IIoTNext

Project Overview: Remote Monitoring of DGs and BMS Across Telecom Sites

To enhance operational reliability and efficiency across telecom tower sites, the project focused on implementing a solution that could control and provide real-time visibility of Diesel Generators (DGs) and Battery Management Systems (BMS). This approach enabled proactive maintenance, optimized fuel usage, and improved uptime for critical network equipment.

To achieve this, a hybrid power management solution was developed and engineered in a compact, industrial-grade cabinet that enables control and remote monitoring of Diesel Generators (DGs), Battery Management Systems (BMS), and Rectifiers across multiple tower sites.

IIoT-Based Remote DG Monitoring Solution for Telecom Towers

Project Outcomes

  • Intelligent Control of DG and Battery Systems

    Intelligent and automated control of Diesel Generators and Battery Systems, enabling optimized power source switching, real-time DG start/stop and battery charge management, resulting in improved energy efficiency, reduced fuel consumption, and enhanced site reliability

  • Centralized Remote Monitoring

    The solution enabled to remotely monitor critical power parameters-such as DG performance, fuel levels, BMS health, and rectifier status-across distributed telecom sites via the IIoTNext Cloud Platform. Data is transmitted through 4G connectivity, allowing continuous visibility of site operations and alarms.

  • Enhanced Uptime & Reliability

    Proactive alerts and alarm notifications for low fuel, generator failure, or BMS faults are sent instantly via SMS and email. This enables field teams to take preventive action, minimizing downtime and ensuring uninterrupted telecom operations.

  • Sustainability & Cost Reduction

    With smart fuel management and optimized generator scheduling, the project delivered measurable reductions in fuel consumption and carbon emissions-supporting client’s sustainability commitments while lowering OPEX.

  • Improved Energy Utilization Efficiency

    By intelligently balancing DG and battery operations, the system reduces idle running hours and ensures batteries are optimally charged and discharged, improving overall energy conversion efficiency.

The Solution

A pre-wired, rack-based hybrid power management solution powered by an industrial edge controller, designed for telecom tower energy automation.

The system intelligently switches between Diesel Generators (DGs), Battery/UPS systems while enabling centralized remote monitoring of critical energy parameters.

It captures real-time operational data-including power generation, electrical performance, fuel usage, temperature, humidity, and switching status and integrates this into an IIoT platform for Remote access and control, Automated reporting (hourly, daily, monthly, yearly) and Performance benchmarking and optimization.

IIoTNext MicrEdge 370 – Hybrid Controller + Industrial IoT Gateway

At the core of the Hybrid Controller Box is the IIoTNext MicrEdge 370, a powerful hybrid controller and industrial IoT gateway. The rack-mountable box is custom-built with an HMI for local display, the hybrid controller, and supporting accessories for seamless integration in telecom tower environments

Key Highlights- MicrEdge 370
  • Multi-source data acquisition: Modbus RTU, CANbus, Solar PV inverter protocols, and hardwired I/Os.
  • Automates switching between DG, Solar PV, and Battery systems using intelligent internal logics and hardwired I/Os.
  • Integrated GSM, Wi-Fi, or Ethernet for flexible internet connectivity.
  • Real-time fuel level monitoring for proactive refueling and reduced pilferage.
  • Fail-safe remote ON/OFF control of gensets via SMS/IIoT platform.
  • Local HMI interface for onsite visibility of critical parameters.

IIoTNext Platform – Centralized Cloud Monitoring

The IIoTNext Platform is a cloud-based monitoring solution, provides real-time visibility and analytics for distributed telecom power assets. It offers operators a single, intuitive dashboard for managing hundreds of sites across regions.

Platform Highlights:
  • Real-time dashboards for energy performance, fuel consumption, and system health.
  • Configurable alerts via SMS or email for critical alarms and events.
  • Automated daily, monthly, and yearly reports in PDF/Excel formats.
  • Role-based access control and encrypted data communication for security.
  • Mobile app and browser-based interfaces for remote access anytime, anywhere.
IIoT Platform For Remote DG Monitoring in Telecom Sites

Result

The deployment of Consyst’s Hybrid Controller Box Solution enabled our client to achieve greater energy visibility, control, and operational reliability across its network sites.

Key Benefits
  • Significant Reduction in Generator Runtime through optimized DG–Battery management.
  • Improved Fuel Efficiency through smart switching between DG and Battery
  • Higher Uptime achieved through proactive alerts and remote fault detection.
  • Simplified Maintenance with cloud-based diagnostics and reporting.
  • Scalability allowing integration of additional sites seamlessly through the same platform.
  • Lower Operational Costs by minimizing site visits and manual data collection.

Architecture

Conclusion

Consyst’s Hybrid Controller Box Solution demonstrates how intelligent automation and IIoT connectivity can optimize telecom power systems. By combining local control with cloud-based monitoring, the solution provides real-time visibility, remote management, and data-driven decision-making-ensuring efficient, reliable, and sustainable power operations for critical telecom infrastructure.

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