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INNEXIV
INNEXIV Remote Monitoring System (RMS) Training Manual
Version 1.0 - DRAFT
11-N0v- 2013
Azeem Taj
Direct:
E-mail:
+92(03458569320)
azeem.taj@innexiv.com
Version
1.0
Date
Author
Approvals required
11-Nov-2013
Azeem Taj
Karim Ullah
CONTENTS
Site Layout
Core Components
Main Modules diagrams and connection diagrams
Sensors Used
List of required Material
Connections and routing and procedure
Generator
Main Power AC
Fuel Tank
Battery Cabinet
CONTENTS
Site Layout
Core Components
Main Modules diagrams and connection diagrams
Sensors Used
List of required Material
Connections and routing and procedure
Battery Bank
Rectifier
ATS External
Fuel Tank
ATS Internal
Generator
Main DB
CONTENTS
Site Layout
Core Components
Main Modules diagrams and connection diagrams
Sensors Used
List of required Material
Connections and routing and procedure
MCU
LL
1 2 3 4
E
1 2 3 4
F
1 2
M
1 2 3 4
1 2
1 2 3
N
1 2 3 4 5 6
I
1 2 3
O
1 2 3
1 2 3 1 2 3
P
1 2
S,2
S,3
S,4
S,5
Q
Q,1
Q,2
Q,3
Q,4
R
Q,5
Q,6
R,1
DC 12 V Ground
+VE
AC CT 1 AC CT 1 AC CT 2 AC CT 1 AC CT 3 AC CT 1
+ ve
+ ve
+ ve
- ve
- ve
- ve
White
White Black
Black
Black White
wire
wire
wire
wire
wire
wire
LL
LL
LL,1
LL
LL,2
LL
LL,3
LL
LL,4
M,1
E
E,1
L,1
220 V
E,2
F
E,3
E,4
L,2
L,3 Negative
220 V 220 V
R,2
F,1
DC 12
+VE
M,2
M,3
Ground
CP
Status
G
F,2
G,1
N
M,4
G,2
DC 12 V Ground DC 12 V Ground
+VE
+VE
H,1
Delay
Gen
SIGNAL
H,2
N,1
N,2
N,1
N,3
N,1
N,4
GBV
12V
+Ve
GBV
12V
- Ve
Spare
GEN
Status
N,1
N,5
N,1
N,6
Feed
back
Delay
GEN
Relay
Feed DC CT 12
back
+VE
AC
CUT
Relay
I
H,3
I,1
AC CUT
Signal
I,2
R,4
R,5
5v
TX
RX
N,1
N,1
R,3
O,1
O,2
P
O,3
P,1
Ground DC CT
Signal
J
I,3
J,1
J,2
9 Number 9 Number
Right
Left
Low fuel
P,2
DC 48V DC 48V
-Ve
+Ve
K
J,3
K,1
K,2
10 Number 10 Number
right
Left
ACP
K,3
X
T
1
V
1 2 3
U,1
U,2
U,3
A
1 2
1 2
C
5 6
1 2
1 2
Delay gen
cut relay
A-1
A-2
A-3 A-4
Feed
Back
Two
Feed
Back
One
B-1
B-2
B-3
B-4 B-5
B-6
RTU
Battery
- ve
RTU
Battery
+ve
Gen Status
Relay
220
AC CUT
Relay
AC Cut
IN
AC CUT
OUT
C-1
C-2
Gen
Status
CP
STATUS
CP Status
Relay
220
C-3
C-4
D-1 D-2
AC Cut
Signal
Delay Gen
Signal
D-3
N
-VE 220
D-4
N
-VE 220
220 +ve
220 +ve
CP MC
GEN MC
Energizing Energizing
point
point
CONTENTS
Site Layout
Core Components
Main Modules diagrams and connection diagrams
Sensors Used
List of required Material
Connections and routing and procedure
Sensors
AC CT Coil Sensor
DC CT Coil Sensor
Fuel Sensor
CONTENTS
Site Layout
Core Components
Main Modules diagrams and connection diagrams
Sensors Used
List of required Material
Connections and routing and procedure
(1/3)
6 Core Cable
4Core Cable
Cat 6Cable
PVC Box
(2/3)
GI Spiral
Saddle Clamp
Din rill
Connecting strip
Lugs
Jubilee clamp
(3/3)
Insolation Tape
Silicon
Rawal Plug
CONTENTS
Site Layout
Core Components
Main Modules diagrams and connection diagrams
Sensors Used
List of required Material
Connections and routing and procedure
12
1
2
C
O
R
E
1
11
2
10
3
C
A
B
L
E
1
9
4
8
5
7
1
11
2
10
3
9
8
7
1
2
C
O
R
E
C
A
B
L
E
Y
2
4
6
8
10
12
11
11
2
4
6
8
10
12 core cable
12 core cable
Installation Process
Before installation Process
1. Call Guard when reached on site
2. Call Innexiv NOC when reached on site
3. Call TP NOC for Access
4. Check Site status before installation (CP availability , Gen working Properly , ATS and MDB)
5. Select Place for MCU Mounting
Installation Process
1.
Power Up MCU
2.
3.
4.
5.
6.
DDF Connection
7.
NOC Testing
Mount RTU
Required H/W
MCU
GPRS
MCU Box
MCU Battery
IRM
Jubilee clamp
Glands
Process
Fix jubilee Clamp under the Din rail and tight din rail Screw
Required IRM
Din rill
Jubilee Clamp (3in)
Screw & nut
Process
Powering up MCU
Required IRM
Process
Connection from
BATTERY BANK to
DC-PSU
POSITIVE
Connected to
Wire type
Notes
DC-PSU: DC+
RED Single Core
X - 12
POSITIVE
DC-PSU to
BAM
POSITIVE
12VDC (Output)
W-1
Black Single Core
Y-1
RED Single Core
Y-2
Black Single Core
Twist wire White Orange /Orange (Cat 6 cable) Connect one end of cable Connecting pad y
Port y1
Twist wire white Green /Blue (Cat 6 cable) Connect one end of cable Connecting pad y Port
y2
Twist wire White Orange /Orange (cat 6 cable) Connect other end of cable Connecting pad R
Port R1
Twist wire r white Green /Blue (Cat 6 cable) Connect other end of cable Connecting pad R
Port R2
Now check MCU status if its ok Call to INNEXIV NOC and bind the RTU
Required IRM
Process
Route the 12 Core cable from BAM to both sides of the batteries separately (one from right and
one from left) as per wire numbering but do not connect the wires with battery terminal
Fix 23 lugs on each individual wire of 12 core cable on battery terminal side
Start connection lugs and wires on the Positive terminal side of batteries but do not connect top
right battery i.e. connect only 23 batteries but not the 24th. Dont connect Positive terminal of
batteries at this stage.
Connect one side of 0.5mm cable with DC positive terminal of DC (PSU) and the other side of
cable with intentionally left last port of right sided X connecting pad (X12) of BAM
First remove left sided 13 port connecting pad W from BAM and connect 12 core cable wire
from 2nd port to 13th Port (Leave 1st port) of W connecting pad top to down with positive
terminal wire.
Then remove the right sided 12 port connecting pad X from BAM and connect the positive
terminal 12 core cable with the connecting pad X in sequence but leave the last bottom 12th port
empty.
Now connect 1.5MM cable with negative terminal of 1st battery and connect the other end with
DC PSU negative terminal i.e. 3rd port.
Now connect another 1.5 MM cable with intentionally left top right battery of BAM with its
Positive terminal and connect the other end of the cable with the 2nd # positive terminal of DC
(PSU).
Now Connect one side of 0.5mm cable with DC negative terminal of DC (PSU) and the other
side of the cable with the intentionally left first port of left sided W connecting pad of BAM
(W1).
Process
1. We have already used White orange/Orange and White Green Blue Numbers wires for
power up to MCU (PAGE # 4)
2. Connect White Blue wire with connecting pad Y3 of BAM and the other end with connecting
pad R3 of RTU (MCU).
3. Connect Green wire with connecting pad Y4 of BAM and the other end with connecting pad
R4 of RTU (MCU).
4. Connect white Brown with connecting pad Y5 of BAM and the other end with connecting pad
R5 of RTU (MCU).
1
2
3
4
5
6
7
B
O
B
A
O
R
A
D
R
D
T
O
C
O
N
N
E
S
C
T
I
O
N
8
9
DC CT
10
CAT 6
Color Reference
BAM
Signal
Routing
Description / Type
MCU
Number of
wires
POSITIVE 12VDC
Y-1
GROUND
Y-2
white orange
/orange
white green /blue
BAM Feedback
Y-3
white blue
Transmit signal
Y-4
green
R-4
Receive signal
Y-5
white Brown
R-5
-
48VDC - TBV
W-1
X - 12
Brown
white orange
/orange
white green /blue
DC CT 'POSITIVE
white blue
DC CT 'GROUND
Green
O-2
white
brown/Brown
O-3
Notes
Spare
POSITIVE
DC CT Signal
POSITIVE
Color
Connection from
Connected to
Wire type
DC-PSU: DC+
DC-PSU: DC-
X - 12
W-1
Y-1
Y-2
POSITIVE
(Input)
12VDC (Output)
NEGATIVE 12VDC (Output)
POSITIVE
Cable
number
R-3
P-1
P-2
2
O-1
Signal Routing
Description / Type
BAM
Connector Pad & Port Reference
Cable Type
IMPORTANT
NOTES
POSITIVE - Battery # 1
W-2
POSITIVE - Battery # 2
W-3
POSITIVE - Battery # 3
W-4
POSITIVE - Battery # 4
W-5
POSITIVE - Battery # 5
BATTERY BANK
POSITIVE - Battery # 6
CELLS
1-12
POSITIVE - Battery # 7
to BAM
POSITIVE - Battery # 8
W-6
W-7
W-8
W-9
6
7
8
12 CORE CABLE
POSITIVE - Battery # 9
W - 10
10
POSITIVE - Battery # 10
W - 11
10
11
POSITIVE - Battery # 11
W - 12
11
12
POSITIVE - Battery # 12
W - 13
12
13
POSITIVE - Battery # 13
X-1
POSITIVE - Battery # 14
X-2
POSITIVE - Battery # 15
X-3
16
POSITIVE - Battery # 16
X-4
17
X-5
X-6
X-7
20
X-8
21
POSITIVE - Battery # 21
X-9
POSITIVE - Battery # 22
X - 10
10
POSITIVE - Battery # 23
NOT IN USE
X - 11
NA
11
NA
14
15
18
19
22
23
24
12 CORE CABLE
WRONG
CONNECTION
WILL DAMAGE
BATTERY
ANALYZER
WRONG
CONNECTION
WILL DAMAGE
BATTERY
ANALYZER
TBV (Total Bank Voltage) ,DC PSU and BAM Connection with MCU
Fuel sensor
PVC Box
Cable 6 core
Connecting strip
Spiral pipe
Gland
Saddle Clamp
Screw
Rawl plug
Process
Connect the 4 terminals connecting strip from left to right with three (3) fuel sensor wire in below mentioned
way;
Connect from the same 4 terminal connecting strip left to right with 3 temperature sensor wires in same above
way except its signal wire should be connected to the Empty 4th terminal of the connecting strip. However Red
(Positive) with Red (Positive), Black ground (Negative) with Black ground (Negative).
Now use the 6 core fuel sensor for connecting fuel sensor to MCU or RTU in following reference
Process
First check the space for insertion the cables in DB 4core cable use for Voltage measurement 1 st Red cable
with Red (220V) 2nd Yellow connected with Yellow (220V) 3 rd Blue with Blue (220) 4rh Black cable with Black
(Neutral)
AC CTs Connections
1st Ct fixed on with Red wire 1st phase
2nd Ct fixed on with Yellow wire 2st phase
3rd Ct fixed on with Blue wire 3rd phase
Line #
MCU
Signal
Routing
Description / Type
Cable
Type
Cable Reference
E-1
E-2
E-3
NEUTRAL
E-4
Q-1
Q-2
Q-3
Q-4
Q-5
10
Q-6
11
NA
White Brown
NA
Brown
MDB to MCU
12
Red
4-Core
Green
Blue
Black
White Orange
Orange
white Green
Cat-6
Blue
white blue
Green
MDB
ATS Connection
Required Module
ARM
Required IRM
Cat 6 Cable
1 mm cable
Spiral
Glands
Process
After tracing CP cut breaker Remove wire from The breaker connect it ARM Connecting Pad B Connect port B4
and connect wire port B6 ( ARM) Insert CP cut Breaker
After tracing Delay gen wire Remove wire from There connect it ARM Connecting Pad B Connect port B1 and
connect wire port B3 ( ARM) Insert Back to Removal place
Check for 220 V on auxiliary coil of GEN MC and connect it with D1.
Use White orange /orange Pair ( Cat 6 ) For Gen Battery Positive connect to MCU Connecting Pad N Port N1
Use White Green /Green Pair (Cat 6) For Gen Battery Negative connect to MCU Connecting Pad N Port N2
Use Orange cable of (Cat 6 # 1) for connecting port A2 of connecting pad A of ARM with port N6 of
connecting pad N of RTU.
Use Cat 6 cable for connecting ARM to MCU.
First Use white orange cable of (Cat 6 # 1) for connecting port A1 of connecting pad A of ARM with
port N5 of connecting pad N of RTU.
Use White Green cable of (Cat 6 #1) for connecting port A3 of connecting pad A of ARM with port
F1 of connecting pad F of RTU.
Use Blue cable of(Cat 6 # 1) for connecting port A4 connecting pad A of ARM with port F2 of
connecting pad F of RTU.
Use White Orange cable of (Cat 6 # 2) for connecting port C1 of connecting pad C of ARM with port
M3 of connecting pad M of RTU.
Use Orange cable of (Cat 6 #2) for connecting port C2 of connecting pad C of ARM with port N4 of
connecting pad N of RTU.
Use White Green / Blue cable of( Cat 6 #2) for connecting port C3 of connecting pad C of ARM with
port H1 of connecting pad H of RTU.
Use White Blue /Green cable of ( Cat 6 #2) for connecting port C4 of connecting pad C of ARM with
port I-1 of connecting pad I of RTU
Types of ATS
External ATS
Internal ATS
Signal Routing
ARM
Description / Type
Cable Color/Type
NOTES
1
2
3
4
ATS to ACP
Module
HIGH
HIGH
B-1
B-3
B-4
B-6
D-1
D-2
D-3
ARM
Line #
8
9
10
11
12
13
14
15
16
17
Signal Routing
Description / Type
HIGH
VOLTAGE
CONNECTIO
In case of IPS& Deep Sea use B - 6
NS!
in place of B - 5
CAT 6
Color Refrence
Number of Wires
Color
POSITIVE 12VDC
GROUND
A-1
A-2
A-3
1
1
1
1
2
A-4
C-1
C-2
C-3
C-4
-
1
1
2
2
1
1
White orange
Orange
White Green
Blue
White Blue /Green
White Brown
/Brown
White Orange
Orange
White Green/Blue
White Blue /Green
White Brown
Brown
Cable number
PUT SITE
LOAD ON
BATTERY