INSPECTION CIRCLE, JABALPUR

TEST SCHEDULE

SMPS POWER PLANT

Document No TD/SW-3512 /TS/SMPS

No of Pages. 5
Issue No. II
Issued By: T&D Circle, Jabalpur
Approved By: CGM T&D Circle
Date of Issue: 12.06.2008
Amendment No (If Any) 01
Document No TD/CFA/TS-INFRA/PH-VII/02
No of Pages: 05
Issued by: Inspection Circle Jabalpur
Date of Issue: 02/11/2012

Restricted use by BSNL Employees only

“FIX IT RIGHT AT THE FIRST INSTANCE”

INSPECTION CIRCLE SMPS POWER PLANT
JABALPUR TEST SCHEDULE

TEST SCHEDULE FOR SMPS BASED POWER PLANTS

S. No. NAME OF TEST REFERENCE REMARK

1. LAR Location: As per approved lay out plan.
2. Cabling, termination- check. Physical check for proper gauge of lead
& proper termination.
3. Operation & maintenance
manuals check.
4. Equipment Configuration As per purchase order.

5. Earth Earth resistance should be Less than or

equal to 0.5 Ohms.
6. Insulation Test (To be taken With 500V DC Meggar
before heat run test ) . AC Input & Earth- > 2 M Ώ
. DC Out put & Earth- > 1 M Ώ
. AC Input & DC out put- > 5 M Ώ
7. Load limiting Voltage drooping should occur on load
(Voltage droop) 100%+5% at the O/P voltage range –
44.4 to 56 volts.
8. EFFICIENCY . At nominal input, output and full rated
load: for single phase AC better that
85% and for three phase AC better than
90%.
. For other specified input, output
conditions and load between 50% to
100% should be better than 85% for
single phase AC and better than 87%
for three phase AC.
9. Voltage Stability: The prescribed float voltage settings
(a) Auto Float mode (Range are-
-48V to 56 V) . -54Volts for VRLA Battery
(b)Auto Charge Mode (-do-) . -52.8 Volts for conventional Bty
(c)Manual Boast mode . Normally 2.3 V/cell till changeover to
(Range 56 v to 65V) float mode.
. Voltage 55.2 Volts

10. Power Factor If power factor meter is not available,

the reading may be taken from panel
meter.

TD/CFA/TS-INFRA/PH-VII/02 AMMENDMENT-1, Page 1 of 5

ISSUE-II Dated 02/11/2012
INSPECTION CIRCLE SMPS POWER PLANT
JABALPUR TEST SCHEDULE

11. Voltage Regulation Test The DC output voltage shall be

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

TD/CFA/TS-INFRA/PH-VII/02 AMMENDMENT-1, Page 2 of 5

ISSUE-II Dated 02/11/2012
INSPECTION CIRCLE SMPS POWER PLANT
JABALPUR TEST SCHEDULE

15.2 DC Over voltage protection Each rectifier module shall be fitted

with an internal over-voltage Protection
circuit In case output DC voltage
exceeds –56V with tolerance of +_ 0.25
V the over voltage protection circuit
shall operate & shut off the faulty
module. Shutting-off of faulty FR/FC
module shall not affect the operation of
other FR/FC operating in the rack. The
circuit design shall ensure protection
against the discharge of the Battery
through the FR/FC module in any case.
FR/FC module should be fully
protected against short circuit.

15.3 Fuse/Circuit Breakers Fuses or circuit breakers shall be

provided for each FR/FC module as
follows:
Live AC input line
Negative D C output
Against failure of Control sensing
circuit.
All fuses/circuit breaker used shall be
suitably fault rated.

16. Load Sharing Percentage variation should be less

than +_10% of average current per
rectifier module while loaded between
50 to 100% of its rated capacity.

17. Meter and their calibrations Accuracy +_1.5% of the range

18. Battery Monitoring

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

TD/CFA/TS-INFRA/PH-VII/02 AMMENDMENT-1, Page 3 of 5

ISSUE-II Dated 02/11/2012
INSPECTION CIRCLE SMPS POWER PLANT
JABALPUR TEST SCHEDULE

18.2 Battery Health Monitoring in To keep the battery in healthy state the
Auto Mode battery condition shall be continuously
monitored. On restoration of AC mains
after an interruption, depending on the
battery condition (depth of discharge)
sensed, the system shall change over to
Auto Charge mode to charge the
battery at higher voltage of 55.2V till
the battery is fully recouped.
18.3 Battery Current Limiting In Auto Mode to ensure the availability
Circuit of required exchange load and safely of
the battery, the current in each battery
path shall be settable as per the battery
capacity so that the battery path current
is kept to 10% of battery AH capacity.

18.4 Temperature Compensation There shall be provision for monitoring

for Battery the temperature of battery and
consequent arrangement for Automatic
temperature compensation of the
FR/FC output voltage to match the
battery temperature dependant change
characteristics. The output voltage of
the rectifier in Float/Change operation
shall decreases or increase at the rate of
72mV (3mV/cell, 24 cell battery) per
degree increase or decrease in
temperature over the set voltage. The
output voltage shall decrease till the
open circuit voltage of the battery is
reached. The open circuit voltage range
shall be settable between 2.1V/cell to
2.2V/cell to 2.2V/cell. The increase in
output voltage due to decrease in
compensation has been taken care of by
the tripping of the unit due to output
voltage high 0.56V) protection A
tolerance of +/-5mV may be acceptable
over the specified rate of 72mV/degC.
The nominal distance between the
battery & power plant may be 20
meters failure of temperature
compensation circuit including sensors
shall create an alarm and shall not lead
to abnormal change in output voltage.

TD/CFA/TS-INFRA/PH-VII/02 AMMENDMENT-1, Page 4 of 5

ISSUE-II Dated 02/11/2012
INSPECTION CIRCLE
JABALPUR
19. Heat Run test
(Temperature rise test of
component may be taken if
possible)
20. Check of operation of SMPS
with E/A set.
21. General inspection:-
QA Approval, Sign writing,
lighting protection, wiring
neatly secured in position,
adequate supports, spare
components etc.
TD/CFA/TS-INFRA/PH-VII/02
SMPS POWER PLANT
TEST SCHEDULE
8 hours at full load
Transformer and Chokes 70C
Transistor/diode/FET etc. 60 C. In
vigorous at atmosphere condition if
room ambient temperature reaches to
50 C, then rack shell be capable of
withstanding at room ambient
temperature of 50 C measured at a
distance of 1 foot from the equipment.
- Availability of cabling diagram,
placed in the inside of the front door or
any other convenient place for ready
reference of the maintenance staff.
- Details of the fuse rating and type. In
case of fuses on PCBs, the rating shall
be either on the fuse or PCB.
- All non current carrying metal parts
shall be bonded together and Earthed
with suitable marking.
- A name plate shall be suitably fixed
on each rack/module and contain
following information:
Specification Number:
1 Type of the Unit:
2 Manufacturer’s name and
identification:
3 Model No.:
4 Unit Serial No.:
5 Input voltage and phase :
6 Output Voltage and Current:
7 Year of manufacture:
9. Suitable for battery
capacity:
AMMENDMENT-1, Page 5 of 5
ISSUE-II Dated 02/11/2012