
32A 5POLE (IP67)

6mm

41

NEU

MOBILE GENSET INPUT

40

39

38

37

MCB13

S3
32A 1-0-2 /4P
ATS BYPASS

14
15
16

10
11
12

6
7
8

2
3
4

K1

.
K2

F1 FS CS LOP HET LFI COM NO

2
1

.
K1

.
K2

L1

L2

Cabinet 2

L3

46

47

85

L3
84

L2
83

25A 3P L1

MCB5

48

45

L1

L2

L3

Cabinet Spare

48

TB69

24V

T2

GEM ACT

CRITICAL

75

74

AMF 2

RS485

AMF 1

Mains Fail

67

GEM FAIL

GEM3

CT In

66

A
B

IGLCD

PMM

V SENSE

IGLCD
RJ45

COM

POWER IN

PMM
I SENSE

TS1

FANS

N24V

Louver 1

24V
GND

FAN1

TX
RX

PWR
GND

PWR
GND
TX
RX

RS485 A
RS485 B

2A
2A

F11

Note:
Net color coding:
1 = L1 = Red
2 = L2 = Yellow
3 = L3 = Blue
4 = N = Black

2A

F7
F8,9,10

2A

59

N24V

P24V

GEM3.AMF.NO

F6

F12,13,14

2A

Description

SENSING LINE1,2,3AMF
Not Used

109

110

Note:
All Terminal Blocks Are 2.5mm sq Unless Specified
All AC Power Wiring (L1, L2, L3) Is Done With
4mm sq Flexible Wire while Nuetral Wiring Is Done With
6mm sq Flexible Wire, Unless Specified

GENSET LINE1 AMF

INDICATOR LAMPS

RECTIFIER BAT2.NEG

PSU1 LINE

2A
F5

30A

Rating

FUSE TABLE
Description

BATT.POS
SENSING LINE1,2,3 PMM

Rating

F1

Ref .

FTABLE2

FUSE TABLE
Ref .

FTABLE1

F2,F3,F4

FAN2

73

GEM3.AMF.COM

60

ACTIVE

71

111
72

COM NO

(X7)

CRITICAL

GEM3 ALARMS

COM NO

GEM
FAIL

COM NO

CHANGES: R3B1
BAT2 Terminals Removed (X5)
EXT. TEMP Terminals Removed (X8)
MCB12 Current Rating Corrected
Terminal Added in DC TLC Section
Terminal Block References Updated

NOTE:
24VDC 120mm
Front Door Fan

Thermal SW 45deg C

P24V

GRAPHICAL LCD

+
+
+
-

CHANGES: R3B2

V1
V2
V3
N

CT1
CT1
CT2
CT2
CT3
CT3

LOAD METERING

T1

PWR OUT

65

GND

CS

CT IN
(X5)

RCCB Removed
MCB SP 32A
MCCB 4P 60A
Output Neutral Bar Changed To Earth Bar
Distribution MCB SP Rating Changed To 6A
AMF Control Terminals Reposition

GND

62

PWR

CHANGES: R3B3

DC48-DC24

-48V

SP48D24

GND

49
50
51
48

53
54
55
56
57
58

GEM3

61

GEM3
External CT

GEM Fail Alarm Added

N48V

P48V

62

PMM.CT1+
PMM.CT1PMM.CT2+
PMM.CT2PMM.CT3+
PMM.CT3-

61

GND

(X2)

PMM.V1_sense
PMM.V2_sense
PMM.V3_sense
PMM.N_sense

MCB12
6A SP
For Internal temperature
(Inside Cabinet)

N48V

P48V

-V

BAT1
Rectifier
Battery

.
.

-V

2
1

Charger GND
Charger 12V

TB3

REMOTE START NO

2
1

0.5mm Wire Flexible (White)

L1out

L1in

Wire flexible 4mm sq(Red)

.
TB20

.
TB25

TB11

COM

COM

TB34

TB4

LOW FUEL OUT

LOW FUEL OUT

2
3
4

6
7
8

L2out

L2in

Wire flexible 4mm sq(Yellow)

TB42

TB5

L3in

Wire flexible 4mm sq(Blue)

TB39

TB18

COM

COM
COM

TB7

MAINS FAIL

MAINS FAIL

L1 Mains

TB6

L3 Mains

GENSET RUNNING

GENSET RUNNING

N Mains

COM

COM

L3

TB33

POWER WIRING DIAGRAM 315IPS-ODU

.
K2

COM

10
11
12

L3out

TB22

GENSET FAILURE

GENSET Fail NO

Nout

Nin

Wire flexible 6mm sq(Black)

L2 Gen1

L1
L3 Gen1

TB36
.

TB37

N Gen1

13

16mm sq Din Rail

Terminals

NEU
BAR

TB9

L2
TB38
.

TB35
.

To Other
Modules

14
15
16

2
.
.
1
2

0V

L2 Mains

EARTH
BAR

3
.

-48V

Bat 1 Bat 1 +
+V

TB24

TB56

GENSET ALARMS (X3)

4mm sq Din Rail Terminals

.
.
TB41
.

TB60
.

.
.
1

.
4
.

TB14

2
.
.

-V
TB12

.
1
TB16
.

TB10
.

0V

TB13

L1
.
.
TB55
.

.
.

.
TB61
.

TB63
.

TB43

.
TB62
.

TB15
.

.
.
.

Bat 2 +
Bat 2 GND

Bat 3 Bat 3 +
SIG
+5V

TB23
NO
COM

+5V
SIG
GND
NC
COM

+5V
CS
GND
NO
COM

COM
MF
NO
COM
NC

.
.

CAT5 Cable

NO
COM
NC
1
FAN
2

16mm sq Din Rail Terminals

.
.
.

TB44
.

TB45
.

TB47
.

TB51

K1
.
TB46

.
.

.
.
.

.
.

.
.
TB48
.

TB50
.

TB49
.

.
.
.

TB52
.

TB54
.

TB53
.

1
FAN
2

.
TB32

GENSET CONTROL (X4)

SalTec Powerlink
Page 26 of 28
DS210R00
th
Sep 6 , 2012

Chapter 6 Appendix
Appendix A: Schematic

EARTH BAR

SalTec Powerlink
Page 27 of 28

DS210R00
th
Sep 6 , 2012

Appendix B: Bill of Quantity (BOQ)

Item Code

Sub-Assemblies/Accessories

Qty per IPS

Brand

Power Intake
ABB / Schneider/LS or
equiv.
ABB / Schneider/LS or
equiv.

1601-004

MCB SP 20A; 6kA

1604-001

MCB 63A 4P C Curve

2001-005

VAL - MS 400ST (Valuetrab Surge Arrestor Class C)

Phoenix Contact

2050-001

VAL - MS BE (Valutrab Base Element)

Phoenix Contact

2050-002

MPB 18/1 - 4 (Trabtech Wiring Bridge)

Phoenix Contact

2715-014

Panel Indicator LED Light Red

Klemsan

2715-015

Panel Indicator LED Light Yellow

Klemsan

2715-016

Panel Indicator LED Light Green

Klemsan

OVI (3 )
1601-006

MCB SP 32A; 6kA

ABB / Schneider/LS or
equiv.

9501-096

OVI, Over Voltage Isolator Module (SP110OVI)

SalTec Powerlink

2901-001

Changeover Switch 4 Pole 32A 1-0-2

Bretter or equiv

AMF / ATS
9403-006

AMF, Auto Mains Fail Module (SP205AMF)

SalTec Powerlink

2902-003

Magnetic Contactor 4-P 11kW 230Vac; 12A AC3, 25A AC1

ABB / Schneider/LS or
equiv.

2901-001

Changeover Switch 4 Pole 32A 1-0-2

Bretter or equiv

1508-010

Din Rail Terminal 16mm Blue AVK16

Klemsan

1508-011

Din Rail Terminal 16mm Grey AVK16

Klemsan

1508-012

Din Rail Terminal 16mm Red AVK16

Klemsan

1508-013

Din Rail Terminal 16mm Yellow AVK16

Klemsan

9721-002

Genset Battery Charger 12V (SP072SMPS)

Saltec Powerlink

Mobile Genset
1509-011

Industrial Plug & Socket Set 63A 5P IP67

China

2901-001

Changeover Switch 4 Pole 32A 1-0-2

Bretter or equiv

PDB
2805-005

Current Transformer WJ706 20 (100)A/8(40)mA, Class 0.1, 2500:1

Wanjia

1508-001

Din Rail Terminal 2.5mm Blue AVK2.5

Klemsan

1508-003

Din Rail Terminal 2.5mm Grey AVK2.5

24

Klemsan

1508-004

Din Rail Terminal 2.5mm Red AVK2.5

Klemsan

1508-007

Din Rail Terminal 4mm Red AVK4

Klemsan

1508-008

Din Rail Terminal 4mm Grey AVK4

Klemsan

1508-010

Din Rail Terminal 16mm Blue AVK16

Klemsan

1508-011

Din Rail Terminal 16mm Grey AVK16

Klemsan

1508-012

Din Rail Terminal 16mm Red AVK16

Klemsan

1508-013

Din Rail Terminal 16mm Yellow AVK16

Klemsan

1601-001

MCB SP 6A; 6kA

1603-002

MCB TP 25A; 6kA (for BTS / Rectifier)

1605-001

RCCB DP 25A 30mA (for Utility Socket)

9719-004

PMM, Power Measuring Module (SP305PMM)

ABB / Schneider/LS or
equiv.
ABB / Schneider/LS or
equiv.
ABB / Schneider/LS or
equiv.
SalTec Powerlink

SalTec Powerlink
Page 28 of 28
9403-003

DS210R00
th
Sep 6 , 2012

DC to DC Converter (48V to 24 V) (SP048DTD)

SalTec Powerlink

SalTec Powerlink

Saltec Powerlink

Tower Light (AWL) Section

9402-006

48VDC Tower Light Controller (with sun sensor)

On-Grid Hybrid Controller

9715-003

GEM3 (SP603) with DC-CT

1420-004

OUTDOOR Cabinet IP55

Saltec Powerlink

9521-177

Fan Assembly (Dual Fans, 24VDC)

Saltec Powerlink

IPS Cabinet