Operational and Maintaince

at balchaur section
Gate control system
Other related part
electrical Mechanical Submitted by:
Narayan Prasad (+9779804235570)
Paaila technology/p.vision engg solution
Date:12/30/2022
Table of contents
• Safety
• Abbreviation and definition
• Gate control system
• Introduction
• Operation
• Maintenance

• Appendix
• Electrical systems (mccb, mcb, olr)
• Mechanical system (gear, eot/monorail)
• Electronic parts (smps, mcu/controller, sensor, ssr)
• Communication (fiber, modem)
• Specifications (from design to as built)
• Troubleshooting guide (reading drawing, working way)
• Quick operating card
General Safety: precaution
• Human life is precious so it is suggested to do every work sincerely.
• This project have investment of time and money so use machine and tools properly so that
equipment gives long service.
• Example of Safety recommendation
• Electricity may burn or kill. Use proper mechanism and insulated tools.
• At least use insulating tape on seen part of individual wires, keep away from water.
• Do not use wire as rope alike to hold it.
• Use mcb of proper rating.
• Failing heavy mechanical part, sharp edge may make injury to human.
• Keep long cloth(saree, scarf), hair away from moving parts.
• Drowning in water and fall from height also possible.
• Children (or low mental intelligence/ physically challenged people) and not familiar technician should take
supervision to operate system.
• Read manual and sign or ask related people when necessary.
• Keep workarea clean: Grease, oil, entangled wire, sharp objects on walk path.
• Use white google while using grinder or drill
• While working Two people is advised due to multiple hazard involved
• Operation: operator and helper
• Maintain: technician electrical and/or mechanical and /or helper
Abbreviation and definition
• AC : alternating current, a type of electrical source
• Communication: signal transfer
• DC :Direct current, a type of electrical source
• EOT/monorail: rope based motorized system for hoist purpose
• Gear: mechanical part having tooth to manipulate force/load
• LED : light emitting diode , light source
• MCCB,MCB: miniature circuit breaker
• MCU: microcontroller (electronic controller)
• MoDem: modulator demodulator for signal transfer (optical electrical )
• NEA: Nepal electricity authority
• OLR: overload relay
• optical fiber: wire alike glass thread to transfer signal as light/optic
• RJKIP: rani jamara kularia irrigation project
• sensor: to sense outer environment and give electrical output eg proximity sensor
• SMPS: switch mode power supply (acdc)
• SPP: single phasing protection (other name are VMR/VDR)
• SSR: solid state relay (electronic switch/relay)
• VMR: voltage measurement Relay
Gate control system
• It composes of mainly electrical and electronics and communication
• Electrical: clockwise and anticlockwise rotation of motor will lift gate up and down
through worm gear mechanism.
• Electronics: easy operation of electrical system.
• Communication: for remote operation and monitoring purpose by using optical fiber.
• Features:
• Mechanical Movement of gate is limited to upper and lower limits (electrical switch)
• Overcurrent protection (motor jam) to individual motor through olr
• Short circuit protection to individual motor through mcb
• Main supply single phasing and phase reversal through spp

• Read electrical and mechanical part too

• Safety and precautions
• See safety and proper use technique of mechanical and electrical section.
Multiple hazard may present in workarea.
• The limit switch must be series to corresponding contractor. Exchange of limit
switch will call accident. Check nut bolt of limit switch time to time. If loose
tight it/replace nutbolt.
• Multiple electrical source present, do not mix it.
• From smps: 5vdc,12vdc to mcu and sensor
• Inverter: as backup supply for control system and communication: 220vac
• NEA or Generator: 415vac (different phase of 220vac)
• electrical control for single gate/motor
• Electical and electronic control for single motor/gate control
• Diagram of master slave: remote operation
• Installation of limit switch
Cap for thread

l ow est
Gate n sense
o
positi switch
it
by lim
rotating shaft
h ighest
e
Gate on sens
ti h
posi it switc
m
by li thread

Gate for water

control
• Installation of limit switch
Panel side Motor or gate Gate cap Allowed Upper limit Lower limit from
number height length in movement from ground gear level:
in cm cm level: gate fully detecting tip of
open and thread when
running water gate fully down
splash may In cm
arise (6-9 cm based on
spindle tip)
A: cross 01,02,03,04,05,06 211 223 210 400 9
regulator
B: flush 07,08,09,10,11 200 190 180 500-10 8
C: flush 12,13,14,15,16 200 190 180 500-10 8

D: inlet 17,18,19,20 260 9

Maintainance
• Work involves identify problem, replacing faulty part, tuning.
• Use same/identical parts to avoid unnecessary waste of resource.
• Multiple electrical source present, do not mix it for millisec too.
• Use design file as necessary.
Troubleshooting of some problems
1. Motor not running: no sound from motor
Possible reason Action to do: example
No power Check power on each phase: Vll=380- Check Mccb, Mcb,olr
415volt
Em switch pressed Make em normal Rotate clockwise if pressed
Mcb off Turn on Lift up
Olr activated Rectify overload situation first and Press reset button on olr
Reset it
Gate at its limit Use handle if leaked water not needed

2. Motor not running : sound from motor

Possible reason Action to do: example
No power on any Check power on phase has Check wiring from Mccb, Mcb,
of 1 phase disconnected olr,contractor, motor
Motor jam Use handle
Belt sleep See belt
3. Machine error in automatic mode
Possible reason Action to do: example
Motor not Check power on each phase: Vll=380- Check Mccb, Mcb,olr
running 415volt
Em pressed Make em normal Rotate clockwise if pressed
Mcb off Turn on Lift up
Olr activated Rectify overload situation first and Press reset button on olr
Reset it
Sensor Check and adjust to 5mm Place both sensor in equal distant

4. Phase error in automatic mode

Possible reason Action to do: example
Sensor sequence Exchange sensor output Both sensor output black wire to
exchanged while green/grey at connection box
repair
Sensor distance Check and adjust to 5mm Place both sensor at equal sensitivity
5.Not smooth sound while running motor
Possible reason Action to do: Example/suggested
unregulated power Check power on each phase: Vll=380- May be due to Loose wiring
415volt
Nut bolt loose Tight it with normal force, Check nut
bolt time to time
vibration Rotate shaft and check for mis Align and tight nut bolt
alignment
Metal piece on Remove foreign body if possible Check other wear and tear part
moving part

4. Motor not running in automatic mode

Possible reason Action to do: example
Fuse blown Check fuse in slave Replace with identical value
Communication Check modem power supply, optical Inverter supply, if rx indicator is
fail fiber constant on, ofc may be losse or broken
Appendix
• Electrical systems (mccb, mcb, olr)
• Mechanical system (gear, eot/monorail)
• Electronic parts (smps, mcu/controller, sensor, ssr)
• Communication (fiber,modem)
• Troubleshooting guide (reading drawing, working way)
Electrical system
• Electrical energy is converted to mechanical energy through motor
• Mechanical energy is converted to Electrical energy through
Generator
• Chemical energy is converted to Electrical energy through battery and
inverter
• It is used for gate open/close, lighting, powering dc supply for
electronic part
• Transformer changes voltage and current
• Schematic power supply to all part
• Mccb mcb olr
Mechanical system
• Gate:
• Lubrication to gear, bearings, threaded spindle is necessary
• long cloth ,hair near moving part may call accident
• In EOT/monorail:
• Lubrication to hoist rope protects from environment effect
• If any strand of rope is broken replace it.
• Use of EOT crane/monorail is maintenance purpose only (block gate water).
• The electrical circuit for EOT is similar to Gate . Forward and reverse of motor using
contractor
• Nut/bolt:
• tight the nut-bolt time to time.
• Do not use excessive force for single nut/bolt.
• Special attention unnatural sound, vibration because it indicates problem is near.
Electronic parts
• For dc power for sensor mcu etc 220vac to 12vdc Smps is used. Sensor will
operate at 12v where as mcu operate at 5v.ssr is electronic relay which switch
ac(220)
• vaf meter shows voltage ampere and frequency. It supports voltage till 600v
where as current is through ct coil. Generally 60/5, 100/5,200/5 ct coil is
available on market. Vaf39 should be set according to use example.
Slave circuit is addressed to identify motor. Corresponding lcd is also need to be
address to display stats. lcd have address a1 a2 a3 pin/pad so that upto 8 lcd can be
joined parallel from 0x20 to 0x27.
Panel: a8,a9 Motor Slave Lcd Panel: a8,a9 Motor Slave Lcd
(1,2,3,4,5,6) number address: address: (6,5,4,3,2,1) number address: address:
1,2,3,4 A0,A1,A2 1,2,3,4 a1,a2,a3
A : xxxx11 01 1001 011 B : xxxx10 11 1101 010
A : xxxx11 02 1010 101 C : xxxx01 12 1001 011
A : xxxx11 03 1011 001 C : xxxx01 13 1010 101
A : xxxx11 04 1100 110 C : xxxx01 14 1011 001
A : xxxx11 05 1101 010 C : xxxx01 15 1100 110
A : xxxx11 06 1110 100 C : xxxx01 16 1101 010
B : xxxx10 07 1001 011 D : xxxx00 17 1001 011
B : xxxx10 08 1010 101 D : xxxx00 18 1010 101
B : xxxx10 09 1011 001 D : xxxx00 19 1011 001
B : xxxx10 10 1100 110 D : xxxx00 20 1100 110
Programming microcontroller
Communication system
• The purpose of optical fiber communication technique is ensure high quality
communication occurs in long distance.
• It includes optical fiber cable and modem (optical electrical signal).
• Do not excessive bend in optical fiber cable.
• Keep soft part away from ant, mouse/rat, sharp edges.
• There is extra wire in optical fiber cable which can be used for cctv camera.
Specifications and calculations
• Mcb and olr calculation
• For 5.5hp motor
• Full load current in nameplate 8.4amps: mcb 10amps and olr is 10amps
• Running current measured in field 6-8amps: mcb 16amps and olr is 9 amps
• For 7.5hp motor
• Full load current in nameplate :mcb 16 amps and olr 14 amps
• Field measured current : mcb 20amps and olr 11-16 amps and tuned at 11 amps
Quick operation card:
manual operating gate from near gate

• • Push Up/down switch

Open panel door.
• Check motor is running in • Push EM
• Is MCB on?
ready
• Is EM not pushed? process
required direction
• Push till required(Calculate
finish
• Make MCB off
• Close panel door
• Is manual switch selected? water flow)
Quick operation card:
automatic operating gate from near gate

• Open panel door.

• Push electronic switch
• Is MCB on?
• Give gate height in •
• Is EM not pushed? Close panel door
ready
• Is automatic switch process
percentage finish
• Push same electronic
selected?
switch to confirm
• Is LCD status connected?
Quick operation card
remote operating gate from office

• Is automatic switch • Push required gate

• Not pressing switch
selected on field gate switch
confirms it is in
• Is required gate • Give gate height required
ready
connected? process
by rotating knob finish
monitoring mode in
office.
• If not connected restart • Confirm by same gate
power switch