The place where it will be installed is vetrino near vulchi Dol check the year around weather and adjust the designElectrical Box Design and Component Layout

The electrical box for this project needs to be durable, weatherproof, and capable of housing the RTU and other essential components in a remote, open-field environment. Below is a detailed breakdown of the design and the key components inside the box.

1. Box Design (External Features)

Material: Use stainless steel or polycarbonate for corrosion resistance and durability. It must meet the IP65 or higher standard for protection against dust and water ingress.

Size: The box needs to accommodate an RTU, power systems (batteries, charge controller), and additional communication hardware. A box size of about 600mm x 400mm x 300mm (height x width x depth) should suffice.

Ventilation and Cooling: Include filtered vents to allow airflow and prevent internal condensation. A small thermostatically controlled fan can be added to cool down the components on hot days, especially during summer when temperatures can rise above 80°F (27°C).

Mounting: The box will be mounted on a galvanized steel stand with a concrete base. Ensure the box is elevated about 1.5 meters from the ground to avoid flooding and wildlife interference.


2. Internal Components Layout

The internal components of the box will be arranged in a modular and accessible way, allowing for easy maintenance. Below is the component list and their placement:


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A. Remote Terminal Unit (RTU)

Model: Choose an RTU that supports Modbus, DNP3, or IEC 60870-5 protocols. The RTU should also have 4-20 mA input channels for connecting gas temperature and pressure sensors.

Power Supply: RTU typically operates at 12V or 24V DC, depending on the model.

Mounting: The RTU will be mounted on a DIN rail inside the box for ease of installation and wiring.


B. Solar Power System

1. Solar Charge Controller:

Type: Use an MPPT (Maximum Power Point Tracking) charge controller for efficient power management, capable of handling a 100W-150W solar panel.

Mounting: The charge controller will be mounted near the battery for easy connection.



2. Battery:

Type: Use a 24V, 50Ah deep-cycle AGM or lithium-ion battery for reliable, long-lasting power storage. This should provide enough capacity to power the RTU for at least 24 hours, with additional margin for cloudy days.

Placement: Place the battery at the bottom of the box in a ventilated compartment to ensure proper heat dissipation and access for maintenance.

Battery Box: If using lead-acid batteries, a separate vented battery enclosure is recommended to prevent gas buildup.



3. DC-DC Converter (if needed):

If the RTU operates at 12V but the solar system is 24V, include a DC-DC converter to step down the voltage from 24V to 12V.




C. Sensors and Signal Conditioning

1. Pressure Sensor:

Type: A 4-20 mA pressure sensor compatible with gas measurement and designed for outdoor use, such as a Honeywell or Wika brand sensor.

Wiring: Sensor wires will run through cable glands to maintain the IP rating of the box.



2. Temperature Sensor:

Type: Use a thermocouple or RTD sensor for gas temperature measurement, also with a 4-20 mA output.

Signal Conditioning: If needed, include a signal conditioner to convert the thermocouple signal to 4-20 mA for the RTU input.




D. Communication System

1. Cellular Modem or LTE Router:

Model: A low-power 4G LTE modem with an external high-gain antenna to ensure reliable communication. Models from Sierra Wireless or Digi can be used for long-range data transmission.

Mounting: The modem will be placed inside the box, with the external antenna mounted on the top or side of the enclosure for better signal reception.

Wiring: Connect the modem to the RTU via Ethernet or RS-232/RS-485, depending on the RTU interface.



2. External Antenna:

Install a high-gain LTE antenna on the outside of the box or on the stand. Ensure the antenna is properly grounded to prevent lightning damage.




E. Circuit Protection and Grounding

1. Overcurrent Protection:

Use fuses or DC circuit breakers for each power line (solar panel, battery, RTU) to protect the system from overcurrent and short circuits.



2. Surge Protection:

Install surge protectors for both the power and communication lines to protect against lightning strikes, especially given the exposed nature of the installation.



3. Grounding:

The entire system will be grounded using a copper grounding rod driven into the earth near the installation. The solar panel frame, box, and stand will all be connected to the ground for safety.





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Component Layout Inside the Box

1. Top Section:

Mount the solar charge controller on the back panel at the top section for easy access to the battery and solar inputs.

Place the cellular modem next to the charge controller.



2. Middle Section:

The RTU will be centrally located on a DIN rail, allowing for easy wiring from the sensors and the communication system.



3. Bottom Section:

Place the battery at the bottom for stability, ensuring it’s in a ventilated compartment to avoid overheating. The battery enclosure can be separated by a perforated divider for airflow.

DC-DC converter (if used) will be placed adjacent to the battery.



4. Wiring:

Use cable management clips and conduits to keep all wiring organized and secure. Ensure there are no sharp bends or tight wire runs to reduce wear and tear.





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Conclusion

The electrical box design ensures protection from environmental factors while providing reliable power and communication in a remote location. The internal layout is organized for ease of maintenance and future expansion, with adequate protection against electrical surges and grounding for safety.