operations manual slc-04 lighting controller

Operations ManualSLC-04 Lighting Controller

TAS Powertek Pvt. Ltd. Corporate Office: W-61, MIDC, Ambad, Nasik - 422010, Maharashtra (India)Tel: +91-(253)-2384038 / 2381090Email: [email protected]

mailto:[email protected]

NOTEThese instructions do not purport to cover all details or

variations in equipment, nor to provide for every possible contingency to be met in connection with installation,

operation or maintenance.

Should further information be desired or should particular problems arise which are not covered sufficiently for the

purchasers purposes, the matter should be referred to our TAS Powertek Pvt. Ltd., office.

The contents of this instruction Manual shall not become part of or modify any prior or existing agreement or relationship.

The sales contract contains the entire obligations of TAS Powertek Pvt. Ltd. The warranty contained in the contract

between the parties is the sole warranty of TAS Powertek Pvt. Ltd. Any statements contained herein do not create new

warranties or modify the existing warranty.

The reproduction, transmission or use of this document or its contents is not permitted

without express written authority. Offenders will be liable for damages. All rights are

reserved.

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Index

Index Page ------------------ 1

Features & Specifications ----------- 2

Mechanical Dimensions ------------------- 3

Functional Block diagram ------------------ 4

Back Side terminal layout ------------------ 5

Voltage control Energy saving ESM-1 ------ 6

Phase cutting control Energy save ESM-2 & 3 7

Power and Control Wiring Diagram -------- 8

Front Face of SLC-04 ----------------------- 9

Serial Communication Hardware details --- 10

Various Display Parameters ---------------- 11

Parameter Editing Methods ----------------- 14

Parameter Editing Sub-menu Level-1 ---- 15

Parameter Editing Sub-menu Level-2 ---- 17

Fault finding Guidelines --------------------- 20

Energy Saving Calculations ----------------- 22

GSM- Enabled SCADA connectivity --------- 23

Features:• Totally Micro-processor controlled Digital Signal processing logic for measurements.• All measurements with 1.0 class accuracy.• Supports various energy saving functions.• Various modes for energy saving like Voltage Control and Phase cutting control.• Load V,Iph, In and Cap. current THD measurement. • Totally 6 outputs control for various controls.• Additional load switch on sensing puts lamps to full intensity and after stipulated time delay brings it back to voltage reduced saving.• Flicker free changeover for fluorescent lamps with voltage control operation.• Standard 144 X 144 cabinet for panel door flush mounting.• Serial communication through standard TAS as well as MODBUS protocols. • Protections / Annunciation provided (user settable): Over/under Voltage Over/Under frequency (internally set limits) Over load. Load unbalance. RTC battery down.• Data logging for various parameters for 2months period at an interval of 1hr.• Unit comes along with PC (Windows compatible) software for downloading and viewing the logged data.• GSM modem connectivity drivers are in built and can be connected with SMS driven SCADA system.• Power factor correction logic (optional feature).

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Specifications:• Feed-back Voltage:440Volt (+10%/-30%)• Current input : 1Amp for load feed-back. Optional 5Amp.• Measurement Accuracy: Class 1.0• Auxiliary Supply: 525Vac to 300Vac.• Voltage changeover time for contactors from –99mS. to +99mS.• Output commands: NO contacts each with current rating of 0.5Amp AC. at 240Vac.• RS-232 baud rate selectable from 4.8kBPS to 38.4kBPS.• Operating temperature: 0 to 55oC.• 1.0class measurement Operating temperature: 0 to 50oC.• Storage temperature: -10 to +75oC.• Humidity: 0 to 98%.• Supply frequency: 45Hz to 55Hz.

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Mechanical Dimensions:

Recommended size for cutout on panel door is 138 X 138.

All Dimensions given are in mm.

Maximum weight: (with clamps and terminals) = 2.5kg.

144

144

120

135

135

6

Functional Block Diagram:

V, I, PF and PowerMeasurement

Block(Load Manager)

3 channelCurrent f.b.

3 channelVoltage f.b.

CalculationBlock for• Energy Parameters• Harmonic analysis

Power SupplyBlock.

Keyboard,Display and

Other supportFunctions

Block.

Real Time Clock (RTC)Block for outputs

On/OffOutputs Commands

for energy savingcontrol.

EEPROM For DataLogging

SLC-04

RS-232 Serial Communication.

TAS-01& GSM Modem driver

Protocol stack.

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Above block diagram gives the functional blocks that are built into SLC-04 Street Lighting controller.These blocks are made up with the combination of functions from hardware and corresponding firmware that resides in the Program memory of the micro-processor used therein.

Even though the basic blocks exists as shown in the diagram, there functionality is interdependent. The entire combination is carefully designed so as to have minimum effects of Electrical and Electromagnetic noise level on the functionality of this SLC-04.The firmware written takes into account the various error handling eventualities so that the functioning of this PF relay is error free and highly reliable.

Back Side Terminal Layout:

Output command terminalsRS-232 back side terminals

CurrentFeedback terminals

Voltage Feedback Terminals.Auxiliary Supply Terminals.

- 5 -

- 6 -

Energy saving with Voltage control through switchgear. (ESM-1)

N 3ph Mains

L O A D

C1

C2C3

SLC-04Controller.

In the scheme shown in the above diagram, a usage of duel output tapping transformer is necessary.Contactor C1 shown in this scheme is optional and is used for controlling the input supply to the transformer.C2 contactor is normally used for voltage boosting and C3 contactor is normally used for voltage lowering.

Voltage boosting is during the supply under-voltage conditions as well as during initial switch On. The fluorescent lamps normally requires full voltage for turn On and that too till it achieves its full luminous intensity.Once lamps are fully lighted up, the voltage can be brought down. This reduces the output luminous intensity of the fluorescent lamps but does not put Off the lamps. But by doing so, it reduces the energy input to the lamps.

SLC-04 is programmed so that it can switch On and Off the lamp load at pre-programmed time automatically as well as it can control the time wise energy saving operation too.

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R-PhaseLoad

Y-Phase Load

B-Phase Load

C4

C5

C6

Ph-1

Ph-2

Ph-3

Neutral

C1

Energy saving with Phase control through switchgear. (ESM-2 & 3)

In the scheme shown in the above diagram, a usage of single contact switchgear is necessary.

Contactor C1 shown in this scheme is optional and is used for controlling the input supply to the system.P1, P2 and P3 switchgears that are primarily single contact switchgear are for giving the supply to individual phase loads.

Normally, in such schemes, every third lamp on the street is distributed between the three phases. Thus if only Ph-1 is on, then every one lamp in three lamps would be in on condition.Similarly, if any two phases are on then every two lamps out of three would be on.

During less requirement hours, the scheme can save upto 66% energy.*

SLC-04 is programmed so that it can switch On and Off the lamp load at pre-programmed time automatically as well as it can control the time wise energy saving with either two phase or single phase control too.SLC-04 is intelligent enough to keep track of the equal load utilisation, keeping the maintenance requirements at lowest level.

*conditions apply.

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Voltage & Phase control scheme combined: Three phase Power & Control wiring diagram.

GSMMODEM

R-PhaseLoad

Y-Phase Load

B-Phase Load

C4

C5

C6

Ph-1

Ph-2

Ph-3

N

C1 C2C3

SLC-04

O/p1 O/p2 O/p3 O/p4 O/p5 O/p6 COM

+ - + - + - Bph Yph Rph

Load CurrentFeedback

L1 L2AuxiliarySupply

RS-232TX RX G

V N- B-PhF Y-PhB R-Ph

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Front Facia of SLC-04:

LCD Display

Step status LED indication

Membrane KeypadSerial Communication Port

Usage of the UP and DN key makes the LCD display to scroll up and down. This is used for display of various status as well as for viewing the On line measured electrical values.These keys are also used for changing values in Parameters Editing mode.

Usage of ENT key is for entering the submenu and / or for setting up some values.

The L and R keys are used in changing the position of the cursor from Left to Right and vice-versa.

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PINNO

PC sideConnection

CONNECTION SLC-04

1 NC

2 RXD TXD

3 TXD RXD

4

5 GND GND

6

7

8

9 NC

RS-232 serial communication 9 pin D connector:

5 4 3 2 1

6 7 8 9

TXD

RXD

GND

RS-232 cable connection Details:

In this default display, first line indicates the time HH:MM and the date dd/mm/yy.Second line shows the modes of operation and the health status.

Second line first word is three characters in length. It is :FIX or SUN: This states SLC-04 working mode for Overall On / Off timing. These timings can be fixed “FIX” as stated by user or can be Sunset/Sunrise “SUN” timing. The table of sunset and sunrise timings for all 365 days a year for a given location resides in the memory of SLC-04. This table can be edited and then programmed in SLC-04 by user through PC serial interface. Windows based program for the said purpose is normally supplied on CD-ROM which comes along with this controller.

Second line next seven characters gives various modes.These are “E1”, “V”, “E2”, “E3”.E1: This is ESM1 (Energy Saving Mode 1). In this the scheme is used with voltage control. This display comes on when there is a changeover from C2 contactor to C3 contactor. I.e. the reduced voltage is applied to the lamps.V: This is a voltage control mode. This is active only if ESM1 is activated. With C3 contactor on, if an under-voltage is observed at any one of the phases of input supply voltage, it changes over from C3 to C2 and this “V” is displayed on the screen. This is to prevent the fluorescent lamps being turned off due to excessive under-voltage applied to it.E2 & E3: These are ESM2 and ESM3 energy saving modes. Both these modes are used with phase cutting energy saving. ESM2 is with one phase cutting and ESM3 is with two phase cutting. For ESM3 to be enabled, ESM2 is mandatory to be enabled. Whenever these modes are active, the display E2 and/or E3are turned on.

Second line last part is word with two ASCII characters.These are either “OK” or “BF” or “NV” or “UV”.OK or BF or NV or UV: The last part of the display that is blinking every 500mS indicates the working status of SLC-04. “OK” indicates that unit is working fine without any trip conditions. If there is other indication, the meaning of the same can be as: OK : No Fault BF : Internal Battery Failure. NV : Internal NV RAM check-sum fault. UV : Under voltage on mains beyond working limit.

Display of Various Parameters / Status:This is default display screen giving information on Time, Date, Modes of operation and health status.

The LCD display is made up of 16 ASCII characters per line and there are 2 lines to this display.

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10:10 07/11/06 SUN E1VE2E3 OK

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Average Voltage 00000.0 V (L-N)Average Current 0000.0 A KW SKW 0000.0 0000.0 Apparent power 000000.0 KVAKWH 000141366.0Saved-KWH 000135736.9KVAH 000136581.3PF 1.000 INDFrequency 00.0 HzR-Phase Voltage 0000.0 VY-Phase Voltage 0000.0 VB-Phase Voltage 0000.0 VR-Phase Current 0000.0 AY-Phase Current 0000.0 AB-Phase Current 0000.0 ANeutral Current 0000.0 A

Indicates Average Voltage value of three phase with respect to Neutral.

Indicates the average Current value in three phases of the input supply of the panel.

Here kW is the active power drawn and SkW is the savings in kW. This SkW is seen in ESM conditions.

Indicates Apparent Power in terms of kVA value.

Active Energy (kWh) counter.

Saved Active Energy (kWh) counter.

Apparent Energy (kVAh) counter.

Overall Power Factor of the input supply to panel.

Mains Supply frequency.

Ph-1 (R-phase) Voltage. Ph-N value.

Ph-2 (Y-phase) Voltage. Ph-N value.

Ph-3 (B-phase) Voltage. Ph-N value.

Ph-1 (R-phase) Current value.

Ph-2 (Y-phase) Current value.

Ph-3 (B-phase) Current value.

Neutral Current value.

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Ph-1 (R-phase) Power Factor value.

Ph-2 (Y-phase) Power Factor value.

Ph-3 (B-phase) Power Factor value.

Ph-1 (R-phase) Active Power (kW) value.

Ph-2 (Y-phase) Active Power (kW) value.

Ph-3 (B-phase) Active Power (kW) value.

Ph-1 (R-phase) Reactive Power (kVAr) value.

Ph-2 (Y-phase) Reactive Power (kVAr) value.

Ph-3 (B-phase) Reactive Power (kVAr) value.

Ph-1 (R-phase) Apparent Power (kVA) value.

Ph-2 (Y-phase) Apparent Power (kVA) value.

Ph-3 (B-phase) Apparent Power (kVA) value.

R-Phase PF 1.000 INDY-Phase PF 1.000 INDB-Phase PF 1.000 INDR-Phase KW 000000.0Y-Phase KW 000000.0B-Phase KW 000000.0R-Phase KVAR 000000.0Y-Phase KVAR 000000.0B-Phase KVAR 000000.0R-Phase KVA 000000.0Y-Phase KVA 000000.0B-Phase KVA 000000.0

Display of Various Parameters.

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Method for Keyboard/Display usage.Flow chart for entering into different modes:

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Enter the 4Digit passwordBy use of L, R, UP & DN Keys.

PRESS

Default Display mode

IFPASSWORD

Correct?

NO YES

Enable

PRESS

If PasswordOption is

Enable/Disable.

Disable

Enter Pwd: ****

PRESS

*

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Parameter Editing Submenu Level 1:

1.General: Parameters related with general function and Input/Output

2. System: Electrical system (Mains supply) related parameters.

3. Schedule Control: Schedule Control setting. Various timings etc.

4. Schedule Parameter: Overall Schedule parameter settings.

5. Communication: Parameters related with communication and data logging.

1.General

2.System

3.Schedule Cont.

4.Schedule Para.

5.Communication

*

Parameter EditingSub-MenuLEVEL 2

Sub-menuLevel 1

for Parameter

Editing.

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Parameter Editing Method:(For Submenu Level 2 : L2)

Sub-Menu Level 1.

1.Submenu L2: ****

2.Submenu L2: ****

3.Submenu L2: ****

Exit: No Save

1.Submenu L2: ****

Cursor Blinking at Parameter Values.

key to increment value.

Key to decrement value.

Key to shift cursor Left.

Key to shift cursor Right.

PRESS

PRESS

PRESS

PRESS

2.Submenu L2: ****

Exit: No Save

Exit: With Save

Default Display.

Without saving

With saving

Saving In EEProm





PRESS

PRESS

PRESS

PRESS

Sub-Menu Level 1.

1.Submenu L2: ****

2.Submenu L2: ****

3.Submenu L2: ****

Exit: No Save

1.Submenu L2: ****

Cursor Blinking at Parameter Values.





PRESS

PRESS

PRESS

PRESS

2.Submenu L2: ****

Exit: No Save

Exit: With Save

Default Display.

Saving In EEProm

Screen for 1second





PRESS

PRESS

PRESS

PRESS

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Parameter Editing Submenu Level 2:

Parameter meaning.Parameter Display

POSSIBLE RANGE

Password Option requirementPassword Disable : 0

0: Disable 1: Enable

Change of PasswordChange Password : 0000

0000 to 9999

Loading of default factory settingsLoad Default No : 0

0: NO 1: YES

Energy Counters to be initialised.Reset Energy Cnt No : 0

0: NO 1: YES

Exit Parameters with saving option.Exit : No Save

With Save No Save

Edit Parameters - General

Edit Parameters - System


POSSIBLE RANGE

Rated Voltage measurement reference.Meas. Voltage : 240

NOT EDITABLE

External Potential transformer ratio.EXT-PT Ratio 0001.0:1

0000.0:1 TO 6000.0:1

Primary current of Load measurement.Load CT Primary Current : 1000

1 TO 9999

Autotransformer lower tap ratio.Trafo Ratio : 0.8333

0.1 TO 0.9999


With Save No Save

Edit Parameters - Schedule Control


POSSIBLE RANGE

Selection of Schedule type- Fix or Sun.Enable Schedule - Fixed Time Sch

FIXED TIME SCH SUNRISE/SUNSET SCH

Energy Saving Mode 1 Enable or Disable.ESM 1 Control Enable 1

0 : DISABLE 1 : ENABLE

ESM1 time for turn on.ESM1 ON Time 23:00

00.00 TO 23.59

ESM1 time for turn off.ESM1 OFF Time 06:59

00.00 TO 23.59

Voltage regulator mode with ESM1.ESM1 Vol. Cntrl Enable 1


Voltage reg: Under Voltage sensing.Voltage Point Lower : 220V

0 TO 225

Voltage reg: Resume level for normal V.Voltage Point Upper : 225V

224 TO 299

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Edit Parameters - Schedule Control

Parameter Editing Submenu Level 2:Continued:

Energy Saving Mode 2 Enable or Disable.ESM 2 Control Disable 0



00.00 TO 23.59


00.00 TO 23.59

Energy Saving Mode 3 Enable or Disable.ESM 3 Control Disable 0



00.00 TO 23.59


00.00 TO 23.59

Delay for Energy saving mode after Power On

ES - Power ON Delay :01 mins

1 TO 99

Delay between C1 and C2 turn on.C1-C2 Delay : 050 mS

0 TO 200

C2-C3 or C3-C2 changeover time +ve or -veChangeover time [+ve] 010 mS

POSITIVE NEGATIVE

C2-C3 or C3-C2 changeover time mS valueChangeover time +ve [010 mS]

0 TO 100


With Save No Save


POSSIBLE RANGE

Edit Parameters -Schedule Parameter


POSSIBLE RANGE

Fix: C1 on time setting.Sch1- C1 ON Time 18:30

00.00 TO 23.59

Fix: C1 off time setting.Sch1- C1 OFF Time 06:59

00.00 TO 23.59

Twilight timing setting. Lights to full intensity.Twilight Time : 00 mins

0 TO 99

C1 time turn-on offset sign +ve or -ve.C1 Offset [-ve] 00mins

POSITIVE NEGATIVE

C1 time turn-on offset time setting.C1 Offset -ve [ 00mins]

0 TO 99


With Save No Save

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Edit Parameters - Communication

Parameter Editing Submenu Level 2:Continued:


POSSIBLE RANGE

Unit ID number (Numeric 4 digits)Unit ID : 0000

0000 TO 9999

Baud rate for communication.Baud Rate 9600 : 1

4800, 9600, 19200, 38400, 57600,115200

RTC time setting.Time 04:50:18

00:00:00 TO 23:59:59

RTC date setting.Date 09:01:07

01:01:01 TO 31:12:99

For time & date declaration with new values, set this to YES

Initialize RTC No : 0

0 : NO 1 : YES

NV-RAM to be cleared for all temperory parameters.

Clear NVRAM No : 0

0 : NO 1 : YES

Communication Port choice for RS232 on TAS protocol OR for GSM Modem.

GSM or RS232 GSM : 1

0 : RS232 1 : GSM

GSM Service provider Center number.Service Provider 9822078000

0000000000 TO 9999999999

GSM SMS to be sent to MCU number.SMS Receiver No. 9373902669

0000000000 TO 9999999999


With Save No Save

Note that all the parameters in the Sub-Menu Level 2 should be carefully filled in the SLC-04. Failing to put the correct parameters can make SLC-04 to malfunction.

Its therefore advised that a trained person should only be allowed to change these values.

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Fault Type Probable Reason Action to Take

Unit Does not turn ON. No display on LCD.

•Input auxiliary supply not coming.•Input side fuses blown

•Check the input supply to restore•Check fuses in the unit for OK.

Unit does not turn On any output contactors even if PF is below Lower PF limit.

•Check the supply to the coils of the contactor to be healthy.

• The parameters for timing in Schedule control and/or in schedule parameter are not correct.

•Make supply conditions OK. Check fuses and if blown, put it right.

• Check the schedule parameters to be OK and then save them.

BF indication on Default display.

• Internal Ni-Cd 3.2Vdc battery used for RTC and NV RAM must be drained down.

• Replace this battery in consultancy with TAS trained personnel.

The SLC-04 unit shows wrong values of Power parameters and PF. This is even in spite of the Voltage and Current readings to be shown correctly.

•Synchronisation is improper. I.e. the Phase voltage is not matched with same phase current at input as well as current input may have wrong polarities.

•Correct the CT connections with right polarity and right positioning on SLC-04 connectors, with respect to the corresponding voltage phases.

Fault Finding Guidelines :

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Fault Type Probable Reason Action to Take

Serial Communication is not working.

• Baud rate selection is not proper.• Unit ID is not set properly.• Serial communication cable connections are not proper.

• Select proper baud rate.• Set the unit ID correctly.• Check the serial cable continuity as per the connections given earlier in this manual.

Data logging is not taking place.

• Possible that RTC date is not set properly.

• Change the battery if date has changed without user interface. This should be by help of TAS’s authorised person.

While changeover of C2-C3 or C3-C2, the lamps goes off.

• The Changeover time settings are too high on +ve side.

•Try reducing this parameter setting by small gaps till this problem is eliminated.

Power Fuses blows while C2-C3 or C3-C2 changeover.

• The Changeover time setting are too high on –ve side.

• Increase this setting on +ve side and then slowly reduce this to obtain the optimum results of: no lights switch off while changeover and no fuse blowing.

Fault Finding Guidelines (continued):

- 22 -

Energy Saving Calculation:

1kW / 240V Mercury lamp characteristics.

240V 220V 200V

100V 3

00

W

38

0W

50

0W

Voltage

Wattage

50Hz.

20KHz.

Cut

off

leve

l

Typical Characteristics.

The above characteristics even though typical, matches with a minor differences with most of the fluorescent lamp manufacturers.In view of the same, SLC-04 calculates the energy saving on the basis of typical graph as shown hereunder.

240V 220V 200V

100V

30

0W

38

0W

50

0W

Voltage

Wattage

Lamp Knee Voltage

A

B

- 23 -

General Scheme with SCADA:

SLC-04Controller. (RTU)

Voltage and/or PhaseControl Switchgear / Servo

Block.

LOAD1

LOAD2

LOAD3

GSMModem

CommunicationOn GSM-SMS

GSM-SMSMaster ControlUnit. Server.

MCU.

The communication between the RTU and MCU necessitates the following requirement:

• Per MCU about 2000 units should be able to communicate.

• Every RTU should be able to transmit the data at every one hour.

• Every RTU should be able to send the event triggered communication. This is for indicating the faults and Power ups and Power downs.

• The data size to be sent can be fitted within 100 ASCII characters.

• The reliability of communication should be good, but occasional data loss (say one in 200 or 300) would not make a great problem too.

• The communication charges should be as low as possible.

The above diagram shows the RTU and MCU communication link.

- 24 -

Overall Scheme with SCADA:

The overall scheme with the multiple number of SLC-04 (as RTU – Remote Terminal Units) communicating with MCU on GSM based SMS mode of communication.

SLC-04 SLC-04 SLC-04

- 25 -

Our Contact Details:

Corporate Office/Works/Design Centre: W-61, MIDC, Ambad, Nasik - 422010, Maharashtra (India)Tel: +91-(253)-2384038 / 2381090Email: [email protected] Marketing and After-Sales Service: A/58, Kamal Pushpa, K.C. Road, Bandra, Mumbai-400050.Tel: +91-9930513923Email: [email protected] Regional Office: Delhi191-B, Ground Floor, Padam Nagar (Filter Market),New Delhi - 110007 (India).Tel: +91-9911615701Email: [email protected]




operations manual slc-04 lighting controller

Documents

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voltage control operation

various energy

outputs control

voltage reduced saving

various parameters

load feed

control wiring diagram