ATP Document

PowerCube ICC310 with GEL Battery

Region:
Site Name
Site ID
Address
City
Site Type □ GF □ RT

ATP Document Page 1

ACB Power Solution
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1. Test Procedures: Power Cube 1000 with ICC300 and of GEL 12V 90/150Ah
battery banks inside power cabinet.

Specified Value/ Requirement and Test Test

No Test Item Severity Result
Procedure.
(OK/NOK)

PowerCube ICC310 system installed securely on

Installation of PowerCube Major
1.1 PAD or mounting racks as per site layout
system Cabinet
(approved / as built) No damage observe.
Power ON/OFF the AC Put ON/OFF the AC Input 3pole Circuit Breaker, all Major
1.2
Input the PSU Modules should work properly.
Power input indicator (top): ON
Check the status of the Major
1.3 Protection indicator (middle):OFF
indicators on the PSU
Fault indicator (bottom): OFF
Check the status of the
The internal fans of heat exchanger are working Major
1.4 Heat Exchanger Fan Unit
and check air circulation inside power cabinet.
connections and working
The Surge Protection Devices installed in Rectifier
Check the Surge Protection
Cabinet (PowerCube) shall be in healthy state. Major
1.5 Devices connections and
Check Color on front of SPD shall be GREEN, In
specifications
case of RED/BLACK, it is declared to be faulty
Install AC power cable from AC power supply to
Install AC and Grounding the AC power section of rectifier and check Major
1.6
Cables. terminal connections. Connect earth cable from
system to grounding bus bar.
Install DC (+/-) cables from battery to rectifier; Major
1.7 Install DC Power Cables
make sure no loose connection observed.
Install GEL batteries (12V-90/150Ah) in ICC310
Installation of GEL battery cabinet; arrange each bank/battery. The Major
1.8
in PowerCube cabinet. interconnection strips for each battery string cell
to cell terminal must be tightened.

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2. Test Procedures: Power Parameter Settings adjustment for AGM battery
Observatio Test
NO Test Items Parameters n / Meas. Result
Value (OK/NOK)

2.1 Running status At Normal Working there should be no alarm. Major

Fail the rectifier module and check its light is Major
2.2 Rectifier module failure
turned off and generate alarm.
AC Under and Over Voltage system reference
Check AC Input voltage Major
2.3 value 180V/280V single phase AC and
thresholds values
380V/440V for three phase AC.
Scenario: For 90Ah GEL For 150Ah GEL
2.4 Date and Time SET SET Minor

2.5 Battery Capacity 90*2Ah 150*2Ah Major

2.6 Charge Current limit 0.1C 0.1C Major

2.7 Float Voltage 54.0V 54.0V Major

2.8 Boost Voltage 56.4V 56.4V Major

2.9 Low Battery Voltage 47.0V 47.0V Major

2.10 LLVD 44.5V 44.5V Major

2.11 BLVD 43.5V 43.5V Major

Check the alarm LED’s on On event of alarm RED LED on SMU shall lit on Major
2.12
SMU to give alarm indication.
Check the values at the Display of SMU output
2.13 TEST voltage (54.0V) and Load current should be Major
according the reference value.

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3. Test Procedures: AC / DC and Grounding Cables.
Observatio Test
Specified Value/ Requirement and Test
No Test Item n / Meas. Result
Procedure.
Value (OK/NOK)
AC power cable: Wire 4*16mm2 connected
Specifications / installation & with ACDB to rectifier main breaker. Routed
3.1 routing of AC power separately from other cables. Both end Major
cable.(cable size as per BOQ) connections of AC cable are tightened with
Lugs and terminals covered by sleeves.
Specifications / installation & DC Power Cable: 25mm2 connected with
3.2 routing of DC power battery bank and load. Connect the positive Major
cable.(cable size as per BOQ) and negative cables as per the polarity.
Ground Cable: 25mm2 connected with positive
Specification / installation of
bus-bar of power system and grounding bar of
3.3 GND cables. (size as per Major
site, End to End connectivity of grounding
BOQ)
cable to Bus bar to Earthing pit shall be verified
Labels / Tagging of Cables The Tags must be pasted at the both ends of
(AC / DC / ACB Batteries and every cable inside ICC310 cabinet. All installed
3.4 Minor
Alarm cables etc) AGM batteries are tagged with its battery cell
number for each bank.

4. Test Procedures: Alarm Verification.

Observati
Specified Value/ Requirement and Test on / Test
NO Test Case Result
Procedure. Meas.
(OK/NOK)
Value
Check float voltages on ECC500 screen.
1 Mains Failure Turn Off the Mains power supply from ACDB
Check MF Alarm red led observed at ECC500. Major
Unplug & remove any 2 modules (PSU’s) from the
2 Rectifier Major Alarm
rectifier. Major
Unplug & remove one SPD unit from the rectifier.
3 Rectifier Minor Alarm
Check alarm indication observed on ECC500 Major
Adjust low battery voltage value to 53V from
ECC500
Turn off grid power and let battery to be
4 Low Battery Volt Alarm
discharge till 53V
Check voltage rating on ECC500 if decreased to
53V or below. Again resume the settings to 54.0V Major
Open the door of rectifier cabinet and turn its fan
5 Fan Failure alarm
off. Major
6 Rectifier Door Open Alarm Open the Door of Powercube cabinet. Major

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 5. Test Procedures: Charging and Discharging of GEL Battery.

No Procedure Expected result Test Result

(OK/NOK)
Health check of battery PTML standard battery health check template (attached) is
1 attached with ATP documents for battery testing.
banks
Check GEL Battery for The GEL batteries are not leaked. Check for any leakage
2 leakage / damaged / observed from joints of each cell or any acid corrosion observed
deformed etc. inside cabinet. The GEL battery is not deformed or de-shaped.
Voltage measurement of Take the complete cell by cell voltage readings before
3
batteries commencing battery test.
Shutdown the AC Input supply of Rectifier to take batteries on
4 Battery heath check load.
Check the batteries feeding power to load after disconnection of
AC power. Take the complete bank & cell voltage readings after
5 Battery health check
every 30 minutes. tested battery backup is up to/greater than
designed backup. (3hrs at the time of ATP)

T05-04 Battery Test Results:

BATTERY BANK TEST – CHECKLIST
Time No: Output Output Ambient
Float / Discharge Cell Voltages
(mins) Banks Voltage Current Temp(0C)
Bank 1 Bank 2 Bank 3 Bank 4 Bank 5 Bank 6 Bank 7 Bank 8
Cell 1
Before
Cell 2
Test
Cell 3
Cell 4
Bank 1 Bank 2 Bank 3 Bank 4 Bank 5 Bank 6 Bank 7 Bank 8
Cell 1
30 mins Cell 2
Cell 3
Cell 4
Bank 1 Bank 2 Bank 3 Bank 4 Bank 5 Bank 6 Bank 7 Bank 8
Cell 1
60 mins Cell 2
Cell 3
Cell 4
Bank 1 Bank 2 Bank 3 Bank 4 Bank 5 Bank 6 Bank 7 Bank 8
Cell 1
90 mins Cell 2
Cell 3
Cell 4
Observations: RESULTS

Last Discharge O/P Voltage Discharge Time(Hrs)

Pass Fail Not Run

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6. Snag List

ACB Power Solution ATP Snags Classification

Snag Classification
ATP Workmanship
Snag Details (Major/Minor)
Factor(WM) *
Date

Note: *WF: Means Snags reported due to Workmanship /Human Factor.(Technical Expertise , Skills lacking. Poor
Workmanship etc)

Huawei Representative PTML Representative

Name:_____________________ Name:_____________________

Signature:__________________ Signature:__________________

Date:______________________ Date:______________________

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 Contents:

Status
S # No. Test Items Tests Fail
Pass
T01 Installation of Power System

T01-01 Installation of new PowerCube ICC310 4

T01-02 Installation of GEL Batteries with PowerCube 4

T02 Commissioning of Power System with GEL Batteries

T02-01 Commissioning of PowerCube1000 Cabinet. 5

T03 AC / DC / Grounding & Alarm Cables

Installation of AC Power Cable, DC Cables and 5

T03-01
Grounding Cables/SPD

3
T04 Site Tagging and Labels

T05 Test Procedures

T05-01 Site External Alarm Tests 6

T05-02 Charging and Discharging Test of Batteries 5

T05-03 Battery Test Results: 1

4
T06 Documentation Required

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T02 Installation of Power System

T02-01 Installation of PowerCube1000 with ICC310 Cabinet.

Objective
Verify that the installation of the PowerCube 1000 System with ICC310 rectifier and fixation of cabinets;
CPMU, PSU’s connections which complies with the engineering specifications according to system manual.
Result:
PassFailNot Run
Comment & Remark:

Prerequisites
 The Power Cube1000 installation as per site approved design. (Refer: site layout)
 The rectifier modules are installed in Rectifier Cabinet.
 Cabinet Security and Locking mechanism for PowerCube1000.
Procedure Expected result Result
1. Installation of 1.1: The Power system is installed securely on the
PowerCube1000 system concrete PAD or mounting racks/ iron beams as per Pass Fail Not Run
Cabinet. site layout (approved / as built).
1.2: No damage has been done to equipment while
installation and door opening of installed power system Pass Fail Not Run
0
can be > 90
2. Installation of Expansion 2.1: The mounting holes for the cabinet must be
Pass Fail Not Run
bolts for Power system carried out by drilling on concrete PAD.
PowerCube1000 . 2.2: The 4 expansion bolts (M12 x 60) are installed
and tightened by using appropriate socket wrench.The Pass Fail Not Run
extra holes for cable entry are properly sealed and
covered by fire proof mud.
3. Check the PSU 3.1: The rated output current of each PSU is 50Amps,
Installation inside power and installed quantity of PSU’s is according to BOQ Pass Fail Not Run
cabinet PowerCube1000. and all should be in working condition.
4. Check the PowerCube 4.1: The Entrance door and locks of
cabinet locks / security POWERCUBE1000 are installed and operational , Pass Fail Not Run
mechanism and holes for door closer is operational
cable entry. 4.2: The PowerCube1000 Cabinet Door sealing is
Pass Fail Not Run
complete and no damage is observed.
Huawei Representative PTML Representative
Name:_____________________ Name:_____________________

Signature:__________________ Signature:__________________

Date:______________________ Date:______________________

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T01-02 Installation of GEL Batteries with PowerCube.

Objective
Verify that the installation of the ICC310 with 90/150AH GEL Batteries complies with the engineering
specifications.
Result:
PassFailNot Run
Comment & Remark

Prerequisites
 The GEL batteries installation as per site layout
 Interconnections of Battery string and banks with system
 Connecting power cable ac/dc and communication cables of power system
Procedure Expected result Result
1.1: The 90/150AH GEL batteries are installed in Power
cabinet according to BOQ. Pass Fail Not Run

1. Installation of GEL 1.2: Check number of battery Banks matches the

Pass Fail Not Run
battery in PowerCube quantity as per BOQ.
cabinet 1.3: The interconnection strips for each battery string cell
Pass Fail Not Run
to cell terminal must be tightened.
1.4: temperature sensor is installed between battery
cells. Pass Fail Not Run

4.1: Positive dc cable is connected both rectifier positive

2. GEL Battery Pass Fail Not Run
bus-bar and battery positive terminal.
connection with power
system +ve and –ve 4.2: Negative dc cable is connected both rectifier
negative bus-bar and battery negative terminal. Pass Fail Not Run
bus bar

Huawei Representative PTML Representative

Name:_____________________ Name:_____________________

Signature:__________________ Signature:__________________

Date:______________________ Date:______________________

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T03 Commissioning of Power System

T03-01 Commissioning of PowerCube1000 Cabinet

Objective
Verify that the commissioning of the Power System connected with ECC500, PSU’s complies with the
engineering specifications.
Result:
PassFailNot Run
Comment & Remark

Prerequisites
 The Power system POWERCUBE1000 commissioning
 The power modules are in working condition.
 The AC / DC and signaling cables are routed and properly connected with batteries and load as well.
 The Alarm connections are extended as per approved from customer and verified from NOC.
Procedure Expected result Result
1. Check the PowerCube1000 1.1: The Power system installed is as per BOQ. Pass Fail Not Run
specifications and check 1.2: No component in Rectifier cabinet is loose or
AC, DC and signal cable damaged. Pass Fail Not Run
connections.
1.3: The power cables (AC/DC) are connected
correctly, check end to end ‘O’ & ‘U’ type lugs
Pass Fail Not Run
connections properly done as per appropriate cable
dia” and punched with lugs presser tool.
2. Check ECC500 2.1: The ECC500 has been installed and in working
commissioning with system condition and ECC500 Display shall be properly
power parameters. visible and each parameter appearing on ECC500 Pass Fail Not Run
shall be viewable. Blurring & disappearance of
parameters shall fall ECC500 into faulty State.
2.2: Set all provided parameters in ECC500 such as
DC float volts, boost volts, charging current; etc shall
be appearing on ECC500.
Check 90AH GELB 150AH GELB

Date & Time Set Set

Battery Capacity 90*2Ah 150*2Ah
Charge Current
Limit
0.1C 0.1C

Float Voltage 54.0 V 54.0 V Pass Fail Not Run

Boost Voltage 56.4 V 56.4 V

Low battery
Voltage
46.0V 46.0V
LLVD Voltage 44.5 V 44.5 V
BLVD Voltage 43.5 V 43.5 V

3. Check the alarm LED’s on 3.1: On event of alarm RED LED on ECC500 shall lit
Pass Fail Not Run
ECC500 on to give alarm indication.
3.2: No alarm is present on the Rectifier indicator
ECC500. Both battery & load power ratings visible on Pass Fail Not Run
ECC500 are according with the specifications.

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 4. Check the status of the Heat 4.1: The Heat Exchanger Fan Unit of power system is
Pass Fail Not Run
Exchanger Fan Unit connected with rectifier distribution breaker units.
connections and working.
4.2: The internal fans of heat exchanger are working Pass Fail Not Run
and check air circulation inside power cabinet.
7. 5. Check the status of the 5.1: Power input indicator (top): ON
indicators on the PSU. 5.2: Protection indicator (middle): OFF Pass Fail Not Run
5.3: Fault indicator (bottom): OFF
Huawei Representative PTML Representative
Name:_____________________ Name:_____________________

Signature:__________________ Signature:__________________

Date:______________________ Date:______________________

T03 AC / DC / Grounding & Alarm Cables

T03-01 Installation of AC Power Cable, DC Cables and Grounding Cables/SPD

Objective
Verify that the AC power cable, DC Cables and PGND cables &SPD are correctly processed and installed.
Result:
PassFailNot Run
Comment & Remark
Prerequisites
 All internal cables (AC / DC / Alarm) are installed.
Procedure Expected result Result
1. Check the specifications and 1.1: The AC power cable installed to power up the
2
installation & routing of AC rectifier is Wire 4*16mm (Cores: Red, Yellow, Blue, Pass Fail Not Run
power cable.(cable lengths & Black) connected with ACDB to rectifier main breaker.
size as per BOQ)
1.2: The AC Power cable must be routed separately
from other cables. Both end connections of AC cable
Pass Fail Not Run
are tightened with Lugs and terminals covered by
sleeves.
2. Check specification and 2.1: The Rating of DC cable from Rectifier to Battery
Pass Fail Not Run
installation of DC Power should be as per BOQ.
cable. .(cable lengths & size 2.2: No joint lies in the middle of the DC power cable.
as per BOQ)
Both end connections of DC cable are tightened with Pass Fail Not Run
Lugs and covered by sleeves.

3. Check the specification and 3.1: The rating of grounding cable Wire, 450 / 750V,
Pass Fail Not Run
installation of GND cables. 16mm^2, yellow green, 110A.
(cable lengths & size as per 3.2: Lugs at both ends of the power cables and
BOQ) PGND cables are soldered or securely crimped. Pass Fail Not Run

4. Check the Surge Protection 5.1: The Surge Protection Devices installed in
units connections and Rectifier Cabinet (PowerCube1000 ) shall be in Pass Fail Not Run
specifications.. healthy state.
5.2: The SPD rating installed in Built-in power system
Pass Fail Not Run
of PowerCube1000 Cabinet is ~30/ 60KA-255Volt~.

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 5.3: Check Color on front of SPD shall be GREEN, In Pass Fail Not Run
case of RED/BLACK, it is declared to be faulty.
Huawei Representative PTML Representative
Name:_____________________ Name:_____________________

Signature:__________________ Signature:__________________

Date:______________________ Date:______________________

T04 Site Tagging and Labels.

Objective:
Verify that the Tagging and Labels of each new installed part /spare are proper.
Result:
PassFailNot Run
Comment & Remark
Prerequisites
 Check Tagging and Labels of each item for newly installed system / cabinet / cables etc.
Procedure Expected result Result
1. Labels / Tagging 1.1: The labeling and tags of every item must be
specifications. adequate as per approved by customer.
Pass Fail Not Run
- The Tags should be bold visible and pasted in printed
form,
1.2: The insulation of tags must be of good quality and
Pass Fail Not Run
can sustain in the environmental conditions.
1.3: Hard Plastic type tags pasted at the outdoor routing
of every cable iff it is routed inside duct / GI flexible pipe. Pass Fail Not Run

2. Labels / Tagging of 2.1: The Tags must be pasted at the both ends of every
Cables (AC / DC / cable inside PowerCube1000.
Pass Fail Not Run
communication /
Alarm etc)

Huawei Representative PTML Representative

Name:_____________________ Name:_____________________

Signature:__________________ Signature:__________________

Date:______________________ Date:______________________

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T05 TEST PROCEDURES
T05-01 Testing of Extended Alarms of PowerCube1000 Rectifier from NOC
Num of Test Case EAS Alarm Test # 1
Name of test Case Mains Failure
1. MF Alarm cable is extended to EMUA and ECC500 from both ends,
Preset Conditions 2. Rectifier is commissioned,
3. ECC500 is working.
Test Procedures 1) Check float voltages on ECC500 screen.
2) Turn Off the Mains power supply from ACDB
3) Check MF Alarm red led observed at ECC500.
4) Call to NOC for MF Alarm verification
5) Restore Wapda supply and check float voltages again.
Expected Results Mains Failure alarm reported to NOC.
Test Results Pass /  Fail

Num of Test Case EAS Alarm Test # 2

Name of test Case Rectifier Major Alarm
Preset Conditions 1. Major Alarm cable is extended to EMUA and ECC500 from both ends,
2. Rectifier is commissioned,
3. ECC500 is working.
4. PSU’s are working
Test Procedures 1) Check float voltages on ECC500 screen and Alarm LED is OFF.
2) Unplug & remove any 2 modules (PSU’s) from the rectifier.
3) Check alarm indication observed on ECC500
4) Call to NOC for Alarm verification
5) Connect the PSU’s again with rectifier and check Alarm indication OFF.
Expected Results Rectifier Major alarm reported to NOC.
Test Results Pass /  Fail

Num of Test Case EAS Alarm Test # 3

Name of test Case Rectifier Minor Alarm
Preset Conditions 1. Rectifier is commissioned,
2. CPMU is working.
3. SPD is connected with mains supply
Test Procedures 1) Check float voltages on ECC500 screen and Alarm LED is OFF.
2) Unplug & remove one SPD unit from the rectifier.
3) Check alarm indication observed on ECC500
4) Call to NOC for Minor Alarm verification
5) Connect the SPD unit again with rectifier and check Alarm indication OFF.
Expected Results Rectifier Minor alarm reported to NOC.
Test Results Pass /  Fail

Num of Test Case EAS Alarm Test # 4

Name of test Case Low Battery Volt Alarm
Preset Conditions 1. Alarm testing if battery bank voltages are Low.
2. To be test on battery discharging condition
Test Procedures 1) Adjust low battery voltage value to 53V from ECC500
2) Turn off grid power and let battery to be discharge till 53V
3) Check alarm indication on ECC500 when voltage reaches below 53V
4) Confirm alarm from NOC
5) Turn ON Grid breaker
6) Adjust low battery voltage value back to 48.0V from ECC500
Expected Results Low Battery alarm reported to NOC.

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 Test Results Pass /  Fail

Num of Test Case EAS Alarm Test # 5

Name of test Case Fan Failure alarm
Preset Conditions Temp Alarm testing if Temperature inside POWERCUBE1000 cabinet increased.
Test Procedures 1) Open the door of rectifier cabinet and turn its fan off.
2) Call to NOC for Fan failure alarm verification.
3) Again restore power supply of Heat Exchange Unit.
Expected Results Fan Failure alarm reported to NOC.
Test Results Pass /  Fail

Num of Test Case EAS Alarm Test # 6

Name of test Case Rectifier Door Open Alarm
Preset Conditions Alarm testing for Door of rectifier opens
Test Procedures 1) Open the Door of Rectifier cabinet.
2) Check Rectifier Door open Alarm signal at ECC500 and NOC
3) Call to NOC for Alarm verification.
4) Again close the door of Rectifier cabinet and check Alarm indication OFF.
Expected Results Rectifier door open Alarm reported to NOC.
Test Results Pass /  Fail

T05-02 Discharging Tests of GEL Batteries

Objective:
Verify that the Batteries can be normally charged and discharged after the mains power supply.
Result:
PassFailNot Run
Comment & Remark:
Prerequisites
 The Discharging Test of GEL batteries
 The mains power supply for the Rectifier PowerCube1000 is working normally.
 The BTS is working normally.
Procedure Expected result Result
1.1: PTML standard battery health check template Pass Fail Not Run
1. Health check of battery
(attached) is attached with ATP documents for
banks
battery testing.
2.1: The batteries are not leaked. Check for any Pass Fail Not Run
2. Check ACB Battery for leakage observed from joints of each cell or any
leakage / damaged / acid corrosion observed inside cabinet.
deformed etc. 2.2: The battery is not deformed or de-shaped. Pass Fail Not Run
3. Voltage measurement of 3.1: Take the complete cell by cell voltage readings Pass Fail Not Run
batteries before commencing battery test.
4.1: Shutdown the AC Input supply of Rectifier to Pass Fail Not Run
4. Battery heath check take batteries on load
5.1: Check the batteries feeding power to load after Pass Fail Not Run
disconnection of AC power.
5.2: Take the complete bank & cell voltage readings Pass Fail Not Run
5. Battery health check after every 30 minutes.
5.3: Is tested battery backup is up to/greater than Pass Fail Not Run
designed backup. (3hrs at the time of ATP)

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T06 Documentation Required:
Objective: All SIte related documentation and BOQ provided.
1. BOQ Available Not Available
2. Site Layout (approved / as built)  Available Not Available
3. Power Parameters  Available Not Available
4. Cables specifications  Available Not Available

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