Power Line Signaling Unit

PLSI

Installation Guide
(Document Version BGX501-139-R01)

Safety Instructions

Please take note of the warning and caution icons, presented in this manual, as follows:

Possible Electric Hazard

Existence of dangerous electrical voltage. This operation should only be performed by qualified personnel.

Attention

Kindly give special attention or take precautions whilst performing this operation. The procedure as described in the manual must be followed.

Deliverables

1. 2. 3.

PLSI Cables & Lugs, necessary for connecting PLSI with Bus Hand Gloves

PLSI Installation Guide

Contents

About PLSI Precautions & Safety Practices Tools & Accessories Setup Schematic Pre-Installation Issues Installation Post Installation Issues Changing the Firing Angle Configuring Interval for Transmission Absence Acknowledging the Fault Ensuring Signal Strength Viewing Failure Information Annexure 1: Check List

5 7 7 8 9 9 13 13 14 15 15 16 17

Important
Whilst every effort has been made in preparing the product documentation, the possibility of error always exists. We undertake to correct such errors wherever possible, and request feedback from users in this regard.

BGX501-139-R01

About PLSI

About PLSI

PLSI, an acronym for Power Line Signal Injector is installed as an integral part of the distribution metering system having dual supply sources i.e. Mains and Auxiliary. Such system demands a separate tariff to be applied for Main and Auxiliary supply. This requires recognising current source of supply by the meters for applying the corresponding tariff. PLSI, when installed on the secondary side of a distribution transformer, injects the desired signals into the downstream supply using the supply frequency itself. This signal is detected by the intelligent inbuilt receiver at the meter end. If the signal is available, mains tariff is applied otherwise DG tariff is applied. As the absence of signals is observed as DG Supply, it is necessary to implement this system in such a manner that failure of PLSI is immediately detected and notified. A Failure Detection Unit (FDU) is built in the PLSI which turns ON a hooter on detecting PLSI failure.

PLSI Signaling Technology

The technical method, used for signaling in PLSI, is an innovative technique of intentionally creating a small distortion in the voltage waveform near the zero cross over. The voltage distortion is created by causing a controlled short circuit, from phase to neutral, through a SCR. The controlled short circuit is achieved by firing the SCR at a very small measured angle just before the zero cross over, when the voltage is approaching to the zero from the positive half cycle (i.e. at. 180). The voltage driving the short circuit current is very small as voltage is approaching zero value. The short circuit is sustained in the negative half cycle for the same angle value after the zero cross over. By this time, the SCR automatically switches off due to reversed polarity. Hence, the duration of the short circuit is generally only for a few electrical degrees, i.e. 24o to 48 (depending on the exact angle, before zero cross, when the SCR was fired), and this corresponds to a time of 1.3 to 2.6 milliseconds. The inrush of currents, due to this temporary and controlled short circuit, has an imperceptible impact on the system equipment due to two reasons- Firstly, the peak current is not large enough to cause a mechanical stress and second, the duration of the short circuit is so small that the heating effect due to current (I2 x time) is also negligible. The peak voltage driving the short circuit is very low (VpeakSin 12 to Vpeak Sin 24, i.e. 24 volts - 94 volts), compared to the nominal value of 230 volts prior to the short circuit. The driving voltage also decreases sharply when the zero cross over approaches. Such a small voltage can only cause a small short circuit current, as the current is restricted by source impedance (i.e. impedance of transformer at the upstream). The short circuit creates a distortion in the voltage waveform as shown in the following diagram:

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PLSI Installation Guide

The distortion of the voltage waveform travels along the power line and is available at all consumer terminals in the system. This method of creating a distortion in voltage waveform near the zero cross over enables the propagation of the distortion along distribution wires to all power recipients. The term "transmission" has been used in this document to describe this propagation. A pair of consecutive sinusoidal cycles is used to describe a signal as "zero" or "one". For a "zero" signal, the first cycle has no distortion in the zero-cross over point and a distortion in the second cycle. For a "one" signal, the first cycle has a distortion in the zero-cross over point and no distortion in the second cycle. The baud rate for signal transmission is therefore 25 bauds (bits per second) for a 50Hz system. The baud rate for an American system, where the power frequency is 60Hz, would be 30 bauds. A zero signal is as follows:

A one signal is as follows:

This signal is detected by in-built receiver module of the Liberty meter to verify the source of supply from distribution transformer. It is interesting to note that these signals (voltage distortions) are not transmitted to wires belonging to any other transformer. That is because the impedance of the transformer and upstream (source) impedance do not cause a short circuit current to flow in other transformers so as to observe a noticeable distortion in voltage waveforms. Other Document to Refer Liberty User Manual (Dual Supply Meter) Liberty Installation Guide (Dual Supply Meter)

BGX501-139-R01

Precautions & Safety Practices

Precautions & Safety Practices

1. This product is designed for LT/LV applications only and should not be used elsewhere. 2. To minimize the risk of electrical shock, avoid any loose or exposed electrical connections near the installation. Use sleeves, and if necessary, you can also use any fast-drying insulation coating to cover such exposed electrical wire. Such coatings are easily available in varnish or aerosol form. 3. Disconnect the supply during the installation. Use insulated hand-gloves while working. 4. Always use proper tools & tackles and avoid using damaged tools. Usage of damaged tools is a major cause of all types of installation related accidents. Additionally, it can cause an irreversible damage to the PLSI and other devices. 5. To prevent any potential damage, always install the PLSI at a height considered to be safe. 6. Always refer to installation & associated documentations and follow the instruction and the practices described.

Safety First

Tools & Accessories

Following tools & tackles are required for installation: 1. 2. 3. 4. 5. 6. 7. Hexagonal Bolt Tightener for M8 Size Bolts Tabular Bolt Torque Screw Driver Cross head Magnetic Screw Driver Cable/Wire Cutting Knife Pliers Hand-gloves Multi-meter

Attention Never use improper & damaged tools

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PLSI Installation Guide

Setup Schematic

The following figure describes the schematic for the PLSI Installation:

From Distribution Transformer

PLSI

Signal Injector Unit Fault Detection Unit Indicator

MCCB

R Y B N N To MCCB & Neutral

From Hooter Relay to Hooters R Y B N

PLSI Unit is installed just near the Distribution Transformer and is connected to the bus bar at the secondary side. The PLSI incorporates three Signal Injector Units; one for each individual phase. These injector units inject the signals into the distribution line. Three signal detector units are integrated with PLSI each of which detects the signal on individual phases. This signal detector detects the PLSI signal continuously for the respective phase. The absence of signal when the phase is available is considered as a PLSI failure and an alarm signal is generated by the Hooter.

BGX501-139-R01

Pre-Installation Issues

Pre-Installation Issues

Before you proceed with PLSI Installation, you must consider the following: Selection of Mounting Location PLSI must be installed near the Distribution Transformer (DT) on the secondary side. PLSI should be placed on a concrete platform. The dimensions of the PLSI are 120 cm X 66 cm X 37 cm (Height X Width X Depth). A concrete platform 2-4 feet above the ground level is most suitable for placing the PLSI unit. A height convenient for user operations should be selected. Hooters must be mounted at a height of 6 ft. or above, to prevent it from any malicious activity. Ratings and Cable Selection The current ratings for the hooter should not exceed 2A. The supply voltage should be 230V AC. Use 1.1 kV super flexible cables (supplied with the PLSI) to connect PLSI with DT. If the length of the supplied cable is insufficient, never use a joint to expand the cable length. Use a complete length of another cable instead. The size of the cable should be selected according to the DT rating. Recommended sizes are tabularised as follows: DT Ratings
In kVA

Sr. 1 2 3 4 5 6 7 8 9 10

Conductor Area
In sq mm

Current Capacity
In amp

100 200 250 315 400 500 630 750 800 1000

6 6 6 6 10 10 10 16 16 25

18 30 34 38 40 46 50 68 71 90

Installation

The step-by-step procedure for installing the PLSI system is described here. 1. Make sure that you have all necessary tools in hand. By visual inspection, check any loose and exposed electrical connection near the installation. If any loose and exposed electrical connections are seen, make necessary arrangement to correct them. Unpack the PLSI. Due to the size & weight of PLSI, it is necessary to visually inspect and confirm that it is not damaged during transportation, loading & unloading. Open the front door of the PLSI. Now open the internal door of PLSI. Check for the healthy conditions of all mounted parts such as thyristors, inductors, MCCB etc. Make sure that all parts are tightly connected. Tighten any loose screw or bolt, if any. Perform for continuity test as prescribed in the Annexure. Make sure that all inductors are connected at 60T tapping position.
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2. Attention You must fill up the form prescribed in the Annexure at the time of installation

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PLSI Installation Guide

3.

First prepare the location for mounting the PLSI unit i.e. concrete platform or some place above the ground level. Now affix the base-frame (provided by SML) on this platform. If necessary, make use of grouting. Prepare a channel for cable passage. Lay down the connecting cables along the channel. Five cables are provided one for each phase and two for neutral. This ensures that high neutral current is distributed. Close the internal door & front door of PLSI and Mount the PLSI on the base-frame. Make sure that conductors are terminated using the lugs. If you are not using the supplied cables, you should terminate the cable using appropriate size lugs. Use colour coded sleeves. Make sure that MCCB is off. Insert each connecting cable into the PLSI panel using gland. Loosen the Rin, Yin and Bin terminals of the MCCB. Connect each of connecting cables to respective terminal (supplied cables are color coded). Now connect the two neutral cables to neutral terminal (one to each terminal) as shown in the picture. Two neutral cables help in distributing the high return current flowing through neutral at the time of transmission.

4. 5.

6. Possible Electric Hazard

7.

Inductors

Thyrsitors

Earth Terminal To Hooter Two Neutral Terminals

Rin, Yin, Bin Terminals Attention It is necessary to earth the PLSI from both the sides 8. 9.

Earth the PLSI panel using the earth terminals provided on each side of the panel. Now, you can connect the hooter as shown in the picture. Hooter rating should be 2A. Dont use a hooter exceeding this rating. Please note this connection is for hooter activation only. Power Supply to the hooter should be provided separately. Initially, switch off the power supply of the hooter.

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BGX501-139-R01

Installation

10. Isolate the bus Now connect the Bus bar. Before sure again that

bar from the distribution transformer. PLSI unit with the mains supply from the making connection with the bus bar, make MCCB is switched off.

11. Resume the supply. Once the PLSI unit is connected to the power supply, all three indicators should be glowing. In case any of the indicators is not glowing, recheck the connections. Check the phase voltage (P-N). 12. Switch on the MCCB and test the MCCB using the trip test button. This must be healthy. Switch the MCCB again. 13. Make sure that fans available on both sides are working. 14. Once the PLSI is powered up, the default display cycle is shown on the Signal Injector Unit. This cycle is repeated at a regular interval.

Mains On

Attention Default firing angle should be set at 18 degree. If this is not the case, you must change the firing angle to 18 degree as described in section Changing the Firing Angle

VOLTAGE indicates that value of voltage on the connected phase follows

Voltage is 234.50 Volts

FIR ANGLE indicates that value of configured firing angle follows.

Attention Firing is off by default. If this is not the case, you must stop the firing at the time of installation by entering code 00000-32423-0

Current firing angle is 18 degree. FIR OFF indicates that firing is inactive. This implies that signals are not being transmitted. FIR ON is indicated when signal transmission is active. By default, the firing is off.

15. Similarly, the default display cycle is also shown on Fault Detection Units. This cycle is also repeated at a regular interval.
Test Display

SIGNAL indicates the signal strength follows

45 BULS indicates that signal strength is 45 BULS. Now press key 1 VOLTAGE indicates that value of voltage on the connected phase follows

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PLSI Installation Guide

Voltage is 234.50 Volts

50 indicates that total 50 messages received till now

Time indicates that current time follows

Time is 12:45

Date indicates that current date follows

Date is 02-10-2005

16. Check the displays of each individual phase for Signal Injector Units as well as Fault Detection Units. 17. Now, you can start transmitting signals. This requires you entering 00000-52425-9 when default display cycle is being shown on the Signal Injector Unit. Follow the procedure as shown below.

Press *

Press key 0

Press key 0 four more times.

Press key 5, 2, 4, 2, 5 in the sequence

Press key 9

Press key # ACCEPTED indicates that your code has been accepted successfully and transmission has been started. You can verify this with default display cycle. In case some error occurs ERROR is shown on the display.

You must perform this operation on all the three Signal Injector Units one by one. Please note that you can stop the transmission by entering the code 00000-32423-0 in the same manner.

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BGX501-139-R01

Post Installation Issues

18. Once the transmission is started, you should verify this with the Fault Detection Unit. Check for the signal strength as follows.
Press *

Enter 0000-51423-9 and press key # ACCEPTED indicate that operation is successful SIGNAL indicates the signal strength follows 45 BULS indicates that signal strength is 45 BULS. Now press key 1. Display should indicate OK status

Attention You may notices some noise produced at the time of transmission

19. Now, power up the supply of hooter. As the transmission is started, the hooter should not make a noise. To check the healthy condition of hooter, stop transmission of a Signal Injector Unit by entering the code 00000-324239. The Fault Detection Unit of the corresponding phase should detect the failure (with in pre-configured interval) and turn on relay of the Hooter circuit followed by the hooter activation. After two minutes, relay is turns off automatically. The Fault Detection Unit turns On the relay repetitively at 30 minutes interval, unless it is acknowledged as described in the next section. 20. Once you have checked all three phases, PLSI is ready for operation. Now restart the transmission again. Close the internal door. If you wish to modify the firing angle and other default configuration, follow the instructions as described in the section Post Installation Issues. 21. Make sure that you fill up the form prescribed in the Annexure 1.

Post Installation Issues

Once you have installed, you can perform following operations with the Signal Injector Unit and Fault Detection Unit.

Changing the Firing Angle

The default firing angle for the transmission is 18 degree. However, you can change the default firing angle, if it is required. Enter 00000-51423-9, when Signal Injector Unit is displaying the default display cycle. The procedure is as follows:

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PLSI Installation Guide

Press *

Enter 0000-51423-9 and press key #

ACCEPTED indicate that operation is successful

AGNLE CFG confirm the firing angle configuration mode Current firing angle is 24 degree. Press key 4 to increase the firing angle in steps of 3 degree Current angle is 27. Press key 6 to decrease the firing angle in steps of 3 degree

Current angle is 24.Press key 6 again to decrease the firing angle in steps of 3 degree Current angle is 21. Press key # to confirm the angle being displayed on the screen. Signal Injector Unit switch to normal mode.

When you increase the firing angle, check current in the connecting cable of respective phase. This should not exceed 50 ampere.

Configuring Interval for Transmission Absence

The Failure Detection Unit continuously scans for the transmitted signals, and detects the absence of transmission if no signal is detected for a pre-configured interval. You can use the key 2 for displaying the configured period.
Press 2, when the default display cycle is being displayed

5 indicates that configured period is 5 minutes

This interval is user defined and can be configured by entering 00000-00XXX-7 where XXX is the period in minutes. Follow the instructions as below:

Press *, when the default display cycle is being displayed Enter 00000-00XXX-7 and press key #. For example, enter 00000-00005-7 for configuring 5 minute ACCEPTED indicate that operation is successful

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Post Installation Issues

Acknowledging the Fault

When Failure Detection Unit detects the absence of transmission, it turns on the hooter relay. This relay automatically turns off after two minutes. The Failure Detection Unit keeps on repeating the same at thirty minutes interval until it detects the signal again or acknowledged by the user. User can acknowledge the fault by entering 0000051423-9.

Press *, when the default display cycle is being displayed Enter 00000-51423-9 and press key # ACCEPTED indicate that operation is successful

Ensuring Signal Strength

For satisfactory information of the system, it is necessary to ensure that enough signal strength is available at each meter. The recommended signal strength at the FDU is 40-45 Buls. This implies that signal strength in the range of 25-35 Buls is received at the metering end. The signal strength at the Fault Detection Unit can be verified using the code 0000-51423-9. You should also verify the signal strength at metering sites of the tail ends. The procedure for checking signal strength at the Liberty meter is as follows:
Press * when default display cycle is being displayed

Enter 0000-51423-8 and press key #

ACCEPTED indicate that operation is successful

SIGNAL indicates the signal strength follows

25 BULS indicates that signal strength is 25 BULS.

If the sufficient signal strength (20 Buls or above) is not available at the tail end of the distribution line, it is necessary to increase the strength of transmitted signal. There are two different ways to increase the signal strength:

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PLSI Installation Guide

By increasing the firing angle at the transmission end. The maximum permissible limit is 27 degree. By reducing the inductor turns. You should use this method only if is not possible by increasing the firing angle. When increasing the signal strength, ensure current in the connecting cable of corresponding phase doesnt exceed 50 ampere. Use digital clamp millimeter for this.

When using inductor turns for increasing the signal strength, you should reduce the firing angle first and then reduce the number of inductor turns. You can increase the firing angle again, if required.

Viewing Failure Information

You can view failure information logged by the Fault Detection Unit as follows: Use key 1 for displaying the transmission status, date & time of last message received and total count of failure.
Press 1 when default cycle is being shown on the Fault Detection Unit

OK indicates that transmission is OK. FAIL is shown if transmission failure is detected. Wait for 2 seconds

Time of last message received. Wait for 2 seconds

Date of Last message received. Wait for 2 seconds

Total count of failure. Example screen showing 50

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BGX501-139-R01

Annexure 1: Prescribed Form for Installation Check List

Annexure 1: Prescribed Form for Installation Check List

Please check for the following and write down any corrective action taken at the time of installation. Put any additional remark if necessary. Note: Note that following steps do not describe installation procedure. You must refer section Installation for this. Sr No Checking Instructions To be checked before connecting PLSI to the Distribution Transformer 1 Check for any damage visible outside the PLSI Panel. 2 Check for any damage visible inside the PLSI Panel. Check that all parts such as Inductors, Relays, MCCB etc. 3 are at the right place and mounted properly. Any Loose bolts or screw should be tighten Check that all three inductors are connected to the 60T 4 tapping Check for the continuity status. There should be discontinuity between followings lines: **** R Y B N Y Y 5 B Y Y N Y Y Y E Y Y Y Y To be checked after connecting PLSI and Distribution Transformer 6 Check that all indicators are glowing. Check for the Phase to Neutral voltage for each phase. It should be within the suggested limit i.e. 240 Volts 7 approximately. To be checked after Switching On the PLSI MCCB 8 Check that both side fans are working. Check that displays are working for Signal Injector Units. Set the firing angle to 18 degree. Make sure transmission is 9 inactive. 10 Check that displays are working for Fault Detection Units. To be checked after starting transmission Check for the Signal strength at the Fault Detection Units. It should be around 40-45 BULS. Check OK status on display 11 for signal by using Key 1 sequence. Check the currents in the neutral and all three phase 12 cables. It should be below 50 amps in all cases. Check for the signal strength at tail-end of the distribution line for different meters. If required, 13 increase the signal strength. Check the current values again. Make sure that it does not exceed 50 amps. Write down the final value of currents. Status(OK/NOK)

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Secure Meters Limited

P.B. No. 30, E Class Industrial Area Pratap Nagar, UDAIPUR - 313003, INDIA Phone: ++91-294-2492300 to 2492304 Fax: ++91-294-2492310 Email: mktg@securemeters.com

PLSI Copyright @ Secure Meters Ltd. 2006-2007 This manual is a copyright with all rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the copyright owner; the same is proprietary and copyright must be affixed to any permitted copies as were affixed to the original. Secure Meters Ltd. reserves the right to periodically change information. The results generated by PLSI are not subject to copyright, and there is no restriction placed on their use by the original purchaser. No warranties are expressed or implied with respect to the product described, its quality, performance, or suitability for any purpose. In no circumstance will the copyright holder or his agents be liable for direct, indirect, incidental or consequential damages resulting from the use of this manual. No statements contained in this package shall affect the statutory rights of consumers.