OPERATING, MAINTENANCE

AND
USER INSTRUCTION MANUAL
FOR

HBL Make SMPS BASED

INTEGRATED POWER SUPPLY
(Version # D03 S001 H01)

RDSO Spec. # RDSO/SPN/165/2012

(Ver. 3)

Page 1
 INDEX
Sl. No Description Page No
1 Unpacking, Installation and Commissioning 6
1.1 Initial Checkup 6
1.2 Installation and commissioning 7
1.3 Instructions for installation of batteries 7
2 DO's and DON'Ts 8
3 List of abbreviations 9
4 Technical Specification for 10
4.1 SMR Module 10
4.2 Inverter Module 11
4.3 DC-DC Converter Module 12
4.4 CVT Module 13
4.5 Transformer Module 13
4.6 FRBC Rack 14
4.7 ACDP Rack 14
4.8 DCDP Rack 15
5 System Description & Controls 15
6 Rack Level PCB Description & Controls 17
6.1 SCU PCB (HBL/PE/IPS/SCU-01-D03 S001 H01) 17
6.2 Relay PCB (HBL/PE/IPS/SCU-03-D03 S001 H01) 27
6.3 ASM Panel PCB (HBL/PE/IPS/ASM-001-D03 S001 H01) 28
6.4 AC Meter PCB (HBL/PE/IPS/MTR(AC)-001-D03 S001 H01 28
6.5 AC Changeover PCB (HBL/PE/IPS/INV CO-001-D03 S001 H01 29
6.6 DC Meter PCB (HBL/PE/IPS/MTR(AC)-001-D03 S001 H01) 29
6.7 DC SCU PCB (HBL/PE/IPS/SCU-02-D03 S001 H01) 29
7 Module Level PCB Description & Contols 29
7.1 SMR Power PCB(HBL/PE/IPS/SMR-01-D03 H01) 29
7.2 SMR Control PCB(HBL/PE/IPS/SMR-02-D03 S001 H01) 31
7.3 INV Power PCB(HBL/PE/IPS/INV-01-D03 S001 H01) 31
7.4 INV Control PCB(HBL/PE/IPS/INV-02-D03 S001 H01) 32
7.5 DC-DC Power PCB(HBL/PE/IPS/DCDC-01-D03 H01) 32

Page 2
 INDEX
Sl. No Description Page No
8 Module level settings 33
8.1 SMR Module Settings 33
8.2 Inverter Module Settings 33
9 Operating Procedure 34
10 Safety 35
11 Warrantee Certificate 36
12 Trouble shooting procedure 37
12.1 Flowchart for SMR NO output condition 37
12.2 Flowchart for Inverter NO output condition 38
12.3 Flowchart for NO DC-DC Converter module output 39
12.4 Flowchart for NO DC output from FRBC Panel 40
12.5 Flowchart for NO AC output from AC Distribution Panel 41
13 Module Level block diagram 42
13.1 SMR Module Block Diagram 42
13.2 INV Module Block Diagram 43
13.3 DC-DC Converter Module Block Diagram 44
14 Rack Level General Assembly Drawings 45
14.1 General Arrangement Drawing 45
15 Rack Level BOMs 46
15.1 FRBC Rack BOM 46
15.2 ACDB Rack BOM 50
15.3 DCDB Rack BOM 55
16 Rack Level Wiring Diagrams 60
16.1 System Block Diagram 60
16.2 System Inter Connecting Diagram 61
16.3 FRBC Rack Wiring Diagram 62
16.4 ACDP Rack Wiring Diagram 64
16.5 DCDP Rack Wiring Diagram 66
16.6 L.A BOX Wiring Diagram 71
17 Feed back format 72
18 Pre-Commissioning Checklist of SMPS based IPS 73

Page 3
 IMPORTANT NOTICE

1. The Equipment has been designed with latest technology and to be used only in
restricted access areas.

2. Only authorized and qualified persons are permitted to service the equipment.

3. Operators should not attempt repair faulty units, there is no operator serviceable
parts inside.

4. ESD care must be taken while handling the modules

5. ESD care must be taken while handling the modules

Page 4
 CAUTION
1. Before Connecting AC input to the charger, ensure proper regulation of
input supply voltage, i.e, if rated load (No. of modules X 20A) is
connected to mains voltage variation should be within 150-275V.

2. Use sufficient rated cables for connecting input AC and output DC of

charger.

3. At the time of installation and full load test if SMPS modules found
switching OFF and ON continuously, test the modules with rated engine
alternator(1.25 times to charger capacity) and rectify the input mains
regulation problem.

Note: If any damages to the charger are noticed due to poor input AC voltage
regulation or due to use of insufficient rated cables for input, charger warranty
voids.

Page 5
1. Unpacking, Installation and Commissioning:

1.1 INITIAL CHECKUP:

 Ensure that all packages are always kept vertically as per markings on the
wooden packing.
 Check for any visual transport damages on packing.
 Remove packing carefully; use proper tools for unpacking. Avoid hammering.
Care shall be taken such that there shall be no scratches or damages on
panels/modules while unpacking.
 When removing equipment from packing cases, check carefully for loose items
such as connectors, cables, manuals, spare items, and tools etc., which are
to be carefully kept at safe and retrievable places before discarding any packing
materials.
 After unpacking, check for any visual damages on panels and modules.
 Check the materials as per the packing list.
 Check for tight screws/nut bolts on panels/modules (tighten where necessary).
 After all above checks, THE PANELS AND BATTERY ARE TO BE STORED IN DRY
PLACE IN IPS POWER ROOM UNDER NORMAL ATMOSPHERE CONDITIONS, NOT
EXPOSING THEM TO SUN, RAIN, DUST AND MOISTURE.
 Handle the packages/modules carefully. They shall not hit other objects, shall
not be toppled or dropped.
 The movement of materials can be handled manually without any special
erection tools. In case of usage of any tools, the packages are to be slinged fully.
No erection tools or no slinging when once unpacked. Storage shall be in re-
packed condition and not exposed to sun / rain / dust / moisture.

Page 6
1.2 INSTALLATION AND COMMISSIONING:

• The Racks shall be installed with sufficient space(as per spec) at rear and front for easy
maintenance and servicing.

• Racks shall be fixed with bolts through base mounting holes.

• Racks shall be properly earthed with suitable cable to Power Earth (PE).

• Initial battery connection & load connection shall be done without energizing the system.

• To maintain proper voltage regulation at the battery, Cable installed between charger
and battery must be proper size to minimize voltage drop.

• Ensure correct positioning of the individual modules on to their corresponding rack.

Note: 1. Use the resistive load only while conducting the full load test.

1.3 INSTRUCTIONS FOR INSTALLATION OF BATTERIES TO FRBC PANEL:

• Make sure before connecting the battery FRBC Panel should be OFF.

• Make sure that batteries are connected properly. i.e. positive (+VE) of battery to +VE
and negative (-VE) of battery to respective battery path terminal (Refer system
Schematic diagram).

• Observe Whether green LED is glowing or not in Battery reverse indication PCB
(HBL/PE/IPS/BTY-001-D01 H01),if red LED glows verify connections as per polarity.

Page 7
2. DO'S & DON'TS:

DO'S:

 KEEP ALL MCB’S IN OFF POSITION BEFORE CONNECTING THE AC MAINS TO THE SYSTEM.

 ENSURE THAT ALL PANELS ARE PROPERLY EARTHED; EARTHING RESISTANCE SHOULD BE < 2ῼ
BETWEEN IPS SYSTEM EARTH POINT TO EARTH PIT.

 ENSURE THAT ALL THE CABLES ARE PROPERLY TIGHTENED.

 CONNECT AC MAINS TO INPUT TERMINAL BLOCK (TB1) WITH PROPER SEQUENCE i.e. P,N &E FOR
1ø INPUT.

 BEFORE CONNECTING THE BATTERY, CHECK THE PERFORMANCE OF ALL SUB-MODULES

INDIVIDUALLY (FRBC / INVERTER / DC-DC CONVERTER / AVR&STEP DOWN TRANSFORMERS).

 CONNECT BATTERY KEEPING ALL SWITCHES/MCB’S IN OFF POSITION.

 CONNECT BATTERY WITH CORRECT POLARITY (+VE TO RED, -VE TO BLACK) AND OBSERVE
WHETHER GREEN LED IS GLOWING OR NOT IN HBL/PE/IPS/BTY-001-D01 H01 CARD FOR
ENSURING BTY. CONNECTED PROPERLY OR NOT.

 ENSURE THAT ALL THE LOADS ARE CONNECTED TO IPS THROUGH MINIMUM RECOMMENDED
CABLE SIZES.

 AC & DC CABLES ARE TO BE TIED SEPARATELY AND ROUTING TO BE DONE PROPERLY.

DONT’S:

 DO NOT SWITCH ON SYSTEM IF RED LED (BTY. REVERSE INDICATION) GLOWS IN

HBL/PE/IPS/BTY-001-D01 CARD OF FRBC RACK. (CORRECT THE WIRING UNTIL GREEN LED
GLOWS.)

 DO NOT ALLOW THE BATTERY TO FEED THE LOADS WITHOUT FULLY CHARGED. (THE CONDITION
OF BATTERY FULLY CHARGED IS THAT THE COULOMB COUNTER IN IPS CONTROL SHOULD BE
SAME AS SETTED AH CAPACITY).

 DO NOT SWITCH ON THE IPS SYSTEM IF THE VOLTAGE BETWEEN NEUTRAL & EARTH IS >
4VAC.

 DO NOT IGNORE START GENSET ALARM. THIS HELPS TO AVOID DEEP DISCHARGE OF THE BTY. &
GIVES LONG LIFE.

 DO NOT DISTURB FACTORY SET VOLTAGES/CURRENT UNLESS NECESSITATED AT SITE. (REFER

ADJUSTMENT INSTRUCTION OR MANUAL FOR GUIDANCE).

 DO NOT ATTEMPT FOR SERVICING THE MODULES ON YOUR OWN BY OPENING THEM.

Page 8
3. LIST OF ABBREVIATIONS:

AFTC Audio Frequency Track Circuit

AVR Automatic Voltage Regulator
AMF Panel Auto Mains Failure Panel
ASM Assistant Station Master
ACDP AC Distribution Panel
DSA Distribution Switching & Alarm Unit
DG Set Diesel Generator Set
DCDP DC Distribution Panel
DOD Depth of Discharge
EMI Electromagnetic Interference
FRBC Float Rectifier Cum Boost Charger
IPS Integrated Power Supply
IS/IEC Indian Standard/ International Electro technical Commission
LEMP Lightning Electromagnetic Impulse
LCD Liquid Crystal Display
LED Light Emitting Diode
LMLA Low Maintenance Lead Acid
MTBF Mean Time Between Failures
MOV Metal Oxide Varistors
PI Panel Interlocking
PF Power Factor
PWM Pulse Width Modulation
RE Railway Electrification
RFI Radio Frequency Interference
SMPS Switch Mode Power Supply
SSI Solid State Interlocking
SPD Surge Protection Devices

Page 9
 4. TECHNICAL SPECIFICATION:

4.1 TECHNICAL SPECIFICATION FOR SWITCH MODE RECTIFIER (SMR) MODULE:

(Float Rectifier Cum Boost Charger)

Sl.No. Description Value

1 Model 110SP20
2 Input Voltage (Nominal 230V , 150V To 275 V AC , 50 ±2% Hz
Voltage, working Range and Freq.)
3 DC Out Put Voltage LMLA BTY VRLA BTY
Float Mod 118.25V 123.7
Boost Mode 133.0V 126.5V DC
4 Out Put Current 20A
5 Out Put Voltage Regulation ±1% (25% Load to 100% Load )
6 Efficiency >90% (Nominal I/P voltage at 100% load)
7 Total Harmonic Distortion < 10% at 50% to 100% of rated load
8 Power Factor >0.9 from 40% to 100% load
9 Dielectric Levels 1KV RMS at 50 Hz for 1 Min. between AC
I/P & Earth.
1KV RMS at 50Hz for 1 Min. between AC
I/P & DC I/P.
10 Insulation Levels >10M Ohms
11 Connections Irreversible plug in type male & Female
Connectors at I/P & O/P

12 O/P Voltage Ripple (RMS) < 300mV W/O BTY

Page 10
4.2 TECHNICAL SPECIFICATION FOR INVERTER:

Sl.No. Description Value

1 Model 230SP2KVA

2 Input DC Voltage 110V , 98 V To 138 V

(Nominal Voltage and working Range)
230V AC, 50±1Hz and 2KVA
3 AC Out Put Voltage, Freq. and Power

4 Waveform Distortion < 8%

5 Out Put Voltage Regulation <±2% of 230V AC at 25% - 100% rated load

6 Efficiency >85% at rated load.

7 Total Harmonic Distortion < 10% at 50% to 100% of rated load

1KV RMS at 50 Hz for 1 Min. between AC I/P &
8 Dielectric Levels Earth.
1KV RMS at 50Hz for 1 Min. between AC I/P &
DC I/P.

9 Insulation Levels >10M Ohms

10 Connections Irreversible plug in type male & Female Connectors at

I/P & O/P

Page 11
4.3 TECHNICAL SPECIFICATION FOR DC-DC CONVERTER MODULE:

Sl.No. Description Value

1 Model DC DC Converter
(Out put Voltage as per Sketch)

2 Input DC Voltage 110V , 98 V To 138 V

(Nominal Voltage and working Range)
As per Sketch
3 Out Put Voltage

4 Ripple (RMS) <50mV

5 Out Put Voltage Regulation ±1% of the set value for load variation of 10%
to 100% rated

6 Efficiency >50% 10VA to 50VA, >75% 50VA to

150VA, >80% 150VA and above
1KV RMS at 50 Hz for 1 Min. between AC
7 Dielectric Levels I/P & Earth.
1KV RMS at 50Hz for 1 Min. between AC
I/P & DC I/P.

8 Insulation Levels >10M Ohms

9 Connections Irreversible plug in type male & Female

Connectors at I/P & O/P

Page 12
4.4 TECHNICAL SPECIFICATION FOR CVT MODULE:

Sl.No. Description Value

1 Input AC Voltage 230V , 160 V To 275 V

(Nominal Voltage and working Range)
230V AC
2 Out Put Voltage

3 Out Put Voltage Regulation <±1% FOR 25% - 100% Load Change at
230VAC Input

4 Waveform Distortion < 8%

5 Efficiency >85%

6 Connections Irreversible plug in type male & Female

Connectors at I/P & O/P

4.5 TECHNICAL SPECIFICATION FOR TXR MODULE:

Sl.No. Description Value

1 Input AC Voltage 230V

(Nominal Voltage and working Range)
100V,110V,120V,130VAC tappings
2 Out Put Voltage

3 Out Put Voltage Regulation ±5% AT 230V AC INPUT

4 Efficiency >90%

5 Connections Irreversible plug in type male & Female

Connectors at I/P & O/P

Page 13
4.6 TECHNICAL SPECIFICATION FOR FRBC Panel:

Sl.No. Description Value

1 Model FRBC Panel

2 Input Voltage (Nominal 230V , 150V To 275 V AC , 50 ±2 Hz

Voltage, working Range and Freq.)
LMLA BTY VRLA BTY
3 DC Out Put Voltage Float Mod 118.25V 123.7
Boost Mode 133.0V 126.5V DC

4 Out Put Current No. of modules X 20A

5 Selection of Boost Charging Auto mode through SCU in Rack leve

6 Mounting Free standing floor mounting

7 SCU CONTROLLER Provided to monitor system and to control all

Alarms and Indications

8 LCD 20 X 4 LCD Display

4.7 TECHNICAL SPECIFICATION FOR ACDB Panel:

Sl.No. Description Value

1 Model ACDP Panel

2 Input Voltage 110V DC for Inverter & 230V AC For CVTs

98V – 138DC for Inverters & 150-

3
Input voltage variation 275VAC for CVT's

4 Mounting Free standing floor mounting

Page 14
4.8 TECHNICAL SPECIFICATION FOR DCDB Panel USING DC-DC CONVERTER
MODULES:

Sl.No. Description Value

1 Model DCDP Panel

2 Input Voltage 110V DC

98V – 138DC
3 Input voltage variation

4 No. of DC DC Converters As Per Sketch

5 Types of DC DC Converters As per Sketch

5. SYSTEM DESCRIPTION & Controls :

The IPS system in general consists of a SMR panel, an AC distribution panel, a DC distribution panel, a
Status monitoring panel and a Battery. All the panels are integrated to provide a centralized
uninterruptible power supply for all signaling loads in a station and the battery is used as DC back-up
source.

FRBC Panel:

The SMR panel consists of a set of Switch Mode Rectifier modules and a Micro-controller based Supervisory
Controller Unit with display providing Output Voltage and Output Current. Each SMR is provided with an input
ON/OFF MCB and an output ON/OFF MCB.

A 230V (variable from 150V-275V), 50Hz,single phase AC mains is connected to the SMR panel(Switch Mode
Rectifier). The SMR Panel rectifies the input AC power into regulated DC power. The regulated DC power supply is
then fed to the AC distribution panel, DC distribution panel and battery. Apart from this, the AC power supply in the
SMR panel is looped internally and connected to AC distribution panel to provide AC supply to the CVT's as
applicable for the subject installation. (NOTE: The input voltage should be of minimum 150V at full load of IPS
System, not on no load)

Page 15
AC Distribution Panel:

The AC distribution panel contains inverter modules and magnetic. Each inverter module is provided with an input
ON/OFF MCB.

In this panel, the DC supply from SMR panel output is connected to the input of inverter modules, which converts
DC power into AC power. The output of the inverters (AC) is connected to transformers feeding signal loads. A
CVT is also provided having its input from AC mains directly from SMR panel. The output of CVT is connected to
step down transformers feeding signal loads.

Interlock has been provided at the output of the inverter modules and CVT at their outputs in such a way that the
inverter module-2 is connected to the load incase of failure of inverter module-1 and if inverter module-2 also fails
CVT is connected to the load automatically. On restoration of any inverter module, the load gets connected to
inverter automatically.(If both inverters are restored,load will be connected to inverter-1module)

The panel also consists of one CVT/Transformer/s for track circuit loads, the input for which is directly given from
AC mains looped from SMR panel.

DC Distribution Panel:
The DC distribution panel is provided with various rating of DC-DC converter modules.

In the DC Distribution Panel, the DC supply from SMR panel output is connected to the input of all DC-DC
converter modules except those modules, which are connected to BLOCK TELE loads. The Block Tele modules are
connected directly to the battery. The input DC is converted into required DC output voltages by various ratings of
DC-DC converter modules to meet the various DC output load requirements.

VRLA/LMLA Battery:

A 110V VRLA/LMLA (55 cells) battery is connected at the output of SMR panel. The battery will give the backup
power to inverters and DC-DC converters in the event of failure of AC source.

Status Monitoring Panel:

The status-monitoring panel is installed in the ASM room. The warning/fault alarms of all sub modules of IPS
system are monitored and extended to the status monitoring panel. This panel has following audio, visual alarms.

a) Start generator
b) Emergency-Start generator
c) System shut down
d) Call S&T Staff
e)Stop generator

Page 16
6. Rack Level PCB Description & Controls:

6.1 SCU PCB (HBL/PE/IPS/SCU-01-D03 S001 H01)

Micro controlled based SCU Card controls battery-charging current by sensing the battery current through
shunt and protects deep discharge of battery by disconnecting from load through LVD Contactor.

It monitors battery-charging current and provide the float-to-boost changeover command to all SMR
Modules to change the modules status from float-to-boost to recharge the battery. SCU commands the
IPS System status details like any failure as a call S&T staff, Battery status alarms during discharging to
SM Panel.

The purpose of SCU is to control or sense the status of various modules (SMR, INVERTER ,CVT, TXR, DC-
DC CONVERTER and ASM PANEL) and to sense the voltages and currents of System, Load & Battery in
the IPS system. The communication between SCU and various modules is achieved through USB & RS-
485. The transfer of sensed data or controlled data between PC and SCU is achieved through the USB
interface.

Page 17
DESCRIPTION OF BLOCKS

MICRO CONTROLLER:

The main component of SCU is Micro controller. It is responsible for controlling various modules
of IPS system through USB & RS485 communications. The internal ADC converts the input voltages &
currents from AC, SYSTEM, BATTERY & LOAD. The controller sends the data after ADC conversion to the
LCD. The communication between PC and SCU is USB. This is accomplished using controllers USART.
The micro controller is a low power CMOS 8-bit micro controller based on the AVR enhanced
RISC architecture.

The main features of micro controller are described below.

 Up to 16 MIPS Throughput at 16 MHz

 Write/Erase cycles: 10,000 Flash/100,000 EEPROM
 Data retention: 20 years at 85°C/100 years at 25°C
 Programming Lock for Software Security
 Six Sleep Modes: Idle, ADC Noise Reduction, Power-save, Power-down, Standby, and
Extended Standby. These are used for low power consumption
 Software Selectable Clock Frequency

LINK SWITCH:

The link switch of power integration make is being used to provide regulated output dc for
different regulator inputs. The link switch is having several advantages as described below.

 Fully integrated auto-restart for short-circuit and open loop fault protection - saves external component
costs
 66 kHz operation with accurate current limit - allows low cost off-the-shelf 1 mH inductor for up to 120
mA output current
 Tight tolerances and negligible temperature variation
 High breakdown voltage of 700 V provides excellent input surge withstand
 Frequency jittering dramatically reduces EMI (~10 dB) -minimizes EMI filter cost
 High thermal shutdown temperature (+135 °C minimum)

Page 18
SCALING CKTS:

Scaling ckts are used for scaling the various voltage levels from system, battery & load to meet
with the internal ADC i/p range of micro controller. In this circuit high precision op amps are used.

The above mentioned op amp is having below features.

 Low noise high precision op amp.

 Extended operating temperature range -40 °C to +125 °C.

 Low input bias current.

 Can be used in wide range of applications.

RS485 TRANSCEIVERS:

RS485 Transceivers are used to convert USART signal levels to RS485 signal levels and vice
versa. These are used to perform communication between micro controller and various
modules(SMR,INVERETR & ASM PANEL etc..) of IPS system. The transceiver used is having +/- 15kV ESD
protection facility and it requires low power for operation.

ISOLATOR 1 & ISOLATOR 2:

Isolators are used for better isolation of signals between micro controller and external peripherals
like ADC and USB-UART converter ic.

USB-UART CONVERTER:

USB-UART converter is used for communication between PC and micro controller. This converter
converts the signal levels from USB compatible to UART compatible levels and vice versa.

Page 19
The advantages of using this ic are given below.

• Entire USB protocol handled on the chip - No USB-specific firmware programming required.
• Integrated internal EEPROM for storing USB VID, PID, serial number and product description strings,
and CBUS I/O configuration.
• New 48MHz, 24MHz,12MHz, and 6MHz clock output signal Options for driving external MCU or FPGA.
• FIFO receive and transmit buffers for high data throughput.
• Support for USB suspend and resume.
• Integrated level converter on UART and CBUS for interfacing to 5V - 1.8V Logic.
• True 5V / 3.3V / 2.8V / 1.8V CMOS drive output and TTL input.
• Fully integrated AVCC supply filtering - No separate AVCC pin and no external R-C filter required.

ADC:

External ADC is used to convert the currents from system & battery and sends the equivalent
digital data to the micro controller. Here 24-bit ADC is used for high precision(accurate) results.

The advantages of using this ic are given below.

I- Low frequency measurement is possible.

II- Can be used in master or slave.
III- Sigma-delta ADC.

LCD:

LCD displays the data, which has come from micro controller. LCD is connected to controller
parallely.

SCU Parameter Selection Procedure:

By default, the LCD displays the following screen.

HBL Power Systems

SW V1.0

The above screen will be displayed for 5sec.This LCD is of 20 x 4 Configuration i.e the screen consists
of 4rows.

• First row displays AC Voltage, Current and alarm about AC failures, Output range and Status
of SMR Modules(Boost Mode or Float Mode).

• Second row displays System Voltage and System Current.

• Third row displays Battery Voltage and Battery Current.

Page 20
 • Fourth row displays all alarms

• (of SMR Modules, Inverter Modules, ASM, Relay Card, AC & DC Meter Cards, AC Changeover
Card, DC-DC Converters, DCSCU) status and if there is no alarm indication, screen will be
displayed as “HEALTHY”.

To get the information regarding different modules and PCB's, Press Menu Button then display shows
about Battery information, if we want to know the battery information then press (Select) Menu
button otherwise press (Scroll) Set button for FRBC,Inverter,Meter AC information,Meter DC
information,AC Switch information,DCDC information,ASM Panel Information and System Setup
information.

For example,if we want to know the ASM Panel information on SCU,press Menu button and then
press scroll button until ASM information will be shown on display and press Select Button,then the
display shows about ASM Panel information (if information is not needed,then press Menu Button).

For Setting of Module's address, press Menu and then scroll button until system setup displays.

Then press select button for module setup, then screen will be displayed as follows:

System Setup
Pls select @ SMR+INV!
SMR: -- -- -- --
INV: -- --

Then to select SMR Module address, all SMR's displays address individually at its display ,then by
selecting the respective SMR/INV Module, the display in screen of SCU indicates that particular
module is OK.[For Inverter Module, Mains ON LED blinks once for MOD1 and for MOD2 Mains ON
LED blinks twice]

Then Press Menu, then LCD displays as follows:

Stored Config:
SMR: -- -- -- --
INV : -- --

To Store Module Configuration, Press Menu.

Page 21
 To Change/Set the User Parameters:

Press Menu until screen displays system setup.

Then press Select, screen displays user parameter setup.
Then again press select,screen displays as follows:

25 BTY PATH CURR LMT

10%
B 1 DEC INC NEXT

For input current limit as per clause no.:4.1.16,set the limit from 5% to 15% using INC or DEC keys.

Press Next(Set) button,then display shows as:

INPUT CURR LMT

50 TO 100%
B 1 DEC INC NEXT
For auto boost to float mode limit, as per clause no.:4.1.11.2,set the DROOPIAC limit from 50% to 100%
by pressing INC or DEC keys. Press Next key, then display shows as:

FLOAT DELAY
0 – 3600 sec
B 1 DEC INC NEXT

For Float delay, set the limit from 0- 3600 sec using INC or DEC keys

Press Menu and Set key at a time, to return to normal display.

SCU Settings:

After getting the default screen, press Menu, then LCD will be displayed as:

Battery Info

Select Cancel Scroll

Then if we press select, then LCD will display:

Bat Voltage – Bat Current

T bat
Bat Ah
RLY(Status) FUSE(Status) MENU

Page 22
Next if we press Menu, then LCD displays:

Advanced BTY Setup

DEC=Force Boost
INC=Clr Coulombctr
SET=Set Coulombctr

Then again press menu to come back (if we press menu again,the main menu will be displayed).Then.
press scroll, then display shows as:

FRBC Info

Select Cancel Scroll

Then if we press select, LCD displays status of SMR Modules (all SMR Module status will be shown by
pressing Scroll button). Then press Menu to come back. Then press scroll, display shows:

Inverter Info

Select Cancel Scroll

Then press select, then display shows status of inverter modules (by pressing scroll button, individual
inverter module status will be displayed). Then press menu & then press scroll, then LCD displays as:

AC Meter Info

Select Cancel Scroll

By pressing Select, Status of Meter AC will be displayed. Then press menu and then press scroll, then
LCD displays as:

Meter DC Info

Select Cancel Scroll

Then,by pressing select, status of Meter DC will be displayed. Then press menu and then scroll,then
display shows as:
AC Switch Info

Select Cancel Scroll

Page 23
Then,by pressing select,status of ACSO will be displayed. Then press menu and then scroll, then display
shows as:

DCDC Info

Select Cancel Scroll

By pressing select, display shows status of DCSCU. Then press Menu & then press Scroll, then display
shows as:

ASM Panel Info

Select Cancel Scroll

By pressing select, display shows status of ASM Panel. Then press Menu & then press scroll, then display
shows as:
System setup

Select Cancel Scroll

Then, by pressing select button,display shows as:

Module setup

Select Cancel Scroll

Then,press select,then display shows as:

System setup
pls select @SMR+INV!
SMR: – – – –
INV: – --

Page 24
To set the SMR Module address, set '01' on module display by pressing INC button. Then, SMR displays
as ID 01.

Then SCU displays as:

System setup
pls select @SMR+INV!
SMR: OK – – –
INV: – --

Follow the same process for all SMR Modules. For Inverter modules, if Mains ON LED of inverter module
blinks once, then INV1 is OK and if LED blinks twice, INV2 will be OK.

Then press Menu, display shows as:

Stored Configuration:
SMR: – – – –
INV: – –

Then press Menu & then scroll, display shows as:

User Parameter setup

Select Cancel Scroll

Then press select, so that all parameters i.e. (INIT, Mains Available, Mains Low, Mains High, Mains Delay,
Input path curr.LTD , Min charge AC Droop, Drop comp, Drop tolerance, Transient delay, Load high,
Overload , Battery fuse, System fuse, Min Droop, Float voltage, Boost voltage, To float voltage, To float
current, Battery Capacity, Cells, Battery Disconnect, Temperature coefficient, Float delay, AH for boost,
BTY PATH CURR LMT, Battery reconnect, AH Battery Low, AH Battery Emergency ,AH Battery Shutdown,
CT Ratio, Buzzer time, SMR Error mask,INV error mask, DC DC error mask, PCB error mask, Call staff
mask, Status Mask, Full charged time, Shunt Battery, Inverter Voltage, ACSO delay, ACSO persist, SMR
Beep, SMR Shutdown, INV Beep, INV Shutdown, Shunt sys, ACDP Mask, Module Current Limit, Mains
Hysteresis, Password, AC Meter CT Ratio) will be displayed by pressing NEXT Key.

After that, press Menu + Exit to get back to main screen. Then press Menu, display shows as:
System setup

Select Cancel Scroll

Page 25
 Then press select, then display shows as:

User parameter setup

Select Cancel Scroll

Then press scroll, then display shows as “Enter Password”. Then press select and enter password.
(Press Menu for INC in decimals).Then the display will be:

Enter Password
00000

B 1 DEC INC OK

After entering password press OK, then display will be:

Enter Password
00001
Password OK

Followed by,
Enter Password
Password Valid:300s

Select Cancel Scroll

Then press scroll,then the display will be:

All parameter setup

Select Cancel Scroll

Then press select & then by using INC & DEC keys, all parameters will be setted.

Page 26
Then press menu + exit and then press Menu, then the display will be as:

Manual Mode

Select Cancel Scroll

Then press select and then set the system voltage and system current by using INC & DEC keys.

6.2 Relay PCB (HBL/PE/IPS/SCU-03-D03 S001 H01):

Micro-controller based relay PCB consists of following potential free contacts and battery LVD relay
contacts.
1. Master alarm call S & T staff
2. INV1 fail
3. INV2 fail
4. FRBC fail
5.Mains fail
6.Battery low
7.Call S & T staff
8.Battery LVD Contacts

Whenever command gets from SCU micro-controller,it will operate according to related potential free
contacts as well as LVD Contacts. For this card,power supply gets directly from battery.

Page 27
6.3 ASM Panel PCB (HBL/PE/IPS/ASM-001-D03 S001 H01):

The micro-controller based status-monitoring panel is installed in the A.S.M room. The warning / fault
alarms from all sub modules of IPS system are commanded through SCU micro-controller to the status
monitoring panel. This panel has following audio, visual alarms.

 Start generator

 Emergency-Start generator

 System shut down

 Call S&T Staff

 Stop generator

 ACK/Reset

 LED Test.

6.4 AC Meter PCB (HBL/PE/IPS/MTR(AC)-001-D03 S001 H01):

AC Meter PCB consists of micro-controller & 16 x 2 LCD Display. Basic function of AC meter
card is to measure inverters, TXR's & CVT modules Output Voltage,total signal current and if any module
fails,fail alarm will be displayed on the LCD.

This card has 9 input channels to measure the output voltages and signal current. The
measuring value is displayed by scrolling automatically one by one, if we want particular module voltage
then we can select by pressing up and down keys.

Page 28
 6.5 AC Changeover PCB (HBL/PE/IPS/INV CO-001-D03 S001 H01):

Micro-controlled based AC change over card main function is to keep the signal load on INV-1 always, if
INV-1 fails signal load will change over automatically to INV-2, if both inverters are failed then load will
change over to signal CVT module. On restoration of any inverter module, load will be shifted to that
particular inverter module, if both inverters are restored load will change over to INV-1. Change over time
is setted from 30ms to 500ms through SCU settings. For change over function, TRIAC's are used for
smooth change over.

6.6 DC Meter PCB (HBL/PE/IPS/MTR(AC)-001-D03 S001 H01):

DC Meter card consists of micro-controller and 16 X 2 LCD. Basic function of DC meter is to measure the
DC DC Converter voltages, for this we have to connect the DC-DC Converter output probes to the test
points which are provided at the front side of DCDB Panel.

6.7 DCSCU PCB (HBL/PE/IPS/SCU-02-D03 S001 H01) :

Micro-controlled DCSCU PCB main function is to command the failure signal of any DC-DC Converter to
SCU in SMR Rack. Each DC-DC Converter group is connected to DCSCU to monitor the status of DC-DC
Converter in that group.

7. Module Level PCB Description & Controls:

7.1 SMR Power PCB(HBL/PE/IPS/SMR-01-D03 H01):

SMR Power PCB Consists of 3 sections.

 PFC Section
 DC-DC Converter Section
 Buck-Converter Section

PFC Section:

In this section, RL1 acts as inrush current limit. The inputs to this section are 'L' and 'N' terminals which
states mains AC input Line (CN9) and Neutral (CN11). The Output from this (after in-rush limit) is fed to
Boost Mosfet (T20) and Boost Inductor (L4) after rectification by GL1 bridge.

PFC Section is designed as a boost regulator for power factor correction. The important specification for
power factor correction is to improve Power Factor. An active power factor corrector does this by
programming the input current in response to input voltage. Power factor is defined as the ratio of real
power to apparent power. It consists of Mosfet (T20), Diode (D25 & D26), PFC Choke (L4), Boost
Capacitors (C69 to C72) and Boost IC (IC22).

The AC input is given to bridge (GL1) for rectification and the output of the bridge is given to Mosfet
(T20). IC22 is a Power Factor Pre-regulator. It Controls the output by saying the output voltage, input

Page 29
voltage by PWM logic. It also controls the power factor and current distortion. A driver IC 'IC21' is used to
drive the Mosfet. During the ON time of Mosfet, energy stored in choke and capacitor will deliver power
to load and during OFF time of Mosfet, energy stored in the choke will deliver to the capacitor. So, bulk
Capacitors are used in the output (i.e.C69 to C72).

The importance of this section is to maximize the input power factor and minimize the input harmonics.
In Power factor Correction section, the AC input voltage will be rectified to high voltage DC. This raw
voltage DC is fed to switching Power Mosfet to produce regulated DC Voltage with respect to input AC
Voltage varying from 150V-275VAC.The Output of PFC Voltage is 425VDC.

DC-DC Converter Section:

The basic function of DC-DC Converter Section is to produce PWM pulses which controls output voltage
and current to get desired output. Soft start facility is provided through 'IC20'. The PWM Pulses
generated by the PWM IC are fed to Planar transformer,which are meant for isolation, through driver IC
(IC19) at fixed frequency.

This section is for high frequency switching purpose. It consists of Planar transformer (TR1) and
MOSFET's (T12-T15) in full bridge configuration.

Through Mosfet's (T12-T15), PFC output voltage is converted to pulsating DC Voltage and is fed to Planar
transformer and will produce 300VDC through diodes(D7,D9,D10,D11).

Planar transformers can be constructed as stand alone components, with a stacked layer design or a
small multilayer PCB, or integrated into a multilayer board of the power supply.

Important advantages of planar Transformer are:

1. Very low profile.

2. Excellent thermal characteristics.

3. Low leakage inductance.

4. Excellent repeatability of properties.

Buck-Converter Section:

A buck converter is a step-down DC to DC Converter. Its design is similar to the step-up boost converter,
and like the boost converter it is a switched mode power supply that uses two switches (a transistor and
a diode), an inductor and a capacitor.

3-Phase Buck-Converter Section mainly consists of Buck-Controller IC (IC7), Output chokes (L1,L2,L3),
blocking diode (D8) and Mosfets (T1 to T6). By high frequency switching through Mosfets (T1 to T6), the
DC Voltage 300V will be step down to 110VDC through Buck-Controller IC (IC7).

Page 30
7.2 SMR Control PCB(HBL/PE/IPS/SMR-02-D03 S001 H01):

SMR Control Card Consists of LCD display,Micro-controller,LED's(Float,Boost,Input ON & Over Voltage)

and tactile switches (Reset,Menu,Inc,Dec & Set). After getting Vcc Supply for micro-controller,LCD will
display the status of module like Output Voltage, Output Current, Output Power,Temperature,Bus
Voltage, Vcc of micro-controller and healthiness of module.

We can set Output Voltage & Output Current by using INC/DEC Switches.

7.3 INV Power PCB(HBL/PE/IPS/INV-01-D03 S001 H01):

Micro-Controller based Inverter Power PCB consists of 3 sections:

 PFC Section

 DC-DC Converter Section

 DC-AC Converter Section

PFC Section:

The inputs for this PCB are CN7 & CN8. PFC Section Consists of Mosfet (T16), PFC Choke (L11), Boost
Capacitors (C44-C47,C72,C78), Diode(D12) and Boost IC (IC24).IC24 is a Power Factor Pre-regulator. It
controls the output by saying the output voltage, input voltage by PWM logic. It also controls the Power
Factor & Current distortion. A driver IC 'IC18' is used to drive the Mosfet 'T16'. During the ON time of
Mosfet, energy stored in choke and capacitor will deliver Power to Load and during OFF time of Mosfet,
energy stored in the choke will deliver to the capacitor through D12.So, Capacitors are used in the output
(i.e. C44-C47,C72,C78) of PFC. The Output of PFC Voltage is 180VDC.

DC-DC Converter Section:

Through high frequency switching operation using Mosfet's (T12,T13,T14,T15), which are configured in
full-bridge configuration, converts PFC Output Voltage to Pulsating DC Voltage and is fed to input of
planar transformer and the output of planar transformer is pulsating DC and this voltage is fed to diodes
(D7,D9,D10,D11) and will produce 400VDC.

DC-AC Converter Section:

Then by using micro-controller 'IC10' and switching of Mosfet's (i.e T2 & T3 are of low freq switching
and T4 & T5 are of high frequency switching),the 400VDC is converted to 230VAC/50Hz after filtering
using output choke (L3).

Page 31
7.4 INV Control PCB(HBL/PE/IPS/INV-02-D03 S001 H01):

Inverter Control Card Consists of Micro-controller, LED's (Input ON, Output ON, INV ON Load, INV OVR
Load, INV Fail, Fan Fail) and tactile switch (for Reset).

7.5 DC-DC Power PCB(HBL/PE/IPS/DCDC-01-D03 H01):

Function of DC-DC Converter module is to provide DC of different voltage from 110VDC input supply.
The DC input voltage is passed through EMI,RFI & Surge Protection circuit. The input DC under voltage
and over voltage circuit monitors the voltage and indicates Output fail indication if it is below 98V or
more than 138V.

This input DC is converted into 110VAC through Mosfet's T7 to T10. This AC is fed to Planar transformer.
The input of this rectangular pulse is of magnitude 110V at nominal input. The output of Planar
transformer is rectified by D9 & D14.

This rectified voltage (V bus) is applied to Buck Converter to get required output voltage.

Page 32
8. Module Level Settings:
8.1 SMR Module Settings:
By default, the following screen will be displayed.

HBL POWER
SYSTEMS

Followed by,

SW
V1.0

After 20sec, the following screen will be displayed.

STARTUP
SHD 05DC

Then Press Menu,then the display shows as:

Limits

Then Press Set, Voltage limit gets displayed as shown below:

95.0V

By using INC Push-button, increase voltage limit to maximum value.Then again Press Set Key, so
that current limit gets displayed as shown below:

8A

Again by using INC Push-button, increase current limit upto maximum value. Then Press Set followed
by Menu,then display shows information regarding Power,Fan(rpm),Bus Voltage,Temperature & Vcc.
8.2 Inverter Module Voltage Settings

To set the inverter module voltage, we have to go to all parameters settings in SCU Menu,then by
changing Parameter No.:44,we can set the inverter output voltage.

Page 33
9. OPERATING PROCEDURE

Under normal condition, when the AC mains is available, the FRBC will float / boost charge the battery
and feeds the power to the inverter modules and DC-DC converter modules. When any of the modules
(FRBC module or Inverter module or DC-DC converter module fails the same is indicated in Status
Monitoring Panel as ‘Call S & T staff’. In the event of input AC power supply fails, the battery supplies the
power to the inverter modules and DC-DC converter modules.

During prolonged AC failures, a protection has been provided to avoid battery being subjected to deep
discharge. This has been provided through a battery low isolating contactor. When the battery is
discharged to its 50% capacity, an alarm is annunciated in the Status Monitoring panel, which is situated
in ASM room cautioning ‘Start Generator’. When discharged to 60% of its capacity an alarm is
annunciated in Status Monitoring Panel cautioning ‘Emergency Start Generator’. When discharged to 70%
of its capacity, the power supply to the signal loads is Cut – off and an alarm is annunciated indicating
‘System shutdown’. Power supply to DC-DC converters however will continue.

The above is a general description of the system. For specific configuration, at a station, please
refer the enclosed block diagram as applicable for the subject installation.

START GENERATOR

 Do not allow the battery to drain further once “START GENERATOR” alarm is observed.

 Do not ignore “START GENERATOR” alarm. Please start the Generator immediately.

 Do not allow battery to drain further when once “EMERGENCY, START GENERATOR “
alarm is annunciated. START GENERATOR without any delay.

 Don’t wait till “System Shut down “ alarm is annunciated. This alarm cuts-off the total
signals feed.

Depth of discharge setting for ASM Box

Battery Coulomb Counter in SCU sets 100% AH Capacity when trickle charging current of the battery
decreases below 1000mA after defined time (1min.)This condition is known as full charged battery. when
battery is in discharging condition,Coulomb counter counts depth of discharge and generates below
alarms in ASM Panel.

Page 34
 • 50% Depth of Discharge (DOD) – calls for Start Generator

• 60% Depth of Discharge (DOD) – Calls for Emergency, Start Generator

• 70% Depth of Discharge (DOD) – Calls for System-Shutdown except the DC Circuits.

When the battery is discharged to 1.85V/cell for LM or 1.80V/cell for VRLA battery, all the loads except telephones
are disconnected from the battery.

10.Safety:

Before switching on the input AC supply, please ensure that the

body of the Cabinet is PROPERLY EARTHED.

Page 35
 11.WARANTEE CERTIFICATE

THIS IS TO CERTIFY THAT OUR EQUIPMENT IS WARANTEED

AGAINST ANY MANUFACTURING DEFECTS AS PER RDSO
Specification No # RDSO/SPN/165/2012 Ver. 3.0. DURING THIS
PERIOD IN THE EVENT OF ANY DEFECT OCCURRING SOLELY ON
ACCOUNT OF WORKMANSHIP OR COMPONENTS OUR LIABILITY
IS LIMITED TO RECTIFYING OR REPLACING AT OUR OPTION.

Page 36
Page 37
Page 38
Page 39
Page 40
Page 41
 CONTROLLED COPY

Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
1 9000009005 IPS SYSTEM NR 38 5 440 1.00 PC
2 6000033652 FRBC RACK ASSY IPS/440 1.00 PC
3 6000002636 CONSOLE FRBC H 1530xW 730xD 500MM 1.00 PC RACK
4 6000009573 MODULE SMR 110V/20A HBL 5.00 PC FRBC MODULE
5 6000009570 MODULE INVERTER 1.5KVA / 2KVA HBL 1.00 PC INV MODULE
6 6000009574 MODULE STATUS MONITORING PANEL HBL 1.00 PC ASM
7 1000005624 CONTACTOR 50ADC 3P,110V DC 1NO+1NC SCH 1.00 PC FRBC-K1
8 1000016643 SHUNT 75MV 100A DC 1%ACC AE 2.00 PC FRBC-SH1&SH2
9 1000020058 TXR SEN10/10/50VA 460VAC SEC20/42/120VAC 1.00 PC FRBC-T1
10 1000021934 TXR 230V/10VAC 100mA 1.00 PC FRBC-T2
11 4000036500 SOCKET 5 PIN 5A ANCHOR MAKE: 1.00 PC FRBC 5A Junction Box
12 1000013663 RELAY SOLID STATE NO TYPE H12WD4875G CRY 1.00 PC FRBC-SSR1
13 1000006280 CURRENT T/F 75/5A AC RING TYPE AE 1.00 PC FRBC-CT1
14 1000013790 RESISTOR 1E,11W CERAMIC CASING 1.00 PC FRBC CT1 Resister
15 1000008477 HEAT SINK ALUMINIUM 3081(EIA1717) EIA 1.00 PC FRBC SSR1 Head sink
16 1000007682 FUSE 80A,500V AC 120KA BUSSMANN 1.00 PC FRBC-F1
17 1000007673 FUSE 20A,550V AC 80KA BUSSMANN 1.00 PC FRBC-F2
18 1000007680 FUSE 63A,415V AC 80KA CS 1.00 PC FRBC-F3
19 1000007624 FUSE BASE 160A,690V AC BUSSMANN 1.00 PC FRBC-F1 FUSE Base
20 1000007635 FUSE BASE 32A,500V AC BUSSMANN 1.00 PC FRBC F2 FUSE Base
21 1000007645 FUSE BASE 63A,415V AC CS 1.00 PC FRBC-F3FUSE Base
22 1000017454 SPD VAL-MS 120ST VAL-MS BE/FM 3.00 PC FRBC SPD 1-3
23 6000017044 PPCB HBL/PE/IPS/SCU-01-D03 S001H01 HBL 1.00 PC FRBC-A1
24 6000017048 PPCB HBL/PE/IPS/SCU-03-D03 S001H01 HBL 1.00 PC FRBC-A2
25 6000017029 PPCB HBL/PE/IPS/BTY-001-DO1HO1 1.00 PC FRBC-A3
26 1000000019 48V5.8W_DCFAN_EEC0384B2-0000A99, SUNON 2.00 PC FRBC-FAN1&2,
27 6000017031 PPCB HBL/PE/IPS/FAN-D03 H01 1.00 PC FRBC-A4
28 1000002946 CABLE RJ45 LENGTH 300MM 1.00 PC FRBC SMR 2 to SMR 4
FRBC SMR1 to SMR 2,
29 1000002947 CABLE RJ45 LENGTH 500MM 2.00 PC
FRBC SMR3 to SMR4,
30 1000021959 CABLE RJ45 LENGTH 1100MM 1.00 PC FRBC-A1/CN2 to SMR1
FRBC -A1/CN3 to ACDB-
31 1000021971 CABLE RJ45 8PIN LENGTH 2300MM 1.00 PC
INV 1
FRBC- A1/CN6 to FRBC
32 1000021960 CABLE RJ11 4PIN LENGTH 1200MM 1.00 PC
-A2/CN2
FRBC-A2/CN3 to ACDB-
33 1000002941 CABLE RJ11 4PIN LENGTH 2000MM 1.00 PC
A1/CN1
34 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 15.00 Mtr
35 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.00 Mtr
36 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.00 Mtr
37 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 9.00 Mtr
38 1000002088 CABLE FR 10 SQMM CU MT ST 1C RED HV 5.50 Mtr
39 1000002094 CABLE FR 10 SQMM CU MT ST 1C YEL HV 1.50 Mtr
40 1000002078 CABLE FR 10 SQMM CU MT ST 1C BLK HV 4.00 Mtr
41 1000002179 CABLE FR 25 SQMM CU MT ST 1C RED HV 3.00 Mtr
42 1000002183 CABLE FR 25 SQMM CU MT ST 1C YEL HV 3.00 Mtr
43 1000002167 CABLE FR 25 SQMM CU MT ST 1C BLK HV 2.00 Mtr
44 1000001889 CABLE TIES 100MM 60.00 PC
45 1000001887 CABLE TIES FR TYPE 150MM 45.00 PC
46 1000001894 CABLE TIES 200MM 100.00 PC
47 1000001897 CABLE TIES 300MM 70.00 PC
48 1000010065 LUG 1.5SQ MM CU PIN TYPE 5.00 PC
49 1000010100 LUG 2.5SQ MM CU PIN TYPE 4.00 PC
50 1000010148 LUG 4-6SQ MM CU PIN TYPE 15.00 PC
51 1000010073 LUG 10SQ MM CU PIN TYPE 20.00 PC
52 1000010091 LUG 16SQ MM CU PIN TYPE 13.00 PC
53 1000010116 LUG 25SQ MM CU PIN TYPE 17.00 PC
54 1000010064 LUG 1.5SQ MM CU FORK TYPE 12.00 PC
55 1000021925 LUG 1.5SQmm CU RINGTYPE M6 3D 5.00 PC
56 1000010106 LUG 2.5SQ MM CU RING TYPE M8 5.00 PC
57 1000010154 LUG 4-6SQ MM CU RING TYPE M8 35.00 PC
58 1000010094 LUG 16SQ MM CU RING TYPE M8 4.00 PC

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 CONTROLLED COPY

Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
59 1000010121 LUG 25SQ MM CU RING TON TYPE M8 TON JA 16.00 PC
60 1000018595 TERMINAL END PLATE GREY KUT10 ELMEX 6.00 PC
61 1000021926 TERMINAL BLOCK KUT35 GREY ELMEX 5.00 PC
62 1000018567 TERMINAL BLOCK KUT2.5 GREY ELMEX 16.00 PC
63 1000018566 TERMINAL BLOCK KUT10 GREY ELMEX 12.00 PC
64 1000018788 TERMINALS END PLATES FOR KUT 2.5 EL 5.00 PC
65 1000006766 DISTRIBUTION BLOCK 57A 1X4 GREY ELMEX 5.00 PC
66 1000017304 SOLDER WIRE Sn/Pb:60/40 22SWG LEAD BHVNI 0.03 Kg
67 1000012695 PCB SUPPORTER 10.00 PC
68 1000012201 OMEGA RAIL 1MTR 1.00 PC
69 1000006382 DIN RAIL W:35MM UNSLOTTED CHS TYPE 1MTR 2.00 PC
70 1000006994 END CLAMPS 35 MM DIN RAIL CHANNEL 22.00 PC
71 1000009517 LABEL 100 (L) x 55 x 0.8 AL ANOD FRBC 1.00 PC FRBC Rating Plate
72 3000002722 LABEL ALUMINIUM EARTHING 25X25X0.8 mm 2.00 PC
73 1000021930 LABEL 50(L)x25(W)x1.6(T) BWB 1.00 PC
74 1000021975 LABEL 120(L)x25(W)x1.6(T) BWB 1.00 PC
75 1000021976 LABEL 350(L)x25(W)x1.6(T) BWB 1.00 PC
76 1000009677 LABLE 120 (L) x 60 (W) x 0.8 (T) AL ANOD 1.00 PC
77 1000001829 CABLE DUCT 45MMx45MM B TYPE 1MTR LENGTH 1.00 PC
78 1000001830 CABLE DUCT B TYPE 25MMx25MMx2MTR LENGTH 1.00 PC
79 1000001724 BUSBAR INSULATORS M6 X30 2.00 PC
80 1000017487 SPIRAL TUBE 6MM BLACK 15.00 Mtr
81 1000017485 SPIRAL TUBE 12MM BLACK 7.00 Mtr
82 1000017102 SLEEVES 3MM HEAT SINKABLE TYPE BLA 2.00 Mtr
83 1000017112 SLEEVES HEAT SHRINKABLE TYPE 6MM BLACK 1.50 Mtr
84 1000017113 SLEEVES HEAT SHRINKABLE TYPE,10MM(BLACK) 1.50 Mtr
85 1000017081 SLEEVES 16MM HEAT SINKABLE TYPE BLA CHA 2.00 Mtr
86 1000007217 FERRULE TUBE 2.5MM WHITE 10.00 Mtr
87 1000007221 FERRULE TUBE 4.2MM WHITE 10.00 Mtr
88 1000007223 FERRULE TUBE 5.5MM WHITE 10.00 Mtr
89 1000009287 INK RIBBON HLK-IR300B(C) LM-370/380 BLK 1.00 PC
90 1000021912 INK RIBBON TAPE LM-TP309W WHITE MAX 1.00 PC
91 1000007263 FILE CLIPS BIG 1.00 PC
92 1000020915 WASHER SPRING MS ZINC PAS M5 15.00 PC
93 1000020914 WASHER SPRING MS ZINC PAS M4 74.00 PC
94 1000020916 WASHER SPRING MS ZINC PAS M6 16.00 PC
95 1000020917 WASHER SPRING MS ZINC PAS M8 6.00 PC
96 1000020909 WASHER SPRING MS ZINC PAS M10 4.00 PC
97 1000020799 WASHER NYLON M3(I/D:3mm) 8.00 PC
98 1000020849 WASHER PLAIN MS ZINC PAS M3 2.00 PC
99 1000020850 WASHER PLAIN MS ZINC PAS M4 86.00 PC
100 1000020851 WASHER PLAIN MS ZINC PAS M5 34.00 PC
101 1000020852 WASHER PLAIN MS ZINC PAS M6 62.00 PC
102 1000020853 WASHER PLAIN MS ZINC PAS M8 8.00 PC
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104 4000003731 BOLT(HEX) MS M5X15mm 16.00 PC
105 1000001374 BOLT(HEX) MS M6x10mm 6.00 PC
106 1000001378 BOLT(HEX) MS M6x20mm 4.00 PC
107 1000001380 BOLT(HEX) MS M6x25mm 4.00 PC
108 1000001397 BOLT(HEX) MS M8x20mm 4.00 PC
109 1000001346 BOLT(HEX) MS M10x50mm 4.00 PC
110 1000015654 SCREW M4X20MM CHEESE HEAD ZINC PSSVTD 2.00 PC
111 1000015651 SCREW M4X15MM CHEESE HEAD 7.00 PC
112 1000015661 SCREW M4X50 CHEESE HEAD- ZINC PASSIVATED 8.00 PC
113 1000015660 SCREW M4X40MM CHEESE HEAD 2.00 PC
114 1000015641 SCREW M3X6MM CHEESE HEAD 24.00 PC
115 1000015653 SCREW M4X15MM CSK HEAD 50.00 PC
116 1000012074 NUT HEXAGONAL SLOTTED M4 ZINC PASSIVATED 56.00 PC
117 1000012078 NUT HEXAGONAL M5 15.00 PC
118 1000011975 NUT(HEX) M10 4.00 PC
119 1000012079 NUT HEXAGONAL M8 6.00 PC
120 1000001081 BLIND RIVET 2.4MMx6MM 10.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
121 1000012112 NUTS MS ZINC PSSVTD TYPE M6 32.00 PC
122 6000033287 SMR1 I/P HARNESS ASSY 1.00 PC
123 1000002255 CABLE FR 6 SQMM CU MT ST 1C YEL HV 1.65 Mtr SMR1 - CDB1
124 1000002240 CABLE FR 6 SQMM CU MT ST 1C BLK HV 1.65 Mtr SMR1 – CDB2
125 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 2.00 Mtr SMR1 – Earth
126 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
127 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
128 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
129 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
130 1000010106 LUG 2.5SQ MM CU RING TYPE M8 1.00 PC
131 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
132 6000033288 SMR 2 I/P HARNESS ASSY 1.00 PC
133 1000002255 CABLE FR 6 SQMM CU MT ST 1C YEL HV 2.00 Mtr SMR2 - CDB1
134 1000002240 CABLE FR 6 SQMM CU MT ST 1C BLK HV 2.00 Mtr SMR2 – CDB2
135 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.00 Mtr SMR2 – Earth
136 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
137 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
138 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
139 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
140 1000010106 LUG 2.5SQ MM CU RING TYPE M8 1.00 PC
141 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
142 6000033289 SMR 3 I/P HARNESS ASSY 1.00 PC
143 1000002255 CABLE FR 6 SQMM CU MT ST 1C YEL HV 1.50 Mtr SMR3 - CDB1
144 1000002240 CABLE FR 6 SQMM CU MT ST 1C BLK HV 1.50 Mtr SMR3 – CDB2
145 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.00 Mtr SMR3 – Earth
146 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
147 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
148 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
149 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
150 1000010106 LUG 2.5SQ MM CU RING TYPE M8 1.00 PC
151 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
152 6000033290 SMR 4 I/P HARNESS ASSY 1.00 PC
153 1000002255 CABLE FR 6 SQMM CU MT ST 1C YEL HV 1.90 Mtr SMR4 - CDB1
154 1000002240 CABLE FR 6 SQMM CU MT ST 1C BLK HV 1.90 Mtr SMR4 – CDB2
155 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.00 Mtr SMR4 – Earth
156 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
157 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
158 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
159 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
160 1000010106 LUG 2.5SQ MM CU RING TYPE M8 1.00 PC
161 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
162 6000033291 SMR 1 O/P HARNESS ASSY 1.00 PC
163 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 2.50 Mtr *SMR1 – CDB3
164 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 2.50 Mtr *SMR1 – CDB4
165 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
166 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
167 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
168 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
169 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
170 6000033292 SMR 2 O/P HARNESS ASSY 1.00 PC
171 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 3.20 Mtr *SMR2 – CDB3
172 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 3.20 Mtr *SMR2 – CDB4
173 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
174 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
175 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
176 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
177 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
178 6000033293 SMR 3 O/P HARNESS ASSY 1.00 PC
179 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 2.20 Mtr *SMR3 – CDB3
180 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 2.20 Mtr *SMR3 – CDB4
181 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
182 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC

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Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
183 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
184 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
185 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
186 6000033294 SMR 4 O/P HARNESS ASSY 1.00 PC
187 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 3.00 Mtr *SMR4 – CDB3
188 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 3.00 Mtr *SMR4 – CDB4
189 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
190 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
191 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
192 1000010148 LUG 4-6SQ MM CU PIN TYPE 2.00 PC
193 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
194 6000033295 SPD HARNESS ASSY 1.00 PC
195 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 1.20 Mtr
196 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.25 Mtr
197 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.00 Mtr
198 1000010148 LUG 4-6SQ MM CU PIN TYPE 6.00 PC
199 1000010100 LUG 2.5SQ MM CU PIN TYPE 1.00 PC
200 6000033331 FAN Card CN1 HARNESS ASSY 1.00 PC
201 1000004720 CONNECTOR HOUSING 3 PIN 3.96MM ALEX 1.00 PC
202 1000010192 LUG 96T HOUSING ALEX 2.00 PC
203 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 0.60 Mtr A4/CN1/1 – TB16
204 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 0.60 Mtr A4/CN1/3 – TB17
205 6000033332 FAN Card CN2 HARNESS ASSY 1.00 PC
206 1000004718 CONNECTOR HOUSING 2 PIN 3.96MM ALEX 1.00 PC
207 1000010192 LUG 96T HOUSING ALEX 2.00 PC
208 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 1.65 Mtr A4/CN2/1 – FAN1
209 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 1.65 Mtr A4/CN2/3 – FAN2
210 6000033296 SCU X1 Connector HARNESS ASSY 1.00 PC
211 1000021966 CON FEMALE 6PIN 2EDGK-5.08-06P-14-00A(H) 1.00 PC
212 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.00 Mtr A1/X1/1 – T1/ Phase 42V
A1/X1/2 – T1/ Neutral
213 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.00 Mtr
42V
214 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A1/X1/3 – CT1 PIN 1
215 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A1/X1/4 – CT1 PIN 2
216 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.05 Mtr A1/X1/5 – SSR1/3
217 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.05 Mtr A1/X1/6 – SSR1/4
218 1000010065 LUG 1.5SQ MM CU PIN TYPE 6.00 PC
219 1000021925 LUG 1.5SQmm CU RINGTYPE M6 3D 4.00 PC
220 6000033297 SCU X2 Connector HARNESS ASSY 1.00 PC
221 1000021969 CON FEMAL 12PIN 2EDGK-5.08-12P-14-00A(H) 1.00 PC
222 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A1/X2/1 – A3/CN2/1
223 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.70 Mtr A1/X2/2 – CDB5
224 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.40 Mtr A1/X2/3 – CDB4
225 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.40 Mtr A1/X2/4 – CDB4
226 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.70 Mtr A1/X2/5 – CDB5
227 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.70 Mtr A1/X2/6 – SH1/1
228 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.70 Mtr A1/X2/7 – SH1/2
229 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.20 Mtr A1/X2/8 – FROM K1
230 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.20 Mtr A1/X2/9 – SH2/1
231 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.20 Mtr A1/X2/10 – SH2/2
232 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.80 Mtr A1/X2/11 – TB19
233 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.80 Mtr A1/X2/12 – TB18
234 1000021925 LUG 1.5SQmm CU RINGTYPE M6 3D 4.00 PC
235 1000010065 LUG 1.5SQ MM CU PIN TYPE 13.00 PC
236 6000033298 Relay card X1 Connector HARNESS ASSY 1.00 PC
237 1000021967 CON FEMALE 8PIN 2EDGK-5.08-08P-14-00A(H) 1.00 PC
238 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/1 – TB20
239 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/2 – T21
240 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/3 – TB22
241 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/4 – TB23
242 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/5 – TB24

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
243 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/6 – TB25
244 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/7 – TB26
245 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X1/8 – TB27
246 1000010065 LUG 1.5SQ MM CU PIN TYPE 16.00 PC
247 6000033299 Relay card X2 Connector HARNESS ASSY 1.00 PC
248 1000021967 CON FEMALE 8PIN 2EDGK-5.08-08P-14-00A(H) 1.00 PC
249 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/1 – TB28
250 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/2 – TB29
251 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/3 – TB30
252 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/4 – TB31
253 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/5 – TB32
254 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/6 – TB33
255 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.30 Mtr A2/X2/7 – K1 COIL +VE
256 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.20 Mtr A2/X2/8 – K1 NC 1stPIN
257 1000010065 LUG 1.5SQ MM CU PIN TYPE 16.00 PC
258 6000033300 RELAY Card X3 Connector HARNESS ASSY 1.00 PC
259 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 1.00 PC
260 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.40 Mtr A2/X3/1 – BTY + VE
261 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.40 Mtr A2/X3/2 – BTY – VE
262 1000010065 LUG 1.5SQ MM CU PIN TYPE 2.00 PC
263 6000033301 BTY Reverse Polarity Card CN1 HARNESS ASSY 1.00 PC
264 1000004720 CONNECTOR HOUSING 3 PIN 3.96MM ALEX 1.00 PC
265 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.90 Mtr A3/CN1/1 – BTY + VE
266 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.90 Mtr A3/CN1/3 – BTY – VE
267 1000010192 LUG 96T HOUSING ALEX 2.00 PC
268 6000033302 BTY Reverse Polarity Card CN2 HARNESS ASSY 1.00 PC
269 1000004722 CONNECTOR HOUSING 5 PIN 3.96MM ALEX 1.00 PC
270 1000010192 LUG 96T HOUSING ALEX 4.00 PC
271 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.60 Mtr
272 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.10 Mtr
273 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.10 Mtr
274 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.10 Mtr
275 6000033303 BTY Reverse Polarity Card CN3 HARNESS ASSY 1.00 PC
276 1000004721 CONNECTOR HOUSING 4 PIN 3.96MM ALEX 1.00 PC
277 1000010192 LUG 96T HOUSING ALEX 4.00 PC
A3/CN3/1 – T1/120V
278 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr
Phase
A3/CN3/2 – T1/120V
279 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr
Neutral
280 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr A3/CN3/3 – T1/20V Phase
A3/CN3/4 – T1/20V
281 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr
Neutral
282 6000033304 BTY Reverse Polarity Card CN4 HARNESS ASSY 1.00 PC
283 1000004718 CONNECTOR HOUSING 2 PIN 3.96MM ALEX 1.00 PC
284 1000010192 LUG 96T HOUSING ALEX 2.00 PC
285 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.40 Mtr A3/CN4/1 - T2 (Sec)
286 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.40 Mtr A3/CN4/2 - T2 (Sec)
287 6000033305 BTY Reverse Polarity Card CN5 HARNESS ASSY 1.00 PC
288 1000004721 CONNECTOR HOUSING 4 PIN 3.96MM ALEX 1.00 PC
289 1000010192 LUG 96T HOUSING ALEX 4.00 PC
290 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A3/CN5/1 – SCU IC
291 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A3/CN5/2 – SCU IC
292 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.75 Mtr A3/CN5/3 – SSR1/4
293 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.75 Mtr A3/CN5/4 – SSR1/3
294 6000033637 ACDB RACK ASSY IPS/440 1.00 PC
295 6000002633 CONSOLE ACDB H 1530xW 730xD 500MM 1.00 PC
296 6000009570 MODULE INVERTER 1.5KVA / 2KVA HBL 2.00 PC
297 6000009561 MODULE CVT 230V/230V 1500VA HBL 1.00 PC
298 6000009560 MODULE CVT 230V/230V 1000VA HBL 1.00 PC
299 6000009572 MODULE ISOLATION TXR 230V/110V 500VA HBL 8.00 PC
300 1000009516 LABEL 100 (L) x 55 x 0.8 AL ANOD ACDB 1.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
301 1000013662 RELAY SOLID STATE NC TYPE CY7552 CRY 1.00 PC
302 1000006242 CURRENT T/F 30/5A AC RING TYPE AE 1.00 PC
303 1000008474 HEAT SINK ALUMINIUM FOR SCO CARD 1.00 PC
304 6000017033 PPCB HBL/PE/IPS/INV CO-001-D03S001H01 1.00 PC
305 6000017039 PPCB HBL/PE/IPS/MTR(AC)001-D03S001H01 1.00 PC
306 6000017031 PPCB HBL/PE/IPS/FAN-D03 H01 1.00 PC
307 1000021426 SWITCHE 16A 1P 4WAY NO OFF 1.00 PC
308 1000000019 48V5.8W_DCFAN_EEC0384B2-0000A99, SUNON 2.00 PC
309 1000002947 CABLE RJ45 LENGTH 500MM 1.00 PC
310 1000021960 CABLE RJ11 4PIN LENGTH 1200MM 1.00 PC
311 1000002941 CABLE RJ11 4PIN LENGTH 2000MM 1.00 PC
312 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 8.00 Mtr
315 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 10.00 Mtr
317 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 8.00 Mtr
318 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 2.00 Mtr
319 1000002088 CABLE FR 10 SQMM CU MT ST 1C RED HV 3.00 Mtr
320 1000002094 CABLE FR 10 SQMM CU MT ST 1C YEL HV 2.00 Mtr
321 1000002078 CABLE FR 10 SQMM CU MT ST 1C BLK HV 5.00 Mtr
322 1000001889 CABLE TIES 100MM 60.00 PC
323 1000001887 CABLE TIES FR TYPE 150MM 45.00 PC
324 1000001894 CABLE TIES 200MM 100.00 PC
325 1000001897 CABLE TIES 300MM 70.00 PC
326 1000010100 LUG 2.5SQ MM CU PIN TYPE 22.00 PC
327 1000010148 LUG 4-6SQ MM CU PIN TYPE 40.00 PC
328 1000010073 LUG 10SQ MM CU PIN TYPE 10.00 PC
329 1000010064 LUG 1.5SQ MM CU FORK TYPE 6.00 PC
330 1000021925 LUG 1.5SQmm CU RINGTYPE M6 3D 15.00 PC
331 1000010075 LUG 10SQ MM CU RING TYPE M6 4.00 PC
332 1000010076 LUG 10SQ MM CU RING TYPE M8 4.00 PC
333 1000010192 LUG 96T HOUSING ALEX 6.00 PC
334 1000018595 TERMINAL END PLATE GREY KUT10 ELMEX 10.00 PC
335 1000018566 TERMINAL BLOCK KUT10 GREY ELMEX 21.00 PC
336 1000018560 TERMINAL BLOCK 4 CONDUCTOR 20A GRY WAGO 5.00 PC
337 1000018598 TERMINAL END PLATE WAGO 3.00 PC
338 1000006766 DISTRIBUTION BLOCK 57A 1X4 GREY ELMEX 6.00 PC
339 1000012695 PCB SUPPORTER 10.00 PC
340 1000012201 OMEGA RAIL 1MTR 1.00 PC
341 1000006382 DIN RAIL W:35MM UNSLOTTED CHS TYPE 1MTR 1.00 PC
342 1000006994 END CLAMPS 35 MM DIN RAIL CHANNEL 26.00 PC
343 3000002722 LABEL ALUMINIUM EARTHING 25X25X0.8 mm 2.00 PC
344 1000021978 LABEL 450(L)x25(W)x1.6(T) BWB 1.00 PC
345 1000009677 LABLE 120 (L) x 60 (W) x 0.8 (T) AL ANOD 1.00 PC
346 1000001830 CABLE DUCT B TYPE 25MMx25MMx2MTR LENGTH 1.00 PC
347 1000017487 SPIRAL TUBE 6MM BLACK 10.00 Mtr
348 1000017485 SPIRAL TUBE 12MM BLACK 5.00 Mtr
349 1000017102 SLEEVES 3MM HEAT SINKABLE TYPE BLA 1.00 Mtr
350 1000017112 SLEEVES HEAT SHRINKABLE TYPE 6MM BLACK 1.00 Mtr
351 1000017113 SLEEVES HEAT SHRINKABLE TYPE,10MM(BLACK) 1.00 Mtr
352 1000017081 SLEEVES 16MM HEAT SINKABLE TYPE BLA CHA 1.00 Mtr
353 1000007217 FERRULE TUBE 2.5MM WHITE 5.00 Mtr
354 1000007221 FERRULE TUBE 4.2MM WHITE 5.00 Mtr
355 1000007223 FERRULE TUBE 5.5MM WHITE 5.00 Mtr
356 1000004718 CONNECTOR HOUSING 2 PIN 3.96MM ALEX 1.00 PC
357 1000007263 FILE CLIPS BIG 1.00 PC
358 1000021967 CON FEMALE 8PIN 2EDGK-5.08-08P-14-00A(H) 2.00 PC
359 1000020915 WASHER SPRING MS ZINC PAS M5 8.00 PC
360 1000020914 WASHER SPRING MS ZINC PAS M4 74.00 PC
361 1000020916 WASHER SPRING MS ZINC PAS M6 6.00 PC
362 1000020917 WASHER SPRING MS ZINC PAS M8 2.00 PC
363 1000020909 WASHER SPRING MS ZINC PAS M10 4.00 PC
364 1000020799 WASHER NYLON M3(I/D:3mm) 4.00 PC
365 1000020849 WASHER PLAIN MS ZINC PAS M3 4.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
366 1000020850 WASHER PLAIN MS ZINC PAS M4 84.00 PC
367 1000020851 WASHER PLAIN MS ZINC PAS M5 18.00 PC
368 1000020852 WASHER PLAIN MS ZINC PAS M6 12.00 PC
369 1000020853 WASHER PLAIN MS ZINC PAS M8 4.00 PC
370 1000020843 WASHER PLAIN MS ZINC PAS M10 8.00 PC
371 4000003731 BOLT(HEX) MS M5X15mm 4.00 PC
372 1000001370 BOLT(HEX) MS M5x40mm 4.00 PC
373 1000001374 BOLT(HEX) MS M6x10mm 2.00 PC
374 1000001380 BOLT(HEX) MS M6x25mm 2.00 PC
375 1000001346 BOLT(HEX) MS M10x50mm 4.00 PC
376 1000015654 SCREW M4X20MM CHEESE HEAD ZINC PSSVTD 2.00 PC
377 1000015661 SCREW M4X50 CHEESE HEAD- ZINC PASSIVATED 10.00 PC
378 1000015641 SCREW M3X6MM CHEESE HEAD 4.00 PC
379 1000015632 SCREW M3X15MM CHEESE HEAD 4.00 PC
380 1000015653 SCREW M4X15MM CSK HEAD 34.00 PC
381 1000012077 NUT HEXAGONAL M3 4.00 PC
382 1000012074 NUT HEXAGONAL SLOTTED M4 ZINC PASSIVATED 44.00 PC
383 1000012078 NUT HEXAGONAL M5 8.00 PC
384 1000011975 NUT(HEX) M10 4.00 PC
385 1000012079 NUT HEXAGONAL M8 2.00 PC
386 1000001081 BLIND RIVET 2.4MMx6MM 10.00 PC
387 1000012112 NUTS MS ZINC PSSVTD TYPE M6 12.00 PC
388 6000033306 SURGE PROTECTION DEVICE HARNESS ASSY 1.00 PC
389 1000031239 SURGE SPD 230V VAL-MS 230VAC PHONIX 3.00 PC
390 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 1.90 Mtr CDB5 TO SPD
391 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.90 Mtr CDB6 TO SPD
392 1000010161 CABLE LUG COPPER PIN 4 SQMM 5.00 PC
393 1000010073 LUG 10SQ MM CU PIN TYPE 2.00 PC
394 1000012201 OMEGA RAIL 1MTR AR Mtr
395 1000010100 LUG 2.5SQ MM CU PIN TYPE 1.00 PC
396 1000010106 LUG 2.5SQ MM CU RING TYPE M8 1.00 PC
397 6000033331 FAN Card CN1 HARNESS ASSY 1.00 PC
398 1000004720 CONNECTOR HOUSING 3 PIN 3.96MM ALEX 1.00 PC
399 1000010192 LUG 96T HOUSING ALEX 2.00 PC
400 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 0.60 Mtr CDB3 TO A3/ CN1/1
401 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 0.60 Mtr CDB3 TO A3/CN1/3
402 6000033332 FAN Card CN2 HARNESS ASSY 1.00 PC
403 1000004718 CONNECTOR HOUSING 2 PIN 3.96MM ALEX 1.00 PC
404 1000010192 LUG 96T HOUSING ALEX 2.00 PC
405 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 1.65 Mtr
406 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 1.65 Mtr
407 6000033307 AC METER CARD X3 HARNESS ASSY 1.00 PC
408 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 2.00 PC
409 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.65 Mtr A2/X3 TO CT1
410 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 1.65 Mtr A2/X3 TO CT1
411 1000010065 LUG 1.5SQ MM CU PIN TYPE 2.00 PC
412 6000033308 AC METER CARD X5 HARNESS ASSY 1.00 PC
413 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 2.00 PC
414 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A2/X5 TO TB17
415 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.00 Mtr A2/X5 TO TB18
416 1000010065 LUG 1.5SQ MM CU PIN TYPE 2.00 PC
417 6000033309 AC CHANGEOVER CARD X1 HARNESS ASSY 1.00 PC
418 1000021968 CON FEMAL 10PIN 2EDGK-5.08-10P-14-00A(H) 1.00 PC
419 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 1.40 Mtr A1/X1/1 TO SW1/A1
420 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 0.80 Mtr A1/X1/2 TO CDB6
421 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 0.50 Mtr A1/X1/3 TO TB19
422 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 0.50 Mtr A1/X1/4 TO TB20
423 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.20 Mtr A1/X1/5 TO JB1
424 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.20 Mtr A1/X1/7 TO JB1
425 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 0.55 Mtr A1/X1/8 TO CDB2
426 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 0.60 Mtr A1/X1/10 TO CDB1
427 1000010148 LUG 4-6SQ MM CU PIN TYPE 8.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
428 6000033662 AC CHANGEOVER CARD X2 HARNESS ASSY 1.00 PC
429 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 1.00 PC
430 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 0.30 Mtr
431 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 0.30 Mtr
432 1000010059 LUG 0.5-1.5SQMM CU FORK M3.5 3D-3639 3D 2.00 PC
433 6000033310 INVERTER1 MOD I/P CONNECTOR HARNESS ASSY 1.00 PC
434 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
435 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
436 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
437 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 2.70 Mtr CDB3 TO INV1
438 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 2.70 Mtr CDB4 TO INV1
439 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
440 6000033311 INVERTER1 MOD O/P CONNECTOR HARNESS ASSY 1.00 PC
441 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
442 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
443 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
444 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 1.35 Mtr INV1 TO TB19
445 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.25 Mtr INV1 TO JB1
446 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
447 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 2.00 Mtr INV1 TO EARTH
448 6000033312 INVERTER2 MOD I/P CONNECTOR HARNESS ASSY 1.00 PC
449 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
450 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
451 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
452 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 3.60 Mtr CDB3 TO INV2
453 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 3.60 Mtr CDB4 TO INV2
454 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
455 6000033313 INVERTER2 MOD O/P CONNECTOR HARNESS ASSY 1.00 PC
456 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
457 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
458 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
459 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 1.70 Mtr INV2 TO TB20
460 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.00 Mtr INV2 TO JB1
461 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
462 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 2.00 Mtr INV2 TO EARTH
463 6000033314 CVT1 I/P TRACK HARNESS ASSY 1.00 PC
464 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
465 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
466 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
467 1000002255 CABLE FR 6 SQMM CU MT ST 1C YEL HV 2.55 Mtr CVT1 TO CDB1
468 1000002240 CABLE FR 6 SQMM CU MT ST 1C BLK HV 2.55 Mtr CVT1 TO CDB2
469 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
470 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr CVT1 TO EARTH
471 6000033315 CVT1 O/P TRACK HARNESS ASSY 1.00 PC
472 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
473 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
474 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
475 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 1.50 Mtr CVT1 TO JB2
476 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.50 Mtr CVT1 TO JB3
477 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
478 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr CVT1 TO EARTH
479 6000033316 CVT2 I/P SIGNAL HARNESS ASSY 1.00 PC
480 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
481 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
482 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
483 1000002255 CABLE FR 6 SQMM CU MT ST 1C YEL HV 2.55 Mtr CVT2 TO CDB1
484 1000002240 CABLE FR 6 SQMM CU MT ST 1C BLK HV 2.55 Mtr CVT2 TO CDB2
485 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
486 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr CVT2 TO EARTH
487 6000033317 CVT2 O/P SIGNAL HARNESS ASSY 1.00 PC
488 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
489 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC

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 CONTROLLED COPY

Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
490 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
491 1000002222 CABLE FR 4 SQMM CU MT ST 1C YEL HV 1.50 Mtr CVT2 TO TB21
492 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 1.50 Mtr CVT2 TO JB1
493 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
494 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr CVT2 TO EARTH
495 6000033318 TXR1 I/P TRACK CKT UP HARNESS ASSY 1.00 PC
496 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
497 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
498 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
499 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 0.70 Mtr TXR1/X1/1 TO JB2
500 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 0.70 Mtr TXR1/X1/2 TO JB3
501 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
502 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr TXR1/X1/3 TO EARTH
503 6000033319 TXR1 O/P TRACK CKT UP HARNESS ASSY 1.00 PC
504 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
505 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
506 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
507 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 2.10 Mtr TXR1/X2/1 TO TB5
508 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 2.10 Mtr TXR1/X2/2 TO TB6
509 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
510 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr TXR1/X2/3 TO A2/X2/3
511 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr TXR1/X2/4 TO A2/X2/4
512 6000033320 TXR2 I/P TRACK CKT DN HARNESS ASSY 1.00 PC
513 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
514 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
515 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
516 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 0.80 Mtr TXR2/X1/1 TO JB2
517 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 0.80 Mtr TXR2/X1/2 TO JB3
518 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
519 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr TXR2/X1/3 TO EARTH
520 6000033321 TXR2 O/P TRACK CKT DN HARNESS ASSY 1.00 PC
521 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
522 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
523 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
524 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.85 Mtr TXR2/X2/1 TO TB7
525 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.85 Mtr TXR2/X2/2 TO TB8
526 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
527 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.80 Mtr TXR2/X1/3 TO A2/X2/7
528 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.80 Mtr TXR2/X1/4 TO A2/X2/8
529 6000033322 TXR3 I/P (SIGNAL UP1) HARNESS ASSY 1.00 PC
530 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
531 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
532 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
533 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.85 Mtr TXR3/X1/1 TO CDB5
534 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.85 Mtr TXR3/X1/2 TO CDB6
535 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
536 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr TXR3/X1/3 TO EARTH
537 6000033323 TXR3 O/P SIGNAL UP1 HARNESS ASSY 1.00 PC
538 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
539 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
540 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
541 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.95 Mtr TXR3/X2/1 TO TB9
542 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.95 Mtr TXR3/X2/2 TO TB10
543 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
544 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.60 Mtr TXR3/X2/3 TO A2/X1/5
545 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.60 Mtr TXR3/X2/4 TO A2/X1/6
546 6000033324 TXR4 I/P SIGNAL UP2 HARNESS ASSY 1.00 PC
547 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
548 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
549 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
550 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 2.00 Mtr TXR4/X1/1 TO CDB5
551 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 2.00 Mtr TXR4/X1/2 TO CDB6

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 CONTROLLED COPY

Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
552 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
553 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr TXR4/X1/3 TO EARTH
554 6000033325 TXR4 O/P SIGNAL UP2 HARNESS ASSY 1.00 PC
555 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
556 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
557 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
558 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.90 Mtr TXR4/X2/1 TO TB11
559 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.90 Mtr TXR4/X2/2 TO TB12
560 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
561 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.80 Mtr TXR4/X2/3 TO A2/X2/1
562 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.80 Mtr TXR4/X2/4 TO A2/X2/2
563 6000033326 TXR5 I/P SIGNAL DN1 HARNESS ASSY 1.00 PC
564 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
565 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
566 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
567 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.90 Mtr TXR5/X1/1 TO CDB5
568 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.70 Mtr TXR5/X1/2 TO CDB6
569 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
570 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr TXR5/X1/3 TO EARTH
571 6000033327 TXR5 O/P SIGNAL DN1 HARNESS ASSY 1.00 PC
572 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
573 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
574 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
575 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 1.90 Mtr TXR5/X2/1 TO TB13
576 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.70 Mtr TXR5/X2/2 TO TB14
577 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
578 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.90 Mtr TXR5/X2/3 TO A2/X1/7
579 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.90 Mtr TXR5/X2/4 TO A2/X1/8
580 6000033328 TXR6 I/P (SIGNAL DN2) HARNESS ASSY 1.00 PC
581 1000004878 CONNECTOR STR/RE 3PIN UMNL 0640714 2.00 PC
582 1000004793 CONNECTOR PLUG HOUSING 3PIN UMNL 0350766 1.00 PC
583 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 3.00 PC
584 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 2.10 Mtr TXR6/X1/1 TO CDB5
585 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.60 Mtr TXR6/X1/2 TO CDB6
586 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
587 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 1.50 Mtr TXR6/X1/3 TO EARTH
588 6000033329 TXR6 O/P SIGNAL DN2 HARNESS ASSY 1.00 PC
589 1000004795 CONNECTOR PLUG HOUSING 4PIN UMNL 0350779 1.00 PC
590 1000004879 CONNECTOR STR/RE 4PIN UMNL 0641776 2.00 PC
591 1000010146 LUG 3-6SQ MM PH BR M6 UMNL SKJ 12-10 AMP 4.00 PC
592 1000002149 CABLE FR 2.5 SQMM CU MT ST 1C YEL HV 2.10 Mtr TXR6/X2/1 TO TB15
593 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 1.60 Mtr TXR6/X2/2 TO TB16
594 1000015730 SCREWS SELF TAPPING (M4X9.5MM) 2.00 PC
595 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.20 Mtr TXR6/X2/3 TO A2/X2/5
596 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 3.20 Mtr TXR6/X2/4 TO A2/X2/6
597 6000033645 DCDB RACK ASSY IPS/440 1.00 PC
598 6000002647 CONSOLE H 1530xW 654xD 500MM 1.00 PC
599 6000009563 MODULE DCDC 12-28/1A HBL 2.00 PC
600 6000009565 MODULE DCDC 12-40/1A HBL 5.00 PC
601 6000009566 MODULE DCDC 2-12V/5A HBL 2.00 PC
602 6000009564 MODULE DCDC 12-28V/5A HBL 4.00 PC
603 6000009567 MODULE DCDC 24-32/5A HBL 16.00 PC
604 6000009568 MODULE DCDC 3-6V/0.1A HBL 4.00 PC
605 1000009515 LABEL 100 (L) x 55 x 0.8 AL ANOD DCDB 1.00 PC
606 1000000954 BANANA SOCKET 5MM RED BTI-15-04 1.00 PC
607 1000000953 BANANA SOCKET 5MM BLACK BTI-15-03 1.00 PC
608 1000017456 SPD VAL-MS 60ST VAL-MS BE/FM 6.00 PC
609 6000017045 PPCB HBL/PE/IPS/SCU-02-D03 S001H01 1.00 PC
610 6000017041 PPCB HBL/PE/IPS/MTR(DC)001-D03S001H01 1.00 PC
611 6000017031 PPCB HBL/PE/IPS/FAN-D03 H01 1.00 PC
612 6000011616 POP.PCB REPD/MOV-001-00 SURGEPROTCTION 1.00 PC
613 1000000019 48V5.8W_DCFAN_EEC0384B2-0000A99, SUNON 2.00 PC

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 CONTROLLED COPY

Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
614 1000006449 DIODE LEADED 1N4007 DO-41 1.00 PC
615 1000021956 CABLE RJ45 LENGTH 180MM 15.00 PC
616 1000002948 CABLE RJ45 LENGTH 600MM 3.00 PC
617 1000021957 CABLE RJ45 LENGTH 650MM 4.00 PC
618 1000021958 CABLE RJ45 LENGTH 850MM 3.00 PC
619 1000021959 CABLE RJ45 LENGTH 1100MM 1.00 PC
620 1000021960 CABLE RJ11 4PIN LENGTH 1200MM 1.00 PC
621 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 33.00 Mtr
622 1000002070 CABLE FR 1.5 SQMM CU MT ST 1C RED HV 32.00 Mtr
623 1000002064 CABLE FR 1.5 SQMM CU MT ST 1C BLK HV 33.00 Mtr
624 1000002143 CABLE FR 2.5 SQMM CU MT ST 1C RED HV 23.00 Mtr
625 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 22.00 Mtr
626 1000002137 CABLE FR 2.5 SQMM CU MT ST 1C GRE HV 20.00 Mtr
627 1000002216 CABLE FR 4 SQMM CU MT ST 1C RED HV 22.00 Mtr
628 1000002206 CABLE FR 4 SQMM CU MT ST 1C BLK HV 22.00 Mtr
629 1000002088 CABLE FR 10 SQMM CU MT ST 1C RED HV 2.00 Mtr
630 1000002078 CABLE FR 10 SQMM CU MT ST 1C BLK HV 2.00 Mtr
631 1000001889 CABLE TIES 100MM 60.00 PC
632 1000001887 CABLE TIES FR TYPE 150MM 45.00 PC
633 1000001894 CABLE TIES 200MM 100.00 PC
634 1000001897 CABLE TIES 300MM 70.00 PC
635 1000010065 LUG 1.5SQ MM CU PIN TYPE 72.00 PC
636 1000010100 LUG 2.5SQ MM CU PIN TYPE 2.00 PC
637 1000010153 LUG 4-6SQ MM CU RING TYPE M6 32.00 PC
638 1000010073 LUG 10SQ MM CU PIN TYPE 6.00 PC
639 1000010064 LUG 1.5SQ MM CU FORK TYPE 12.00 PC
640 1000010155 LUG 4-6SQ MM CU RING TYPE M4 10.00 PC
641 1000018595 TERMINAL END PLATE GREY KUT10 ELMEX 16.00 PC
642 1000018566 TERMINAL BLOCK KUT10 GREY ELMEX 30.00 PC
643 1000018560 TERMINAL BLOCK 4 CONDUCTOR 20A GRY WAGO 30.00 PC
644 1000018598 TERMINAL END PLATE WAGO 11.00 PC
645 1000001746 BUSBAR_COPPER_20MMx3MM 2.00 PC
646 1000012695 PCB SUPPORTER 10.00 PC
647 1000012201 OMEGA RAIL 1MTR 1.00 PC
648 1000006382 DIN RAIL W:35MM UNSLOTTED CHS TYPE 1MTR 2.00 PC
649 1000006994 END CLAMPS 35 MM DIN RAIL CHANNEL 40.00 PC
650 3000002722 LABEL ALUMINIUM EARTHING 25X25X0.8 mm 2.00 PC
651 1000031237 LABEL 500(L)x25(W)x1.6(T) BWB 1.00 PC
652 1000021903 LABEL 250(L)x25(W)x1.6(T) BWB 1.00 PC
653 1000009677 LABLE 120 (L) x 60 (W) x 0.8 (T) AL ANOD 1.00 PC
654 1000001830 CABLE DUCT B TYPE 25MMx25MMx2MTR LENGTH 3.00 PC
655 1000017487 SPIRAL TUBE 6MM BLACK 5.00 Mtr
656 1000017485 SPIRAL TUBE 12MM BLACK 2.00 Mtr
657 1000017102 SLEEVES 3MM HEAT SINKABLE TYPE BLA 1.00 Mtr
658 1000017112 SLEEVES HEAT SHRINKABLE TYPE 6MM BLACK 1.00 Mtr
659 1000017113 SLEEVES HEAT SHRINKABLE TYPE,10MM(BLACK) 0.50 Mtr
660 1000007217 FERRULE TUBE 2.5MM WHITE 10.00 Mtr
661 1000007221 FERRULE TUBE 4.2MM WHITE 10.00 Mtr
662 1000007223 FERRULE TUBE 5.5MM WHITE 5.00 Mtr
663 1000004718 CONNECTOR HOUSING 2 PIN 3.96MM ALEX 13.00 PC
664 1000010192 LUG 96T HOUSING ALEX 30.00 PC
665 1000007263 FILE CLIPS BIG 1.00 PC
666 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 30.00 PC
667 1000021965 CON FEMALE 4PIN 2EDGK-5.08-04P-14-00A(H) 30.00 PC
668 1000020915 WASHER SPRING MS ZINC PAS M5 4.00 PC
669 1000020914 WASHER SPRING MS ZINC PAS M4 136.00 PC
670 1000020916 WASHER SPRING MS ZINC PAS M6 34.00 PC
671 1000020917 WASHER SPRING MS ZINC PAS M8 2.00 PC
672 1000020909 WASHER SPRING MS ZINC PAS M10 4.00 PC
673 1000020799 WASHER NYLON M3(I/D:3mm) 12.00 PC
674 1000020849 WASHER PLAIN MS ZINC PAS M3 8.00 PC
675 1000020850 WASHER PLAIN MS ZINC PAS M4 160.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
676 1000020851 WASHER PLAIN MS ZINC PAS M5 10.00 PC
677 1000020852 WASHER PLAIN MS ZINC PAS M6 62.00 PC
678 1000020853 WASHER PLAIN MS ZINC PAS M8 4.00 PC
679 1000020843 WASHER PLAIN MS ZINC PAS M10 8.00 PC
680 4000003731 BOLT(HEX) MS M5X15mm 4.00 PC
681 1000001374 BOLT(HEX) MS M6x10mm 4.00 PC
682 1000001377 BOLT(HEX) MS M6x15mm 22.00 PC
683 1000001380 BOLT(HEX) MS M6x25mm 4.00 PC
684 1000001346 BOLT(HEX) MS M10x50mm 4.00 PC
685 1000015661 SCREW M4X50 CHEESE HEAD- ZINC PASSIVATED 8.00 PC
686 1000015664 SCREW M4X80MM CHEESE HEAD 2.00 PC
687 1000015641 SCREW M3X6MM CHEESE HEAD 12.00 PC
688 1000015632 SCREW M3X15MM CHEESE HEAD 8.00 PC
689 1000015653 SCREW M4X15MM CSK HEAD 45.00 PC
690 1000012077 NUT HEXAGONAL M3 8.00 PC
691 1000012074 NUT HEXAGONAL SLOTTED M4 ZINC PASSIVATED 51.00 PC
692 1000012078 NUT HEXAGONAL M5 4.00 PC
693 1000011975 NUT(HEX) M10 4.00 PC
694 1000012079 NUT HEXAGONAL M8 2.00 PC
695 1000001081 BLIND RIVET 2.4MMx6MM 10.00 PC
696 1000012112 NUTS MS ZINC PSSVTD TYPE M6 2.00 PC
697 6000033331 FAN Card CN1 HARNESS ASSY 1.00 PC
698 1000004720 CONNECTOR HOUSING 3 PIN 3.96MM ALEX 1.00 PC
699 1000010192 LUG 96T HOUSING ALEX 2.00 PC
700 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 0.60 Mtr A3/CN1/1 - CDB1
701 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 0.60 Mtr A3/CN1/3 - CDB2
702 6000033332 FAN Card CN2 HARNESS ASSY 1.00 PC
703 1000004718 CONNECTOR HOUSING 2 PIN 3.96MM ALEX 1.00 PC
704 1000010192 LUG 96T HOUSING ALEX 2.00 PC
705 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 1.65 Mtr A3/CN2/1 – FAN1
706 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 1.65 Mtr A3/CN2/3 – FAN2
707 6000033333 DC SCU X1 HARNESS ASSY 1.00 PC
708 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 2.50 Mtr
709 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 2.50 Mtr
710 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.50 Mtr
711 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 0.20 Mtr
712 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 0.20 Mtr
713 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 0.20 Mtr
714 1000021964 CON FEMALE 3PIN 2EDGK-5.08-03P-14-00A(H) 3.00 PC
715 6000033334 DC SCU X2 HARNESS ASSY 1.00 PC
716 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 2.70 Mtr
717 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 2.70 Mtr
718 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 2.70 Mtr
719 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 0.20 Mtr
720 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 0.20 Mtr
721 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 0.20 Mtr
722 1000021964 CON FEMALE 3PIN 2EDGK-5.08-03P-14-00A(H) 3.00 PC
723 6000033335 DC SCU X3 HARNESS ASSY 1.00 PC
724 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 1.00 PC
725 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 2.50 Mtr A1/X3/1 – TB3
726 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 2.50 Mtr A1/X3/2 – TB4
727 6000033336 DC METER X1 HARNESS ASSY 1.00 PC
728 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 1.00 PC
729 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 0.65 Mtr A2/X1-SOCKET
730 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 0.65 Mtr A2/X1-SOCKET
731 6000033337 DC METER X5 HARNESS ASSY 1.00 PC
732 1000021963 CON FEMALE 2PIN 2EDGK-5.08-02P-14-00A(H) 1.00 PC
733 1000002309 CABLE FR 0.5 SQMM CU MT ST 1C RED HV 2.50 Mtr A2/X5/1 – TB3
734 1000002049 CABLE FR 0.5 SQMM CU MT ST 1C BLK HV 2.50 Mtr A2/X5/2 – TB4
735 6000033663 LA BOX ASSY IPS SYSTEMS 1.00 PC
736 6000002671 CONSOLE H 400xW 270xD 150MM 1.00 PC LA BOX
737 1000007680 FUSE 63A,415V AC 80KA CS 1.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
738 1000007645 FUSE BASE 63A,415V AC CS 1.00 PC
739 1000017453 SPD FLT35 FLT50N/PE VAL-MS 320ST BE/FM 1.00 PC
740 1000002183 CABLE FR 25 SQMM CU MT ST 1C YEL HV 1.00 Mtr
741 1000002167 CABLE FR 25 SQMM CU MT ST 1C BLK HV 0.70 Mtr
742 1000002175 CABLE FR 25 SQMM CU MT ST 1C GRE HV 1.00 Mtr
743 1000010132 LUG 35SQ MM CU PIN TYPE 6.00 PC
744 1000010116 LUG 25SQ MM CU PIN TYPE 9.00 PC
745 1000010121 LUG 25SQ MM CU RING TON TYPE M8 TON JA 16.00 PC
746 1000021962 TERMINAL BLOCK CTS50/70N 70SQMM GRY CW 6.00 PC
747 1000012201 OMEGA RAIL 1MTR 1.00 PC
748 1000006994 END CLAMPS 35 MM DIN RAIL CHANNEL 4.00 PC
749 1000015653 SCREW M4X15MM CSK HEAD 4.00 PC
750 3000002722 LABEL ALUMINIUM EARTHING 25X25X0.8 mm 1.00 PC
751 1000009681 LABLE 90 (L) x 25 (W) x 0.8 (T) AL ANOD 1.00 PC
752 1000008277 GROMET GR25 DIA25 5.00 PC
753 1000020850 WASHER PLAIN MS ZINC PAS M4 8.00 PC
754 1000020852 WASHER PLAIN MS ZINC PAS M6 4.00 PC
755 1000001383 BOLT(HEX) MS M6X40mm 1.00 PC
756 1000015653 SCREW M4X15MM CSK HEAD 4.00 PC
757 1000012074 NUT HEXAGONAL SLOTTED M4 ZINC PASSIVATED 6.00 PC
758 1000009990 LMLA BATTERY 110V,300AH 60 CELLS 1.00 PC BATTERY
759 SPARES
760 1000007681 FUSE 6A,550V AC 80KA BUSSMANN 1.00 PC
761 1000007673 FUSE 20A,550V AC 80KA BUSSMANN 1.00 PC
762 1000007680 FUSE 63A,415V AC 80KA CS 1.00 PC
763 1000011796 MULTIMETER PROBE RED&BLACK 2MTR LENGTH 1.00 PC
764 1000002078 CABLE FR 10 SQMM CU MT ST 1C BLK HV 8.00 Mtr
765 1000002088 CABLE FR 10 SQMM CU MT ST 1C RED HV 6.00 Mtr
766 1000002143 CABLE FR 2.5 SQMM CU MT ST 1C RED HV 4.00 Mtr
767 1000002053 CABLE FR 0.5 SQMM CU MT ST 1C GRY HV 20.00 Mtr
768 1000002129 CABLE FR 2.5 SQMM CU MT ST 1C BLK HV 4.00 PC
769 1000002094 CABLE FR 10 SQMM CU MT ST 1C YEL HV 2.00 Mtr
770 1000002167 CABLE FR 25 SQMM CU MT ST 1C BLK HV 5.00 Mtr
771 1000002183 CABLE FR 25 SQMM CU MT ST 1C YEL HV 5.00 Mtr
772 1000002175 CABLE FR 25 SQMM CU MT ST 1C GRE HV 5.00 Mtr
773 1000010065 LUG 1.5SQ MM CU PIN TYPE 20.00 PC
774 1000010100 LUG 2.5SQ MM CU PIN TYPE 4.00 PC
775 1000010073 LUG 10SQ MM CU PIN TYPE 12.00 PC
776 1000010116 LUG 25SQ MM CU PIN TYPE 8.00 PC
777 1000010121 LUG 25SQ MM CU RING TON TYPE M8 TON JA 2.00 PC
778 1000007149 FAN DC BRUSHLESS 12VDC 3WIRE SUNON 2.00 PC
779 1000000055 AC EXHAUST FAN 220/230VAC 90W 1350RPM 1.00 PC
780 4000037115 SPANNER-RING 12-13 TAPARIA 1.00 PC
781 4000037126 SPANNER-RING 6-7 TAPARIA 1.00 PC
782 1000015647 SCREW M4X10MM CHEESE HEAD 150.00 PC
783 1000020914 WASHER SPRING MS ZINC PAS M4 150.00 PC
784 1000020850 WASHER PLAIN MS ZINC PAS M4 150.00 PC
785 4000037108 SPANNER FLAT SIZE:6 & 7 MAKE:TAPARIA 1.00 PC
786 4000037109 SPANNER FLAT SIZE:8 & 9 MAKE:TAPARIA 1.00 PC
787 4000037096 SPANNER FLAT SIZE:10 & 11 MAKE:TAPARIA 1.00 PC
788 4000037097 SPANNER FLAT SIZE:12 & 13 MAKE:TAPARIA 1.00 PC
789 4000024303 NOSE PLIERS 6” 1.00 PC
790 4000032930 SCREW DRIVER 713 TAPARIA 1.00 PC
791 4000032931 SCREW DRIVER 827 TAPARIA 1.00 PC
792 4000032932 SCREW DRIVER 901 TAPARIA 1.00 PC
793 4000032933 SCREW DRIVER 911 TAPARIA 1.00 PC
794 4000032934 SCREW DRIVER 912 TAPARIA 1.00 PC
795 4000032935 SCREW DRIVER 921 TAPARIA 1.00 PC
796 4000032936 SCREW DRIVER 933 TAPARIA 1.00 PC
797 4000044079 WIRE CUTTER 6 MM 1.00 PC
798 4000028608 PLIER 165MM P.NO. 1621-6 TAPARIA 1.00 PC
799 4000037127 SPANNER RING SIZE:8 & 9 MAKE:TAPARIA 1.00 PC

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Multi Level BOM for IPS SYSTEM - IPS/440

Doc#: 5 20 88 0111, Rev A
Object description
Sl # Part Number QTY Un Asm
L1 L2 L3 L4
800 4000037114 SPANNER RING SIZE:10 & 11 MAKE:TAPARIA 1.00 PC
801 1000021924 CABLE RJ11 6PIN LENGTH 30000mm 1.00 PC
802 1000003342 CAPACITOR ELE 30MFD 600VAC EPCOS 1.00 PC
803 1000003361 CAPACITOR ELE 36MFD 600VAC EPCOS 1.00 PC
804 1000003408 CAPACITOR ELE 48MFD 600VAC EPCOS 1.00 PC
805 1000007682 FUSE 80A,500V AC 120KA BUSSMANN 1.00 PC
806 1000002167 CABLE FR 25 SQMM CU MT ST 1C BLK HV 30.00 Mtr
807 1000002179 CABLE FR 25 SQMM CU MT ST 1C RED HV 30.00 Mtr
808 PACKING MATERIALS
809 3000002543 TXR WOODEN BOX 290(H)x725(W)x435(D)MM 2.00 PC
810 3000000637 CVT WOODEN BOX 390(H)x380MM(W)x400(D)MM 2.00 PC
811 3000002288 SPARE WOODEN BOX 400(H)x500(W)x400(D)MM 1.00 PC
812 3000001911 PKG BOX PLYWOOD SMRINV 600x400x390 2.00 PC
813 3000001876 PKG BOX PLYWOOD DCDC 580x520x560 2.00 PC
814 3000001910 PKG BOX PLYWOOD SMRINV 400x400x390 1.00 PC
815 3000000639 DCDB WOOD.FRAME 1475(H)x654(W)x500(D)MM 1.00 PC
816 3000000669 FRBC WOOD.FRAME 1475(H)x730(W)x500(D)MM 1.00 PC
817 3000000005 ACDB WOOD.FRAME 1475(H)x730(W)x500(D)MM 1.00 PC
818 1000001716 BUBBLE SHEET 70.00 Mtr
819 3000004354 CORRUGATED BOX 463 (H)x445 (W)x303 (D)MM 1.00 PC
820 3000002513 THERMOCOLE 1MTR(H)x0.5MTR(W)x20MM (T) 70.00 PC
821 3000001469 PACKING TAPE BROWN COLOR HBL LOGO 2 INCH 10.00 PC
822 1000009710 LAMINATION PAPER A4 SIZE 12.00 PC
823 2000001171 NAILS 3" 1.00 Kg
824 3000001393 NAILS 1 1/2” 0.50 Kg
825 2000001169 NAILS 2 1/2" 2.00 Kg
826 DUMMY PLATES
827 1000031065 SMR/INV DUMMY COVER 136HX355WX1.6THK D03 2.00 PC
828 1000031066 DCDB DUMMY COVER 210HX66WX1.6THK D03 12.00 PC

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 Annexure-N

CUSTOMER FEEDBACK FORM

Dear Sir

We have supplied you IPS / Battery Charger/ Battery dis charger to your esteemed
organization. Please give your feedback for our product performance & services.

Satisfactory Not satisfactory (With specific fault if any)

Suggestions (if any) :

Customer’s sign ------------------

 Pre-Commissioning Checklist

of

SMPS based IPS

REFERENCE: SPECIFICATION NO. RDSO/SPN/165/2012

SIG0101 (Revision 2)

Number of pages 11

RESEARCH, DESIGNS & STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

MANAK NAGAR

LUCKNOW - 226011

1
DOCUMENT DATA SHEET

Designation

SIG 0101 (Revision 2)

Title of Document

Pre-Commissioning Checklist of SMPS based IPS

Authors: See Document Control Sheet

Name: T.K. Khare

Designation: Joint Director / Signal

Approved By

Name: Shri Mahesh Mangal

Designation: Sr.Executive Director /Signal, RDSO

Abstract

This document defines the guidelines for Pre-Commissioning Checklist of SMPS

based IPS.

2
Document control Sheet

Designation Organization Function Level

Joint RDSO Member Prepare

Director/Signal

Sr.ED /Signal RDSO - Approval

3
 PRE-COMMISSIONING CHECKLIST FOR SMPS BASED IPS SYSTEM

1. STATION DETAILS
Zonal Railway Number of main signals
Division Number of shunt signals
Station Name Number of point machines
IPS Make Number of Axle Counters
RE/Non RE Number of Track Circuits
No. of lines / Roads Type of Track Circuit
(AFTC/DC)
Power availability Number/Type of Indoor
hours / day relays
DG set rating Number/Type of outdoor
relays
Type / capacity of Interlocking ( RRI/SSI/PI)
battery (LM/VRLA)
IPS SL.Number MFG Date
Installation Date Input feeder rating

2. PRE-COMMISSIONING REQUIREMENTS

S.N ITEM Specified Measured Remark

. Value/provision Value / (OK/Not
Observation OK)
A Ambience of IPS Room

A1 Availability of working 1 m (min.) from sides and

space for maintenance. rear. 2 m (min.) in front of
the IPS
A2 Provision of flooring to Pucca floor/ Ceramic tiles
ensure proper cleaning.
A3 Provision of forced Fresh Air fans with
ventilation dampers

A4 Arrangement for (i) Tight closing of doors &

protection against dust. windows; use gaskets if
necessary.

(ii) Washable dust filters on

windows.

(iii) Provision of double

door or entry through
adjoining room to reduce
dust ingress
A5 Provision of Ventilators As per RE Drg. No.
RE/Civil/S-129-2001
(Annexure-I).
Signature of Manufacturer's Representative Signature of Railway Supervisor

4
 S.N ITEM Specified Value/provision Measured Remark
. Value / (OK/Not
Observation OK)
B Batteries
B1 Installation of secondary Installed in separate room /
cell as per para 16.6 of apparatus case.
SEM Pt. Acid proof flooring and tiles
Exhaust fan
Initial charging as per instruction
of battery manufacturer
Use of battery grade sulphuric
acid conforming to IS: 266.
Use of distilled or de-mineralised
water conforming to IS: 1069
B2 Storage period of VRLA Less than 03 months (If the
batteries for IPS battery is being stored for more
than 3 months, freshening
charge should be given once in
3 months as given below. The
charging current should be 10%
to 20% (max.) of rated capacity:-

Float Charge @ 2.25V/cell for

24 hours
Boost Charge - @ 2.30V/cell for
15 hours)
B3 (ii) Initial Charging/ Initial Charging/Discharging
Discharging data sheet of sheet of manufacture for LM
LM battery battery should be attached.

Rated AH
B4 Feeder cable from battery
to charger
120AH 10 sq.mm copper
200AH 16 sq.mm copper
300AH 25 sq.mm copper
B5 Availability of Spare cell in 05 Nos.
charged condition at site
C Commercial/AT Supply
C1 Availability of commercial More than 6 hours in 24 hours
supply (Ref: RB letter No. with least fluctuations
2002/SIG/SGF/3 dt.
24.6.03). (Provision of (Note: Nominal incoming AC
Stabilizer shall be made supply shall be 230V, 50Hz
by Railways if input single phase AC. The specified
supply not stable) AC voltage range for IPS is
150V-270V.)

Signature of Manufacturer's Representative Signature of Railway Supervisor

5
 S.N ITEM Specified Value/provision Measured Remark
. Value / (OK/Not
Observation OK)
C2 Voltage drop in input feeder Less than 30 volts
at full load.
C3 Provision of sources of RE Area
power supply as per para Power supply drawn from AT
16.2 of SEM Pt. II. Up / Dn / Commercial
supply/Genset with auto/
manual changeover facility in
the control panel.

On double/multiple line
sections, at least one AT is
available to ensure power
supply in the event of power
block.

On single line sections where

power supply is drown from a
single AT, a DG set of suitable
capacity has been provided

In big yards, a DG set of

adequate capacity in addition
to supply from AT's and local
source

Non RE Area
Power supply drawn from
commercial feeder. In addition
two standby diesel generators
have been provided
C4 Size of input feeder cable
as per TI Directorate's note
no. TI/PSI/Project/CLS/01
dt. 04.01.02.(Annexure II)
from Auxiliary Transformer
(AT ) / Distribution
transformer to IPS room for
5 KVA AT 2X25 sq.mm Al
10KVA AT 2x70 sq.mm Al
50KVA AT 2x300 sq.mm Al

Signature of Manufacturer's Representative Signature of Railway Supervisor

6
 S.N ITEM Specified Value/provision Measured Remark
. Value / (OK/Not
Observation OK)
C5 Sanctioned Commercial
feeder load (KVA)=S
General Electrical Lighting
load (KVA)=L
Balance available for
Signalling Load(KVA) = S-L

C6 MCB/ Changeover switch 63A 2 pole Amp of Merlin

Gerlin (Telemecanique) /
(Ref: RB letter No. Siemens, Schneider or ABB.
2004/SIG/SGF/3 dt.
25.3.2004.
D DG Set supply
D1 Provision of adequate
capacity DG set (without
AFTC)
4 Line Non-RE 10 KVA
4 Line RE/6 Line RE 10 KVA
6 Line Non-RE 12.5/15 KVA

with AFTC in yard At least 25 KVA

D2 Checking of DG set at
5KW dummy load:
Waveform Sinusoidal
Voltage Regulation within 3%
Frequency 50Hz ± 5% from no load to full
load
D3 Proper termination of Good workmanship
earth and neutral.
E Earthing
E1 Earth resistance of Less than 1 Ohm (without
earthing arrangement. adding water prior to
measurement)
Preferably maintenance free
earth.
E2 Extension of earth to Provided
equipotential bus bar.

Signature of Manufacturer's Representative Signature of Railway Supervisor

7
 S.N ITEM Specified Value/provision Measured Remark
. Value / (OK/Not
Observation OK)
E3 Connection of individual with individual copper insulated
equipment to cable of size
equipotential bus bar:
- IPS racks 16 Sq.mm
- DG sets 16 Sq.mm
-Surge protection devices 16 Sq.mm
F Lightning & Surge Protection
F1 Provision of lightning & The protections are provided at
surge arrestors (As per a) Stage 1 Protection –At input of
Cl. 3.12 of IPS ,
RDSO/SPN/165/2012 (Class B) Line to Neutral &
Neutral to Earth
b) Stage 1 Protection –At input of
IPS
(Class C) Line to neutral
c) Stage 2 Protection -Protection
at the output of IPS for following
cicuits (Class C in common and
differential mode)
i) Relay External
ii) Axle counter
iii) Inverter Output
iv) Point machine
G. Instruction Manual
G1 Instruction Manual Two sets
consisting of Layout drgs.,
Circuit/ System diagram,
PCB Layout etc. (Ref: Cl.
7.1 of
RDSO/SPN/165/2012 )

H Training
H1 Imparting on job training 3 days
to SE/SSE/JE and ESM

3. IPS LOAD DETAILS

N= Number of modules provided in hot standby

S.N ITEM Specified Measured Remark

. Value/provision Value / (OK/Not OK)
Observation OK Not
OK
1. Signalling Equipment load capacity of the DG Set
(KVA) shall be 80% of load
provided at station

Signature of Manufacturer's Representative Signature of Railway Supervisor

8
S.N ITEM Specified Measured Remark
Value/provision Value / (OK/Not OK)
Observation OK Not
OK
2. Relay internal 24-32V/5A ≤5 *(N-2) Amp or
or 24-32V/10A ≤10 *(N-2) Amp
3. Relay external 24-32V/5A ≤5 *(N-1) Amp or
≤10 *(N-1) Amp
4. Axle counter 24-32V/5A ≤5 *(N-1) Amp
5. Block local 12-28V/5A ≤5 *(N-1) Amp
6. Panel Indication12-28V/5A ≤5 *(N-1) Amp
7. HKT/magneto 12-28V/1A ≤1 *(N-1) Amp
8. Block UP 12-40V/1A ≤1 *(N-1) Amp
9. Block DN 12-40V/1A ≤1 *(N-1) Amp
10. Block Tele UP 3-6V/0.1A ≤0.1*(N-1) Amp
11. Block Tele DN 3-6V/0.1A ≤0.1*(N-1) Amp
12. Data logger 24-32V/5A ≤5 *(N-1) Amp
13. SSI 24-32V/5A ≤5 *(N-2) Amp
14. Load on each Signal Tx UP ≤500/1000 VA
15. Load on each Signal Tx DN ≤500/1000 VA
16. Load on Inverter
4 Line ≤1.5 KVA
6 Line ≤2.0 KVA
10 Line ≤3.0 KVA
17. Load on Signalling AVR
4 Line ≤1.5 KVA
6 Line ≤2.0 KVA
10 Line ≤3.0 KVA
18. Load on Track Tx
UP ≤500/1000 VA
DN ≤500/1000 VA
19. Load on Track AVR
4 Line ≤1.0 KVA
6 Line ≤1.5 KVA
20. High voltage disconnect 275 V
21. Low voltage disconnect 150V
22. Battery capacity 300/200AH
23. Battery charging current 30/20A =Y
24. Total Current drawn from 20* (N-2) Amp=X
FRBC at 110 V after one hour
of discharge.
25. Current drawn from FRBC at X-Y
110 V when battery is in float
condition
Signature of Manufacturer's Representative Signature of Railway Supervisor

9
S.N ITEM Specified Measured Remark
Value/provision Value / (OK/Not OK)
Observation OK Not OK
26. Input feeder current at full
load
4 Line Non-RE 32 Amp
4 Line RE 27.2 Amp
6 Line Non-RE 35 Amp
6 Line RE 30.2 Amp
27. Input feeder voltage at full 160 Volts (Minimum)
load
28. Functioning of dynamic Operational (The set
current control. (Battery path limit shall be adjustable
current shall automatically anywhere between
controlled by the input current 75% to 100% of full
in such a way that input load input current)
current shall not exceed the 4 Line NRE 24 to 32A
set limit.) 4 Line RE 20.4 to 27.2A
6 Line NRE 26.1to 34.8
6 Line RE 22.6 to 30.2A
29. Supply fuse 63 A

30. Working of Status Monitoring

Panel (Para 4.10 of spec.)
DOD 50% RED & Audio alarm
60% RED & Audio alarm
70% RED & Audio alarm till
DG is started

Stop DG Set GREEN & Audio alarm

31. Call S&T due to failure of any RED & Audio alarm
module
32. Changeover inv. 1 to 2 and Inverter failure
vice versa
33. Changeover inv. to CVT and Both inverter fail
vice versa
34 DC-DC Converter for spare 02 Nos.
cells 2-12V, 5Amp
35 Temperature compensation Provided for VRLA
battery

Signature of IPS Manufacturer's Representative Signature of Railway Supervisor

Name Name
Designation Designation
Date
10 Date