VBTS Installation Guide

20100903VihaanNetworksLTD.

Precautions

Following All Safety Precautions

Before any operation, read the instructions and precautions in this document carefully to minimize the possibility of accidents. The Danger, Caution, and Note items in the documents do not cover all the safety precautions that must be followed. They merely provide the most basic generic safety precautions that are applicable for this equipment. When operating VNL products and equipment, you must comply with all safety precautions, while also follow additional special safety instructions related to corresponding equipment provided by VNL. The safety precautions in the document are related to only VNL products. VNL is not liable for any consequence results from the violation of universal regulations for safety operations and safety codes on design, production, and equipment use

Complying with Local Safety Regulations

When operating the device, comply with the local safety regulations. The safety precautions provided in the documents are supplementary. You must comply with the local safety regulations.

Qualified Personnel Only

The personnel in charge of installation and maintenance must be trained and master the correct operating methods and safety precautions before beginning work.

Symbols

DANGER WARNING CAUTION TIP NOTE Safety of Personnel

Indicates a hazard with a high level of risk, which if not avoided, will result in death or serious injury. Indicates a hazard with a medium or low level of risk, which if not avoided, could result in minor or moderate injury. Indicates a potentially hazardous situation, which if not avoided, could result in equipment damage, data loss, performance degradation, or unexpected results. Indicates a tip that may help you solve a problem or save times. Provides additional information to emphasize or supplement important points of the main text.

Grounding of the site equipment is important at all times, regardless if the system is in operation or not. Never perform any site work during a thunderstorm. There are no user serviceable parts inside the VNL VBTS or the VNL CCU 100. Any attempt to access any parts inside may result in serious injury or even death. Defective or malfunctioning units should be replaced and returned in unopened condition. The VBTS site is equipped with batteries of very high peak current capability and high energy. The VNL battery stencil shows the proper polarity and is intended to help with safe assembly. Extreme caution must be taken until the battery terminals are secured. Severe burns or blindness can result during short circuit of battery cables.

Device Safety
Check the electrical connection of the device before operation and ensure that the device is reliably grounded. When working on batteries, take measures to prevent short circuits in the batteries. When the equipment is unpacked, it must be powered on in 24 hours. The maximum duration of the power-off state of the equipment is 24 hours during maintenance.

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Features with Key Components

Energy efficient BTS

The mechanically very robust and reliable low power consumption WorldGSM VBTS, specially designed for demanding outdoor applications in rural areas. It is fed by 24V DC and comes with integrated microwave link and antenna.

Internet wireless access point available

Optional wireless access point for internet access can be fitted and fed via 24V PoE from the VBTS.

Simple setup
The entire installation involves erecting the supporting structure for the solar panels and battery compartment, erecting the pole with BTS and integrated microwave link can be done in two hours.

VNL OMC supervision and alarm handling support included

All relevant real time site parameters, including battery state of charge (SOC) have remote supervision support, allowing informed decisions to be made with respect to service or repairs.

Solar power system with hybrid AC power support included

The main consideration is keeping solar panels clean and ensuring proper seasonal alignment on at least a monthly basis. In very clean environments with limited inaccessibility, like mountainous areas at considerable altitude, a check every three months would be adequate, unless the OMC reports any alarm that calls for manual intervention.

Solar power optimized zero maintenance batteries

The battery technology chosen is tubular gel VRLA in discrete 2V cell configurations of 12 cells per system. For safety reasons, the battery compartment is kept closed with a remotely monitored top cover sensor. There is no topping-up or other service required for the duration of the VNL warranty time period. In the event that some form of physical or chemical damage has occurred due to abnormal operating conditions, only the original cell type may be replaced. Due to lead content, controlled recycling is mandatory to prevent harm to humans, domesticated or wild animals or plants. Always keep in mind that lead in any shape and form must be handled responsibly by personnel with adequate training, for additional information, turn to VNL after sales support.

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Important Tools for Installation

Tool

Tool Name

Uses

Description

Requirement

Flatfile,8"

InstallSolarstand

Smoothenedgesin solarframe

Rare

Roundfile,8"

InstallSolarstand

ExpandholeinSolar frame

Rare

PliersCombination General Pliers(Stanleyor Taparia1621 7,178mmlength, insulated) Adjustable spanner,12" length,1.5"span General

Solarframe,Tower erection,Antenna mounting

Must

Solarframe,Antenna mounting

Desirable

Adjustable spanner,8"length, 3/4"span General Solarframe,Antenna mounting Desirable

Wirecutter,16sq mm Scissors General Normalusage,cutting Desirable packingmaterialetc InstallSolarstand Powersystems, Groundingwire cutting\stripping Must

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Important Tools for Installation

RJ11/RJ45Crimper MakeEthernet Handtool(AMP 7901631Proor equivalent) Magneticcompass Leveling cable

Makeandreplace damagedRJ45cables onsite

Must

SetdirectionofSolar frame,AlignT1

Must

CentrePunch(16 228Stanleyor equivalent) Drillmachine(Hilti orBosch),Bitsfor metaland concrete VBTSinstallation InstallSolarstand

antenna Marking,drillingfor nonstandardframes andmembersolar frameelements FasteningVBTSguy wireonrooftops Must Rare

Hacksawwith Blade InstallSolarstand Cuttingsolarframe members Rare

GIropecutter,to cutupto9mm rope VBTSinstallation Guywirecutting Must

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Important Tools for Installation

Mallet(Softface hammer,57540 Stanleyor equivalent) multipurpose nosepliers

InstallSolarstand

Solarframehole adjustments

Desirable

InstallSolarstand

Batterythimble

Desirable

CableTieCutter Antennamounting Solarframe,Antenna mounting, replacements Ringspannerset, Upto20*22. General Solarframe,Tower erection,Antenna mounting Must Must

DoubleEndedC Spannerset,6*7to 20*22and32*36 General Solarframe,Tower erection,Antenna mounting Must

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Important Tools for Installation

ScrewDriver,Flat Head,(Stanleyor Taparia829),8mm Breadth,1.2mm thicktip ScrewDriver, Flat\Philipsdual Head,(Stanleyor Taparia903) DigitalClamp Meter(Multi14S Sigmaor equivalent)

General

Generaluse,Ground connectiontoBTS

Desirable

General

Generaluse

Desirable

General

Checkingbattery, othervoltagesand currents

Desirable

CableCutterfor cablesupto25 mmdiameter CablingforCCU Cutpowercablesfor CCU Rare

AndrewCutter 1/2" Knife General Antennamounting Antennamounting,RF Desirable cables Solarframe,Tower erection,Antenna mounting Desirable

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Important Tools for Installation

Lugscrimperupto 25mm

InstallSolarstand

Solarframe,Tower erection,Antenna mounting

Must

MagneticBitset withscrewdriver General Solarframe,Tower erection,Antenna mounting ToolBox General Tocarrymultiple tools Must Desirable

Rope,pulley VBTSinstallation Synthetic,12mm,20 mtrropeand1Tonne pulley Desirable

Climbersonpole VBTSinstallation Onceerected,climb onpoletohoist pulley,thenhoist replacement Must

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VBTS Configurations and Pre-deployment Checklist

The VBTS caters to the nano cell in the hierarchical architecture. It is designed to be installed on the rooftop of village houses without any additional foundation or civil work. The VBTS is erected on a pole with three sections of 3 m each. The pole is attached to the solar frame and stabilized by three guy wires. The VBTS site can be of the following configurations: Omni cell with 1 TRX Omni cell with 2 TRX Tri-sectored site with 1-1-1 Tri-sectored site with 2-2-2 Bi-sectored site with 2-2
Checks Status

Checkthelevelingoftheroofandavailabilityof theplaceholder/hookstoinstalltheguywires

Checkthatthehooks/placeholdersonthe rooftoparesoplacedthataftertheguywires areinstalled,theyare120apartfromeach other CheckthatlineofsightispossibletotheTier2 patchantennamountedonthenearestRBTS site Checkloadingcapabilities.VNLsystemis designedwithanassumptionofstrengthofthe typicalrooftopas150kg/sqmto300kg/sqm

Checkthewoodencrateorsystemsurfacefor anydamagebeforemovingthesystem.Incase, anydamageisseen,contactthetransport company

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VBTS Solar Stand and Pole

The VBTS solar stand is housing the power system and must be assembled first for stability and electrical safety reasons. The purpose of this mechanical structure is to support the solar panels, the battery compartment as well as the pole with all BTS and WiFi access point equipment including antennas and lightning arrestor, so proper assembly and alignment is very important. Refer to the section on Battery Enclosure Installation Workflow to ensure the basic stability of the solar stand structure before even considering any further steps in the installation effort. Follow the Site Cabling Installation Workflow in this document for all battery and CCU related electrical connections, but wait with the solar panel placement to avoid damage to the glass surfaces until all pole adjustments are final and nobody is stepping on the supporting structures. The VBTS pole should be assembled in fulcrum arrangment first as shown in the first figure from left. Pull the pole structure in to the final position. Place guy wires at an angle of 120, confirm startup as given in the section VBTS Microwave Link and Access Point Initiation.

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VBTS Solar Stands with Latitude Tilt

The VBTS solar stand is housing the power system and must be assembled first for stability and electrical safety reasons. The purpose of this mechanical structure is to support the solar panels, the battery compartment as well as the pole with all BTS and WiFi access point equipment including antennas and lightning arrestor, so proper assembly and alignment is very important.
Months Formula Used Delhi Abidjan Durban

Novemberto January Februaryto April MaytoJuly

Latitude+ 23.4 Latitude

52

29

29

30

Latitude 23.4

18(north)

53

Augustto October

Latitude

29

30

The 1 TRX VBTS is equipped with two solar panels. The latitude adjustment should be followed for each geographic location as per the guidelines provided in this section.

The 2 TRX VBTS needs 3 solar panels and a larger battery pack, but the power system still fits in the same battery compartment as for the 1 TRX version.

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VBTS System Interconnection Information

Bottom side of VBTS with power cabling and RJ 45 connectors. Mounting bracket is intended for pole placement. Tower mount detail can be found in the WorldGSM RBTS assembly instructions.

The RJ 45 cable glands are shown as transparent in this image. The left connector is for the optional VBTS access point and the right connector is for CCU supervision and monitoring.

CCU 100 cabling from left to right:

AC mains cable Ethernet connection VBTS 24V power connection Battery cable Solar cables

Please take special note that the CCU may never be opened or serviced in the field. Fixed CCU cabling is tightened with their respective glands directly from factory. Only the battery cable, VBTS load and auxiliary signal connectors should be connected by assembly personnel during site installation.

All cable glands must be properly secured to protect internal electrical connections from damage. Furthermore, the integrity of the weather protection barrier between the cable isolation and the gland itself must be kept intact, otherwise water and pollutants may gain direct entry into the connector housings.

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Site Cabling Installation Workflow

Install PGND cable from solar stand to site ground/earth pit

Install ground cable between BTS and mounting pole and then proceed with the complete battery compartment assembly workflow

Mount the CCU 100, connect the CCU 100 PGND cable (green) to the solar stand and tighten all nuts and bolts firmly. Confirm the presence of washer for good electrical conductivity

Confirm that battery interconnections follow the stencil. Connect the battery cable to the plus and minus terminals and finally to the CCU 100 battery port, tighten CCU 100 connector firmly. Safety hazard!

Connect antenna cable(s) to BTS, RJ45 Ethernet connector, BTS ground screw and finally 24V DC connector

Connect all solar panel cabling, erect pole and finally connect the 24V DC cable at the CCU end and tighten firmly

Confirm that blue LED in BTS is lit and perform backhaul lock routine

16 beeps from CCU

No

Yes Complete the battery compartment assembly and conclude installation

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Battery Enclosure Installation Workflow

Assemble and mount the battery compartment on the solar stand sheet by sheet. Leave one side open

Put the 24V battery bank cell box assemblies inside the battery compartment

Pair the cell box assemblies as per key guides to make one assembly and tighten the nuts and bolts with a wrench

Mount the stencil on the battery bank taking care of polarity and rotation with the help of the guiding pillars present on the cell boxes

Tighten the copper interconnect bus bars

Continue with site cabling installation workflow

Confirm that all glands and gaskets are tight and conclude battery compartment installation

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VBTS Power Reset

Start

Press CCU reset button five times ss times in rapid succession

Is CCU LED turning red?

No

Yes After one minute, confirm CCU normal operation with steady green LED

After five minutes, confirm BTS normal operation with steady blue LED

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VBTS Microwave Link and Access Point Initiation

Start

Confirm that BTS is operational and microwave link established

Can 16 beeps be heard?

No

Yes Confirm cabling for access point and check SSID for local wireless network with notebook PC

Wireless network available?

No

Yes In special cases, use notebook PC with RS232 adapter to confirm the CCU IP-address provided by OMC DHCP, otherwise conclude the procedure and report successful start to customer

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Audio-Visual Indication

CCU 100 LED (inside battery compartment)

TIP

The VBTS site equipment has an integrated audio visual indication to notify the health status of system to installation staff. This section describes the indications in detail.

Category

LED Indication

Event

NopowerfromCCU

Fixedredlight

LoadOff

Redblinkinglight Systemupbutno chargingcurrent Fixedgreenlight Greenblinkinglight

LoadOffandbatterycharging Loadon,Batterychargingbysolar panels BatteryfullychargedwithSOCat 100%,floatchargingactivated

Systemupandbattery chargingcurrentis present

Orangeblinkinglight

SMPSONandBatterychargingby solarorauxiliaryACpower

Fixedorangelight Faultcondition Redgreenalternate blinking

Batterydischarging FaultsSMPSoverheat/Loadfuse trip/ACvoltageunusable

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Acoustics Indications

CCU 100 Beeper Information

Event Beep Pattern

Bootupindication Successfulregistrationon OMC BatteryLow

1sBeep1sSilenceonecycle

0.2sBeep0.2sSilence8cycles 0.5sBeep0.5sSilence2cycles,60s pausethenrepeatallover, continuously

Systemgoingtoshutdown

0.5sBeep0.5sSilencebeepsthis patterncontinuously

Loaddisconnected

1sBeep2sSilencebeepsthispattern continuously

ResetAcknowledgement usingtheresetkeypress, whentheloadisturnedoff ResetRecoveryi.e.when theLoadisturnedbackon afterthedesiredtime. 1sBeep1sSilenceonecycle 0.5sBeep0.5sSilenceonecycle

WhentheACDCchargingis 0.2sBeep0.2sSilence4cycles,30s ON. silencebeepsthispattern continuously

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Power Alarm Thresholds

Function

Parameters

Default Set Values

Load disconnect levels

Loaddisconnect Loadreconnect

22.2Volt 24.5Volt

PWMCharging BoostCharging Control TrickleChargingStartVoltage TrickleChargingStopVoltage Alarm Indications LowVoltageDisconnectWarning EmergencyChargingRequired

<28.4V*@27C >28.4Volt*@27C >28.5Volt*@27C WhenSOC<40% SystemVoltage<=22.5V

NoSolarModulePower

Whenthecurrentdoesnotgo positiveina24Hourperiod

SystemOverVoltage CCUhighTemperature BatteryService

Systemvoltage>30V CCUwarmerthan65C WhentheAhcapacitydrops below80%ofthefactorynew capacity

SolarModuleCleaning

Whenthecurrentneverexceeds 90%oftheratedvalueina5day period.

CCUSMPSfailurealarm

AC/DCstagenotoperational

Batteryboxopenalarm ACvoltunusablealarm

Lidsensorclosingcircuit ACvoltageoutsidetherange90 270VAC

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Troubleshooting

Error symptoms

Possible cause of Error

Troubleshooting/Explanation

Noaudioindicationafter Loosebattery connectingbattery terminals/stencil connections CCULEDisREDandthere Batteriesarelow isnoBTSPower

Tightenthestencilproperlyand thentryreconnectingthe batterycableconnectortoCCU Connectthesystemproperlyto solarpanelsorACpowerto chargethebatteries

CCULEDisblinkingfast

Shortcircuitatload

RemoveBTSpowercableand waitforsometimeandthen pressresetbuttontopower resettheBTS

withgreenredalternate terminal colors

CCULEDisblinkingfast

ACinputvoltageis

MeasuretheACvoltageatthe

withgreenredalternate eithertoolowortoo inlet.Itshouldbeintheinterval colorsduringemergency charging SMPStemperatureis SMPSisoverheated.Turnoff veryhigh theACinputforsometimeand lettheunitcooldown SMPShasfailed ReplacetheCCUafterremoving theACinputcablefromgridor DG BTSispoweredupbut thereisnobeep.The CCUisnotvisibleon OMC TheLANcableis faulty/improper connectorsare crimped MakesurecableisOkand crimpedwellfrombothsides. Pulloutthecableandwaitfor sometime.Insertagainandwait forbeeptocome.BTSshouldbe poweredONinthiscase high 90to270Volts

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Local Console (Advanced Installation)

Local Diagnostics
There is normally no need to perform in-depth analysis or low level configurations during installation in the field. However, a trained engineer can get this Information from the CCU without disturbing the normal functionality of the system. In the upcoming section some of the software accessible commands are given to get the system information.

Needed Accessories and Setup

A small laptop/notebook PC with serial connection to the CCU is needed. A USB to RS232 adapter is recommended. Here are the basic steps to follow: Connect the serial adapter to the CCU RS232 port. Open a telnet program such as tera term or hyper terminal. Follow the port setup per below.

Type the command getccuinfo. This command displays the CCU type, CCU ID, Serial Number, HW version, and MAC address.

Additional Commands
Software version information getswinfo. The information displayed is: Active Software Version Backup Software Version Communication Protocol Version

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Local Console (Advanced Installation)

Boot loader Version

The power system status commend is getstatus. This provides real time information for all the system parameters listed below:

CCU software version Battery current Battery voltage/system voltage Battery State of charge(SOC) in % CCU internal temperature Load current Solar charging current SMPS charging current SMPS temperature AC voltage reading

Finally, to reset the CCU, issue the command reset. This command resets the CCU software but leaves the site power DC feed intact.

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Post-Installation Site Audit

The following should be performed for all BTS sites:

Check the termination of the Ethernet cable to the CCU-100 and the combiner. Check the quality of crimping by visual inspection. Ensure that all interconnections batteries, SPV, and CCU-100 are still firm and without corrosion. Confirm that all (green) grounding cabling is intact and bolts tightened firmly. Ensure that that there is no damage or gaps in the sheet metal battery enclosure and that no equipment is left inside. Check that the remote alarm connector of the compartment lid is working. Check for solar panel damage to the cover glass and also for any small air bubbles trapped between the silicon cells and laminate near the frames, if so, the panel should be replaced. Confirm the north-south solar stand axis of alignment by means of a compass and confirm the seasonal tilt adjustment. Investigate the presence of any non-standard cabling or lamps, indicative of unauthorized use of power, promptly remove and report any such misuse when encountered. Perform RF parameter fine-tuning when all power related checks have been successfully completed.

The following should be performed for VBTS sites in particular:

Carefully look out for twisting or tilting of the VBTS poles with loose guy wires. You can use a theodolite to confirm the incline. Confirm that the guy wires are tout and not corroded. Confirm that the earth pit is damp and that the ground wires are intact.

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Maintenance

Cleaning of Solar Panels

It is recommended to gently clean the solar panels once in approximately 15 days. Always use water and a soft sponge or cloth for cleaning. A mild, non-abrasive cleaning agent can be used to remove hard residue like bird droppings etc. Never use scouring powder, steel wool, scrapers, blades, or any other sharp instruments to clean the glass surface of the solar panels.

Emergency Charging
The WorldGSM power system is designed to have battery autonomy time of 72 hours from fully charged condition to load disconnect during extremely poor weather. Very dense clouds, heavy rains or thick ground fog for continuous 2-3 days can cause battery SOC to fall below 50%. In such events the CCU gives buzzer alarm locally and also generates an alarm on OMC. During such circumstances AC power provided a portable diesel or kerosene AC generator restores SOC to satisfactory levels. The following steps are needed to perform such an emergency charging:
1. 2. 3. 4. 5. 6. 7. 8. 9. Open up the battery compartment locks from sides and remove the top cover. Pull out AC inlet cable of CCU out of box and connect to standard AC socket. Turn ON the genset/grid power switch. CCU gives beep (see buzzer section for pattern) when emergency charging is started. Also, LED color shows the emergency charging activation. At least 4 hours of charging is recommended continuously. After this, remove the AC plug from the generator socket and secure the AC cable. Put the top cover and lock the compartment again. The complete operations information/status is seen by OMC remote monitoring.

10. The voltage range must be 90-270VAC to permit the SMPS stage to work as intended.

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