02_nsn greenc controller maintenance

NSN Green Energy Solution (Rel. 1.1) NSN Green Energy Solution (Rel. 1.1) Maintenance TrainingMaintenance TrainingMaintenance TrainingMaintenance Training

1 © Nokia Siemens NetworksCompany Confidential

Contents

NSN Green Energy Solution Overviewgy

Energy Solution Architecture and Operation

NSN GreenC Maintenance

Company Confidential

NSN GreenC


NSN GreenC Overview

Two Diesel Generators ControlOr

One Generator + Bad Grid Connection

Rectifier Control

Energy Consumption Load Battery Control


Solution Description

Solar Panels Wind Turbines

Solar ChargeC t ll Wind Energy

NSN GreenC

Controller gyController

Company ConfidentialBattery Bank Generator

Contents





NSN GreenC Architecture


Physical Inspection of GreenC (1 DG Layout) -1/5

In case of 1DG versionSo called heartbeat In case of 1DG version, netwatcher will be lit if

AC is available

So called heartbeat signal of PLC, blink

green if OK

Depending if AC source Genset is available LED will

be lit

MAN/AUTO: Indicates GreenC operational state

Service LED: Indicates service is required / Boost Charging is ON


Charging is ON

Alarm LED: Indicate “a” alarm (as of 1) is raised


In case of 2DG version, So called heartbeat one of both netwatchers

will be lit if AC is availablesignal of PLC, blink

green if OK

Depending on what AC source (Grid or Genset 1 / 2) is available, respective LED

MAN/AUTO: Indicates GreenC operational state

Service LED indicates service is required

Al LED i di t “ ” l ( f 1) i i d


will be lit Alarm LED indicate “a” alarm (as of 1) is raised


Will be green when operational, out when

not functioning or defect. LED off does not

mean defect: Please lt d i f

LED of respective relay will be lit when activated



consult drawings for correct indication details


Will be green when operational, out when


not functioning or defect. LED off does not

mean defect: Please lt d i f



consult drawings for correct indication details

Physical Inspection of GreenC -5/5y p

Check for cable wire faults like over heat, burnt, cut etc.Check for any accidental physical damage in the controller.Check PLC display, ports, switches etc.Check Alarms individually and thoroughly.Check if no relays are loose by pressing all of them down iny y p gto place.Check if all bridges are well positioned by pressing themddown.Check if all Input/output connectors from PLC are well fixedby pushing them in to placeby pushing them in to place.Check if both connectors on Traco Transformer/convertersare well inserted.


are well inserted.

Front Panel LED Indication

LED1 (Top LED) RED: Manual Operation Mode GREEN: Automatic Operation Mode

LED2 (Middl LED)LED2 (Middle LED) RED: Generator Service Alarm ORANGE: Boost Charging ActiveORANGE: Boost Charging Active GREEN: None of The Above

LED3 (Bottom LED)LED3 (Bottom LED) RED: One or More Alarms Pending GREEN: None of The Above


NSN GreenC Shelf Control Buttons -1/2Mode Knob

Manual position, turn left to put system in manual mode.This mode should only be active if maintenance is occurringon site, generator or rectifier maintenance., gThe generator will not start at a pre-defined time to start acharge cycleA t ti k b t i ht thi d i th l tiAutomatic knob, turn right, this mode is the normal operationfor the controller.All automated functions of the controller will be executed.


NSN GreenC Shelf Control Buttons -2/2Bypass knob

To be used only if PLC malfunction.Start generator manually and turn bypass knob to the rightpositionpThe AC from generator will be bypassed to the rectifier to keepthe site alive and charge batteries.

P i di tiPower source indicationUpon detection of AC from gen 1 or gen 2, respective light willcome on to identify the power source.y p


Two Generator PLC Inputsp

DI01-DI16 – 16 Digital Intpus Used for digital alarm/sensor inputs UI01-UI03 – 3 Universal Inputs Reserved Inputs for future useAI01-AI06 – 6 Analog Inputs Used for analog sensor inputs (like current values/temperature etc)VOUT Supply outputVOUT Supply outputGND GroundAIGND Analog Input Ground


Two Generator PLC Outputsp

DO01 DO18 18 Digital Outputs Used for outputs to relay triggersDO01-DO18 – 18 Digital Outputs Used for outputs to relay triggers SP01-SP02 – 2 SpareIN+ / IN- DC Input to PLC24Vdc IN PLC Voltage supply InputGND GroundRS485+ / RS485- For Communication Port PLC ConfigurationRS485G RS485 Ground


Two Generator Alarm Connections

Alarm Output PortsPorts


Two Generator AC Connections

3-PHASENeutral


3 PHASE INPUTS

Neutral Ground

Two Generator Contactors and Power Supply

AC/DC PowerContactors – To

switch Power source

AC/DC Power Convertors

DC/DC Power Convertor


Two Generator Netwatcher

Two Netwatchers for

di ACreading AC Input Supply

Voltage


GreenC Interface Navigation Tree g

For navigation through the menus in the GreenC display, thek PG UP d PG DN b d thi ill ll th hkeys PG UP and PG DN can be used, this will scroll throughthe different pages. Ex: a1>b1>c1…For navigation within a page use left and right keysFor navigation within a page use left and right keys,Ex:a1>a2>a3Up and Down Keys are used for modifying valuesUp and Down Keys are used for modifying valuesCentre Key to be used for Enter/Save Options


Navigation Table of NSN GreenC- 1/8g

Section Page Details

A1. Start-up/Mainscreen

Current Operation ModeCurrently Used AC Source (If Charging)Date & TimeDate & Time

A2. Version Info Kernel VersionApplication Version

A. General ControllerI f ti

pp cat o e s o

A3. Location Info Latitude & LongitudeLocation IDInformation Location ID

A4. Ethernet Info IP Assigned By DHCP Or FixedIP Address Subnet Mask & GatewayIP Address, Subnet Mask & Gateway

A5. Config FileACTION: Pressing O will cause thecurrently loaded config.ini file to be read


A5. Config FileRead

currently loaded config.ini file to be readinto memory.Status of last config.ini file read



B. TemperatureInformation B1. Temperatures

Rack temperaturesBattery temperaturesOutdoor temperaturesOutdoor temperatures

C1. Charge Status

Charging / DischargingBattery voltage & current

C Charging

Status Battery state of charge (SOC)

C2. ChargingSOC triggerTime triggerC. Charging

Information C2. Charging Settings 1

Time trigger2nd time triggerDay frequency triggerBattery low voltage charge trigger

C3. Charging Settings 2

Battery low voltage charge triggerEQU charge triggerACTION: Pressing O will run a singlecharge cycle in AUTO mode


charge cycle in AUTO mode.



Will only appear in

Manual Charge StatusACTION: Pressing O will toggle aBoost charge cycle in MANUAL mode.y pp

MANUAL mode. That is OP_MODE = 1.

C4. Charge Manual

g yNote: This charge cycle will notautomatically stop if left in MANUALmode and will continue indefinitely untileither O is pressed again or systemswitches to AUTO mode.Battery Current

D. Site Electrical I f ti

D1. Site Currents

Battery CurrentLoad CurrentRectifier CurrentSolar & Wind Current (If Configured)

Information( g )

D2. Site Instantaneous Power (W)

Load PowerRectifier PowerSolar & Wind Power (If Configured)


Power (W) Solar & Wind Power (If Configured)



D3. Site Total Energy (kWh)

Rectifier EnergyLoad EnergySolar & Wind Energy (If Configured) gy ( ) gy ( g )Grid Energy

D4. Site Day- Rectifier energy Load energy

D. Site Electrical Information

Total Energy (kWh)

Load energy Solar & Wind energy (if configured) Grid energy Rectifier energyD5. Site

Yesterday-Total Energy (kWh)

Rectifier energy Load energy Solar & Wind energy (if configured) Grid energyGrid energy

D6. Reset Energy Total Values ACTION: Press O to reset ALL energy

counters (Total, Day-Total & Yesterday)


( , y y)



E1. Generator 1 Status

Status of Generator 1Generator 1 Alarm informationACTION: If in MANUAL MODE, Press,O to start / stop Generator 1.

E2 Generator 1Current actual runtimeLast cycle runtime

E. Generator Information

E2. Generator 1 Runtime

Last cycle runtimeAverage runtime over all cycles sincelast reset

E3 Generator 1 Configured Service CycleE3. Generator 1 Service Information

Configured Service CycleHours Until Next ServiceTotal Runtime since last Reset

E4. Generator 1 Reset Service

ACTION: Press O To Reset Generator1 Service Interval.




E5. Generator 2 Status

Current Actual RuntimeLast Cycle RuntimeAverage Runtime Over All Cycles Since

Generator 2 screens will only appear if

g yLast Reset Or Initial Commissioning

E6 Generator 2Current actual runtimeLast cycle runtime

Site is configured with two generators. That is

E6. Generator 2 Runtime

Last cycle runtimeAverage runtime over all cycles sincelast reset

E7 Generator 2 Configured service cycleAC_SOURCE_CONFIG = 1.

E7. Generator 2 Service Information

Configured service cycleHours until next serviceTotal Runtime since last reset

E8. Generator 2 Reset Service

ACTION: Press O To Reset Generator1 Service Interval.




F1. Fuel Level Tank SizeFuel Level in % and litres

F. Fuel InformationF2. Fuel Level Alarm & Flow

Fuel Level AlarmFuel Flow Calibration (if configured)

Information Current Fuel Low (if configured

G1. Alarm List 1Generator 1 AlarmGenerator 2 Alarm

G Alarm List

G1. Alarm List 1 Generator 2 AlarmGeneral Alarm

G2 Alarm List 2OUTPUT 1OUTPUT 2G. Alarm List G2. Alarm List 2 OUTPUT 2Config Read Alarm

G3 Al Li t 3Generator Service AlarmF l L Al


G3. Alarm List 3 Fuel Low AlarmFuel High Alarm



G4. Alarm List 4 Fuel Delta AlarmBattery Voltage Low AlarmHigh Temperature Alarm

G. Alarm ListHigh Temperature Alarm

G5. Alarm List 5 Smoke Alarm

H1 . Grid Information Grid Availability

H. Grid Information Information

H2 . Grid Information

Individual phase voltages, currents andpowers measured by energy meterInformation powers measured by energy meter


Navigation Tree of NSN GreenC- 1/2g

A1 VERSION 1.1A2 VERSION INFO A3 LOCATION INFO A4 IP ADDRESS (FIX) A5 CONFIG FILE

Mode: AUTOACSource: NONE

2010/03/29 10:13:20

A2 VERSION INFOKernel: V1.30

Application: F223

A3 LOCATION INFOLAT: 51.183334LONG: 4.833333LOCATION ID: 1

A4 IP ADDRESS (FIX)ADDR:10.20.5.196

MASK:255.255.255.0GW:0.0.0.0

A5 CONFIG FILEPRESS O TO READ

CONFIG FILESTATUS: ERROR

B1 TEMP (degC)RACK: 25.6

BATTERY: 25.6OUTDOOR: 25.6

C1 CHARGE STATUSCHARGING

U:75.34V I:56ASOC (%): NA

C2 CHARGE SETTINGS 1SOC TRIGGER DISABLE

TIME TRIGGER: 20:002ND:0h FREQ:0d

C3 CHARGE SETTINGS 2CHARGE UBAT < 47.00VEQU CHARGE DISABLEPRESS O TO CHARGE

C4 CHARGE MANUALCHARGE STATUS: OFF

PRESS O TOTOGGLE BOOST

CHARGE

D1 CURRENT (A)Battery: 56

Load: 0 Rect: 56Solar: 0 Wind: 0

D2 POWER (W)Load: 0 Rect:30889

Sol: 0 Wind: 0

D3 TOT ENERGY (KWH)Rect:319.4 Load:0

Sol:0Wind:0Grid:0

D4 DAY ENERGY (KWH)Rect:319.4 Load:0

Sol:0Wind:0Grid:0

D5 YESTERDAY(KWH)Rect:319.4 Load:0

Sol:0Wind:0Grid:0

D6 ENERGY RESETPRESS O TO

RESET ENERGY COUNTER


Navigation Tree of NSN GreenC- 2/2g

E1 GEN1 STATUS E2 GEN1RUNTIME E3 GEN1 SERVICE E4 GEN1 RST SERVICEE1 GEN1 STATUSGEN1 : ALARM

GEN1 START ALARMPUSH O TO START GEN1

E2 GEN1RUNTIMEActual : 0h0m

Last Cycle: 0h0mAverage : 0h0m

E3 GEN1 SERVICEService Cycle: 250h

Service in : 250hTot Runtime: 0h 0m

E4 GEN1 RST SERVICEPRESS O TO

RESET GEN1 SERVICEINTERVAL

E5 GEN2 STATUSGEN2 : ALARM

GEN2 START ALARMPUSH O TO START

GEN2

E6 GEN2 RUNTIMEActual : 0h0m

Last Cycle: 0h0mAverage : 0h0m

E7 GEN2 SERVICEService Cycle: 250h

Service in : 250hTot Runtime: 0h 0m

E8 GEN2 RST SERVICEPRESS O TO

RESET GEN2 SERVICEINTERVAL

F1 FUEL LEVELTANK SIZE: 1000LLEVEL: 56%

FUEL LEFT: 560L

F2 FUEL ALARM & FLOW

LEVEL ALARM: OKFLOW CALIB: 0.00

FLOW: 0 00FLOW: 0.00

G1 ALARM LIST 1/5A GEN1 FALSEB GEN2 FALSE

G2 ALARM LIST 2/5D OUTPUT1 FALSEE OUTPUT2 FALSE

F CONFIG READ FALSE

G3 ALARM LIST 3/5G GEN SERVICE FALSE

H FUEL LO FALSE

G4 ALARM LIST 4/5J FUEL DELTA FALSEK BATT LOW FALSE

G4 ALARM LIST 5/5M SMOKE ALARM FALSE

C GENERAL FALSE F CONFIG READ FALSE I FUEL HI FALSE L HI TEMP FALSE

H1 GRID INFOH2 P1 P2 P3

V(V) 240 240 240I(A) 2 5 3 6 3 2


GRID UNAVAILABLEL I(A) 2.5 3.6 3.2P(W) 600 864 768

Contents





GreenC Internal Alarms and Reset -1/6


GreenC Internal Alarms and Reset -2/6Green C creates its own alarms, which can be observed inthe remote monitoring tool or also sent to BTS fromthe remote monitoring tool or also sent to BTS fromconnection points R1 to R12.R1 - Green Controller bypass activeypIndication that Green controller is in bypass mode (emergency mode)To reset, the bypass knob needs to be turned to normal position

R2 – AC1 availableIndication that alternated current is being detected in AC1 position

To reset, generator 1 needs to be stop.

R3 – AC2 availableIndication that alternated current is being detected in AC2 position eitherIndication that alternated current is being detected in AC2 position, eitherfrom generator or from the grid.To reset, only if gen2 or grid is not supplying power


GreenC Internal Alarms and Reset -3/6R4 - Generator x service intervalOne of the generator has reached the maximum programmed runningOne of the generator has reached the maximum programmed runningtime (defined in parameters - GENx_SERVICE_INTERVAL)To reset, after intervention in the generator concerned, go to GreenCdi l E4 E8 d 0display E4 or E8 and press 0

R5 Generator 1 alarmR5 – Generator 1 alarmThis alarm is a sum of 3 conditions:Gen1 external alarm, external physical alarm of the generator.Ge e te a a a , e te a p ys ca a a o t e ge e atoGenerator failed to start, Occurs if controller give command to startgenerator, and no AC is detected.G t f il d t t O if t ll i th d t tGenerator failed to stop, Occurs if controller give the command to stopgenerator and still AC is detected.To reset this alarm you need to turn the system to manual and back to


automatic, but only possible if none of these conditions are active.

GreenC Internal Alarms and Reset -4/6R6 – Generator 2 alarmThis alarm is a sum of 3 conditionsThis alarm is a sum of 3 conditionsGen2 external alarm, external physical alarm of the generator.Generator failed to start, Occurs if controller give command to start, ggenerator, and no AC is detected.Generator failed to stop, Occurs if controller give the command to stopgenerator and still AC is detectedgenerator and still AC is detected.To reset this alarm you need to turn the system to manual and back toautomatic, but only possible if none of this conditions is still active.

R7 - Fuel low (only with NSN green energy controlleranalogue fuel sensor)analogue fuel sensor)Indication that fuel is below the parameter defined inFUEL_LEVEL_LOW.


To reset this alarm the fuel needs to be above the defined value.

GreenC Internal Alarms and Reset -5/6R8 – Fuel High (only with NSN green energy controlleranalogue fuel sensor)analogue fuel sensor)Indication that fuel is above the value defined in valueFUEL_LEVEL_HIGH)To reset this alarm the fuel needs to be below the defined value.

R7&R8 F l Th ft ( l ith NSNR7&R8 – Fuel Theft (only with NSN green energycontroller analogue fuel sensor)Alarm indicates that there was a decrease of the fuel level above theAlarm indicates that there was a decrease of the fuel level above thevalue defined in parameter FUEL_DELTA_HIGH, during an interval oftime defined in parameter FUEL_DELTA_TIME, values defined inLitre/minutes.If this alarm is active, both Fuel low and fuel high alarms will be active.To reset this alarm, controller needs to be put in manual mode and backto a tomatic


to automatic.

GreenC Internal Alarms and Reset -6/6R9 - Battery Low VoltageTriggered When Voltage Of The Batteries Reaches Below ValueTriggered When Voltage Of The Batteries Reaches Below Valuespecified In parameter U_BAT_MINAlarm can be reset only if battery voltage rises above pre-defined value

R10 - High temperature alarmIndicates high temperature on green energy controller rack or batterytemperatureTriggered by temperature when temperature reaches above the valuesgge ed by te pe atu e e te pe atu e eac es abo e t e a ueson parameters T_RACK_HIGH or T_BAT_HIGH

R11 M l d lR11 – Manual mode alarm,Indication that the controller is in manual mode by action of turningmanual knob.


manual knob.To reset this alarm controller needs to be in automatic mode.

Controller Troubleshooting - 1/8g

F l P ibl C A i R i dFault Possible Causes Action Required

1 Check the PIU If PIU is faulty, Repair/

From Grid Supply:

1. Check the PIU y, pReplace

2. Check AC circuit If OFF turn it ON

AC Input Power Failure

breaker of grid If OFF, turn it ON

1. Cable between bi t d t i Repair/ Replace thePower Failure

From Generator:

cabinet and generator is faulty

Repair/ Replace the cable

Generator:2. Check AC circuit

breaker of generator If OFF, turn it ON


Controller Troubleshooting – 2/8g

F l P ibl C A i R i dFault Possible Causes Action Required

1. Check for MANUAL If in MANUAL, turn it to

AC Input Within

and AUTO modes,

AUTO Mode

2. Check for normal and If OFF turn it ONAC Input Power Failure

Within Controller:

bypass operation If OFF, turn it ON

3. Check the functioning f VAGO i l h Repair/ Replace theof VAGO single phase

bridge on the controller.

Repair/ Replace the bridge

1 NW1 F ilAC Output

power failureWithin

Controller:

1. NW1 FailureContact OEM

2. Contractors Failure



Fault Possible Causes Action Required

1 Check cable between

AC Output From

1. Check cable between controller and Rectifier Repair/ Replace Cable

AC Output Failure:

From Rectifier: 2. Rectifier Faulty Repair/ Replace Rectifier

3 Check circuit3. Check circuit breakers of rectifier If OFF, turn it ON

Generator Within 1 Controller is in If in MANUAL turn it toFailed to Start

Within Controller

1.Controller is in MANUAL mode

If in MANUAL, turn it to AUTO Mode




Detach wires from2. Remote Start/ Stop

wiring

Detach wires from GreenC (R16-11 & R16-

14) & short circuit to simulate remote start

Generator Within

3. Loose pin connections, relay not

powered

Check the 4 orange connectors in PLC

failed to start Controllerpowered

4. Wiring from GreenC to Generator Controller

is faulty

Check and repair the wiringis faulty

5. In Automatic mode Battery Voltage

Threshold not reached

Check configuration settings for GreenC for

Battery charging


Threshold not reached Battery charging



From 1 Circuit Breaker ofFrom Rectifier

1. Circuit Breaker of rectifier is OFF Check why and turn it ON

Generator failed to start From

1. Fuses are out Check battery fuses

Check and OPEN the From

Generator2. LLOP and HCT LLOP and CLOSE the

HCT

Check and top up the3. Fuel Level Low Check and top up the fuel.




Check and remove Air

Generator failed to start

FromGenerator

4. Air Locking Check and remove AirLocking.

5 Mechanical failure Contact OEM for5. Mechanical failure within generator

Contact OEM for Generator

Check the faults and put

PLC of GreenC not Within

1. Controller is in bypass mode

Check the faults and put system back in normal

modeGreenC not responding Controller

2. PLC is not getting input 24Vdc power

Check four orange connectors and Traco

power supplies, / f


repair/replace if damaged



3 Internal fuse of PLC is Open PLC cover andPLC of

GreenC not responding

Within Controller

3. Internal fuse of PLC is blown

Open PLC cover and replace the fuse

responding4. PLC is broken Replace GreenC

PLCPLC initialising problem

Within Controller

1. PLC entered cyclic boot sequence

Re-flashing of PLC is required

PLC display values

incorrect

Within Controller

1. Configuration problem while commissioning

Redo the configuration settings and change required parameters


Controller Troubleshooting – 8/8g


PLC display Within 2 Hall's effect current Replace Hall's Effectp yvalues

incorrect

Within Controller

2. Hall's effect current transducer is defective

Replace Hall's Effect Transducer


-----Thank You ----


02_nsn greenc controller maintenance

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