EMSYS CaseStudy Telecom 1 0

EMSYS Wireless Monitoring System Case Study

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Telecom Case Study


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1 PREFACE .......................................................................................... 4

COPYRIGHT NOTICE 4 OBJECTIVES 4

2 OVERVIEW ........................................................................................ 5

INTRODUCTION 5 EMSYS SENSORS 6

WIRELESS BATTERY MONITOR CELLSPY 6 WIRELESS CURRENT TRANSDUCER 7 WIRELESS AMBIENT MONITOR 7 WIRELESS DC BUS MONITOR 7

LOCAL AND CENTRAL GATEWAY 8 MINI GATEWAY 9 WIRELESS REPEATER 9

3 TELECOM REMOTE LOCATION MONITORING REASONING ...... 10

EMSYS SYSTEM PREVENTS UNPLANNED DOWNTIME 10 EMSYS SYSTEM PREVENTS MAJOR FAILURES 10 EMSYS SYSTEM EXTENDS BANK LIFETIME 11 EMSYS SYSTEM ELIMINATES NEED FOR MANUALLY PERFORMED PERIODIC MAINTENANCES 11

4 SYSTEM DIAGRAM EXAMPLE ...................................................... 12

EXAMPLE SYSTEM 12

5 EXTERNAL SYSTEMS INTEGRATION ........................................... 13

OVERVIEW 13 ACCESSING EMSYS GATEWAY THROUGH MODBUS PROTOCOL 13 ACCESSING EMSYS GATEWAY THROUGH SNMP 13

6 EMSYS BMS SOFTWARE .............................................................. 15

INTRODUCTION 15 BMS APPLICATION 16

LATEST READINGS VIEW 17 HISTORY READINGS VIEW 17


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HISTORY LINE GRAPH 18 CONFIGURATION VIEW 19

WEBCONFIG APPLICATION 19 BATTERY BANK TESTING 19

BANK CAPACITY TEST 19 PERIODICAL BANK MAINTENANCE TEST 21

7 EMSYS BMS PROJECT SIZING ..................................................... 23

SIZING OVERVIEW 23 SIZING SUMMARY 23

8 SUPPORT AND TROUBLESHOOTING .......................................... 24


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1 Preface In This Chapter COPYRIGHT NOTICE 4 OBJECTIVES 4

Copyright Notice

The material in this document is the intellectual property of EMSYS Design Inc. We take every care in the preparation of this document, but no guarantee is given as to the correctness of its contents. Our products are under continual improvement and we reserve the right to make changes without notice

Objectives

The aim of this document is to briefly describe the EMSYS Battery Monitoring System for Telecom repeater stations (remote locations). All main features and functionalities will be covered by this document.


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2 Overview In This Chapter INTRODUCTION 5 EMSYS SENSORS 6

WIRELESS BATTERY MONITOR - CELLSPY 6 WIRELESS CURRENT TRANSDUCER 7 WIRELESS AMBIENT MONITOR 7 WIRELESS DC BUS MONITOR 7

LOCAL AND CENTRAL GATEWAY 8 MINI GATEWAY 9 WIRELESS REPEATER 9

Introduction

Businesses that demand uninterruptible power rely on EMSYSs Battery Monitoring System for monitoring and testing to ensure the integrity of their Battery backup system. The Main purpose of the EMSYS Wireless Monitoring Solution for Telecom repeater sites is to monitor all important sites backup power parameters, including Batteries, DC Bus, Charger, DC Current (Charge & Discharge), Ambient parameters (temperature, humidity, etc.). Additionally, the EMSYS Monitoring System provides you a quick and easy solution for performing Bank Capacity Tests, Periodical Maintenance tests and generating appropriate reports. It consists of the following elements:

Sensors (various types) Repeaters Mini Gateway Local and Central Gateway Cloud Virtual Server (optional)

This chapter will describe all the devices and infrastructure requirements for communication between.


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EMSYS Sensors

EMSYS Design offers multiple sensors that measure different physical values for complete site backup power monitoring. All sensors communicate with the EMSYS Gateway via industry standard radio protocol IEEE 802.15.4 on ISM radio band. To receive readings, EMSYS Sensor is ideally not more than 100m away from the gateway, with maximum one non-concrete wall between the Gateway and the sensors. In cases where the distance is more than this, EMSYS Repeaters are used to boost the signal. EMSYS Design currently offers the following sensors:

Wireless Battery Monitor - CellSPY

Wireless Battery Monitors (CellSPY) is measuring the resistance of both metallic and chemical paths. Unlike other monitors on the market which are consuming 10s and 100s of Amps to determine internal battery resistance, CellSPY gets the job done using 1Amp of load current during a 400ms period. The CellSPY is invisible to your batteries by consuming less than 20mA during normal operations. The operator will not have to be anywhere near the batteries to do the readings. The Gateway gathers the information, eliminating expensive reading by technicians. CellSPY is designed to operate in just about any environment. Parameters measured by CellSPY:

DC voltage - indicates state of charge. Undercharged or overcharged batteries will be detected and appropriate alarms will be raised. This parameter can point to bad battery cells.

Terminal temperature - used to generate alarms when there is potential for battery to go into thermal run-away, preventing hazards within battery rooms.

Resistance - High ohmic values indicate faulty battery or inappropriate connections on battery terminals.

AC Ripple voltage - indicates charger behavior. High AC Ripple measurement indicates potential charger related problems.


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Wireless Current Transducer

EMSYSs Wireless TrueRMS and Non-Invasive Current Sensor provides an accurate load/charge level monitoring of DC current loads. It uses unique Dual Core Technology with field proven circuitry to provide a superior solution to DC applications with minimal risk of permanent magnetization, thereby ensuring longer life and better accuracy. Unlike other current transducers on the market, EMSYS WCT-200 offers the same unmatched, accuracy for both low (trickle charge) and high (load) DC currents thanks to its Dual Core Technology. Along with this unique feature, our WCT-200 can be powered directly from DC Bus, which makes its installation a breeze.

Wireless Ambient Monitor

EMSYSs Ambient Monitor WAM-200 measures temperature and humidity inside the battery backup room. Our, web based, application will compare ambient monitor readings with the battery temperatures collected by CellSPY monitors. If thermal runaway is detected it will immediately alert users by sending emails or SMS. WAM-200 can be powered from any USB host device or from an included wall powered adapter. By measuring room temperature and comparing it to battery terminal temperatures, its easy to efficiently detect Battery candidates for thermal run-away.

Wireless DC Bus Monitor The DC Bus monitor measures both, DC and AC ripple voltage across the whole battery bank. The ground fault detection feature continuously measures the voltages between the DC Bus and the ground. The DC and the AC ripple voltage measurements will give us an early warning if the battery charger starts to operate out of spec. Overcharged or undercharged battery banks can reduce the overall battery life and put the battery backup system in danger. Excessive AC ripple voltage will reduce the battery life and inject unwanted noise into the system. In many cases this causes supplied equipment failure.


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Local and Central Gateway

EMSYS Local/Central Gateway, a standalone, ruggedized application Gateway is Linux based server and receives measurements from EMSYS Sensors via IEEE 802.15.4. This Gateway provides web interface to access the BMS application where the station battery backup (sub)system can be monitored. In a highly distributed system with a lot of geographically distributed locations, EMSYS is also offering a Central Gateway, which has the role of data concentrator. It collects all measurements from the station, providing the comfort of having all data displayed at one location. Also, companies often have separated network zones for internal server communications and employer access. In that case, its easier to maintain the bridge between these two zones for one (Central) Gateway, than to all local Gateways. The communication between Local and Central Gateway is bidirectional, through UDP protocol (arbitrary ports). The Central Gateway must be able to access all local Gateways through an Ethernet network, and it needs to be opened at SSH port (23) and one UDP port (by default 22354, but arbitrary). Also, to be able to access the BMS application, standard HTTP port (80) must be opened (port number is also arbitrary). To access the WebConfig configuration application, port 8080 must be opened for inbound TCP access (HTTP communication). Both, local and central Gateways, can serve measurement data to a SCADA system using industry standard ModbusTCP and/or SNMP protocols. Network parameters of both, local and central EMSYS Gateways (IP address, subnet mask and gateway IP address), are configurable through the WebConfig application.


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For central Gateway deployment, there are various options offered by EMSYS Design:

A Gateway machine can be provided by EMSYS Design as a physical server in a ruggedized enclosure.

A Gateway machine can be deployed on the clients cloud infrastructure. In this case EMSYS Design will provide VM image, so the client is in charge of deploying the machine into the cloud infrastructure.

A Gateway machine can be deployed on cloud infrastructure on Amazon Cloud Service. In this case EMSYS Design will maintain the cloud machine.

Mini Gateway

EMSYS Mini Gateway is primarily designed to serve small and remote sites as a Wireless to IP and IP to Wireless Bridge. Its compact size, variety of power sources, and effortless installation makes it a perfect solution for many types of installations. With its built in high power transceiver, it receives the sensor readings via IEEE 802.15.4 and forwards them to central EMSYS Gateway through Ethernet network. Using Mini Gateways, customer can cover multiple remote sites with only single central Gateway. Mini Gateway is fully compatible with POE - IEEE Alternative B. If POE is not available, Mini Gateway is shipped with POE injector which can be connected to any DC power source from 12 to 60 VDC.

Wireless Repeater

Repeater is used in environments where room structure and wall configuration make it hard for Gateway and sensors to communicate. EMSYS Repeater acts as an intelligent signal repeater, preventing package loops and filtering packages while repeating only what is needed. Repeater also significantly boosts signal strength.


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3 Telecom remote location monitoring reasoning In This Chapter EMSYS SYSTEM PREVENTS UNPLANNED DOWNTIME 10 EMSYS SYSTEM PREVENTS MAJOR FAILURES 10 EMSYS SYSTEM EXTENDS BANK LIFETIME 11 EMSYS SYSTEM ELIMINATES NEED FOR MANUALLY PERFORMED PERIODIC MAINTENANCES 11

EMSYS System prevents unplanned downtime

Since batteries can fail in a few days, CellSPY is designed to monitor your battery backup system every hour, not just when the periodic/quarterly maintenance occurs. In case of any failure indication, the Gateway alarm is generated and presented to operators on the BMS application - as an email or SMS message, or through Modbus and/or SNMP protocols for external SCADA systems. This way CellSPY detects possible failures before a single battery cell is able to become an operational risk, but also months before a technician would discover it during a regular quarterly maintenance.

EMSYS System prevents major failures

EMSYS does not monitor only batteries - it monitors the whole site Battery Backup system, indicating problems with the charger, the single battery jar, the air conditioner or the ventilation. By automating battery monitoring youre preventing a lot of potential failure situations. By monitoring battery terminal temperatures, and the ambient temperature, the EMSYS BMS is preventing thermal runaway which can potentially destroy the whole Battery Backup room. The measured temperature can also indicate problems with air conditioning or Battery Backup room ventilation. By monitoring the battery internal resistance, the EMSYS BMS is maximizing the Battery Backup uptime by indicating Cells for replacement before failure. By monitoring the DC Bank Voltage and AC Ripple Voltage on Bank Bus, the EMSYS BMS can monitor Charger status.


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Potential problems are reported to the operator by multiple alarms: If the charger breaks down, the Current Sensor will report zero current for a

long period of time. The DC Bus monitor and CellSPY Battery Monitor will report zero AC Ripple Voltage.

If the air conditioner fails, the Ambient monitor will set off the Ambient temperature alarm and the CellSPY Battery Monitor will report a High Temperature alarm on Battery Terminals.

EMSYS System extends bank lifetime

By industry standards, to ensure uptime, batteries are routinely replaced at a 5-year (10-year for some battery types) interval. With automated battery monitoring, operators are aware of each battery cells health daily, providing information about weak cells, replacing individual cells showing signs of weakness, eliminating the need for total battery bank replacement, avoiding major expenses.

EMSYS System eliminates need for manually performed periodic maintenances

By having an automated system for monitoring and testing, there is no need for periodic sending of technicians for maintenance. This fact alone contributes to quick ROI.


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4 System Diagram Example In This Chapter EXAMPLE SYSTEM 12

Example system

The diagram represents one project with four remote locations (repeater sites), each having its own collection of sensors (of various types). Mini Gateways collect measurements from a sites sensors and all four Mini Gateways forward the measurements to the regional EMSYS Gateways/Servers, which processes and stores them. As an option, regional Gateways can be configured to forward the data to EMSYS Cloud Virtual Machine with BMS software installed. VM can be hosted on Amazon Cloud Service and managed by EMSYS, or it can be deployed on customers host server. Processing power and storage of VM can be increased in matter of minutes, which makes scaling of entire BMS system easier, cheaper and more productive.


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5 External systems integration

In This Chapter

OVERVIEW 13 ACCESSING EMSYS GATEWAY THROUGH MODBUS PROTOCOL 13 ACCESSING EMSYS GATEWAY THROUGH SNMP 13

Overview

To be able to integrate currently installed systems with the EMSYS Battery Monitoring System, local and central Gateways provide all measured data through industry

standard protocols like Modbus and SNMP.

Accessing EMSYS Gateway through ModBus protocol

Modbus is an industry standard protocol in RTU and SCADA systems. Local and central Gateways behave as Modbus slaves, and they are accessible by Modbus master applications. They are providing Modbus via TCP and Serial (RS232 and RS485) port. Values served by Gateway are:

All measurements from sensors (as input registers) Low and high limits for all sensors (as input registers) Measurement timestamps (as input registers) Alarm states for low-low, low, high, high-high alarms for each measurement

(as discrete inputs)

Accessing EMSYS Gateway through SNMP

Often companies have developed internal SNMP infrastructure, so EMSYS Gateway exposes all valuable information through SNMP protocol. Alarms generated on Gateways can be sent to SNMP Manager asynchronously as SNMP traps. Multiple trap destinations are supported. Also, its configurable which alarms will be sent as traps.


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Values served through SNMP protocol are: All measured data All high and low alarm limits Timestamps for each sensor indicating time of last measurement


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6 EMSYS BMS Software In This Chapter

INTRODUCTION 15 BMS APPLICATION 16

LATEST READINGS VIEW 17 HISTORY READINGS VIEW 17 HISTORY LINE GRAPH 18 CONFIGURATION VIEW 19

WEBCONFIG APPLICATION 19 BATTERY BANK TESTING 19

BANK CAPACITY TEST 19 PERIODICAL BANK MAINTENANCE TEST 21

Introduction

Beside sensors, state of the art software that is running on Central and Local Gateways represents the heart of the Battery Monitoring System, as it processes all data received from the sensors and provides applications with visual monitoring of Battery Backup system and system configuration. The main applications used by system operators and administrators are BMS and WebConfig applications. Main features of BMS Software are:

Processing measurement data received from the sensors Alarms: alarm and event engine processes measurement data and generates

alarms when a certain alarm condition is met. There are value based alarms (LowLow, Low, High and HighHigh) as well as time based alarms which are generated when a sensor does not send any reading within a configured amount of time. The alarm acknowledgement mechanism is present and it requires the operator to give attention to each alarm, by acknowledging it.

Events: All important events are stored within the Gateway. Stored events provide the operator a way to recreate a series of sequences that happened during a period of time.

Bank Capacity Test: BMS application provides a Bank Capacity Test feature. With artificial load (optionally provided by EMSYS Design Inc.) the test can be performed by the EMSYS System. The output of the Bank Capacity test is automatically generated into report files in both, PDF format (with graphically presented data) and CSV format (with raw data).

Periodic Maintenance Test: Batteries are typically tested quarterly, on basic parameters (voltage, internal resistance). The EMSYS System can perform bank maintenance tests on demand and automatically generate PDF reports in a matter of minutes.


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Easy sensor configuration & reconfiguration: Sensor configuration is done easily, and once the client needs to add new sensors to the system or to replace the existing ones, its a task that can be done in a few minutes.

Easy system administration: All system parameters are easily configurable through the WebConfig application. Configurable parameters include: network interface configuration, SNMP and Modbus configuration, scheduling data backup, data download, system software automatic updates, user management, etc.

Multiple user privileges: There are three predefined user groups with different privileges: operators, configurators and system administrators.

Data backup: Data backups can be scheduled periodically and also can be done on request. All backups are stored locally on a Gateway but can also be configured to be uploaded to the FTP server

Periodic reporting: Measurement reports contain all readings, like regular reports, but also measurements that meet alarm conditions in case of an alarm report. Reports can be sent to a preconfigured email address.

Email/SMS alarming: When an alarm is created the operator can be alerted by an email that contains information about the alarmed measurement. In US all mobile operators have their own Email2SMS gateway. Emails can be sent to these gateways so the user can receive a SMS message when the alarms are created. SMTP parameters are fully configured and usually a customers internal email infrastructure (SMTP server) is used for emailing purposes.

Accessibility from external systems: All measurements on the Gateway are accessible, by using industry standard protocols such as Modbus (TCP or Serial) or SNMP.

BMS Application

EMSYS BMS Application is a web-based Gateway application that provides HMI functionality to EMSYS System operators, configurators and administrators. BMS Application is used to perform a set of defined tasks. As a Operator, you can use the BMS application to:

View geographical positions of installed remote sites View the latest measurements received from installed sensors (CellSPY

sensors, Current Sensors, etc.) Monitor and acknowledge alarms generated on the Gateway Monitor events generated on the Gateway View historical data for each group, from each remote site for different

historical time periods, separately. View all measurements for each sensor and for different historical time

periods, both separately. Additionally, as a Configurator or Administrator, you can use the BMS application to:

View and modify Gateway configuration of sites and groups (Sensor arrays) within the same Site.

View and modify Gateway reporting configuration View and modify Email Alarming configuration Run battery load/recover tests

BMS Application is a flash application that requires a browser (IE, Chrome, Firefox or Safari) with a Flash Plugin 10.0, or a newer version. No installation process is required on the client machine.


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All measurements are presented in two ways, tabular and graphical. Briefly described below are the most important views of the BMS application.

Latest readings view It contains the latest measured values from each sensor separately. This view also shows alarm regions and indicates if any of measurements are in an alarm condition.

History readings view

One of the main features of the BMS Application is its ability to view and analyze the history of battery measured data. That way some atypical battery behavior can be detected and batteries can be replaced on time to prevent Bank failure.


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Similar to the latest readings view, data is presented in both ways, tabular and graphical. Graphically, data on history view is presented as a CandleStick Chart Graph.

CandleStick charts are typically used in stock trading related graphs. It is a type of bar graphs where each bar represents the range of a measured value movement over a given time interval. As it is shown on the image above, each bar shows the maximum and the minimum (in form of bar) of the battery, as well as the maximum and the minimum (in form on black line below bar) of the bar. Left clicking on any of the bars will open the history of the line Graph view for the selected battery. It is also possible to download all history data in the form of a csv file for further analysis and/or archiving purposes.

History line graph

A history line graph provides a way for operators to monitor the state of health of a single battery, through a selected period of time in the form of a Line graph. This dialog is depicted in the picture below:


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Configuration View

This is the part of BMS application where the main configuration is monitored and updated. It provides a way to update your configuration on the Gateway, easily and quickly. This is necessary if you want to add more sensors to the system or to replace existing ones.

WebConfig Application

EMSYS WebConfig is a web-based application that provides functionalities for administrating EMSYS Gateways. Administrator can use WebConfig application to:

Set common operating system parameters (time related parameters, networking, etc.)

Configure CommServer parameters including Modbus and SNMP parameters Configure WebService parameters Configure BMS Application parameters Configure Database backup process Monitor Gateway functionality by examining log files (by watching live log tail

on the WebConfig page or downloading log files to the local computer for viewing)

Perform System Monitor reconfiguration (sensor replacement, adjusting alarm limits, etc.)

Battery Bank Testing

EMSYS Battery Monitoring System provides you two types of battery tests, as described in following chapters.

Bank capacity test

Upon Battery Backup installation, initial battery commissioning is necessary. Also, a battery capacity check is usually performed on a defined time interval. The EMSYS BMS is capable of performing these tests without any additional mechanical installations on batteries just by using the Gateways software, eliminating risk factors introduced by human cell handling.


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This also significantly reduces costs, as there is no need to hire an external company for bank capacity tests. During a bank capacity test the following parameters are measured on a 10 second interval:

Discharge current Battery DC voltage Battery AC Ripple voltage Battery terminal temperature DC Bus voltage Bus AC Ripple voltage

After the test is finished, report files are created automatically in both PDF (for graphical and tabular data visualization) and CSV (containing raw data) formats. Below is a graphic sample of a Bank Capacity Test report:

Also, on the same page with graphics, tabular data containing all measured values is displayed for easier analysis. Sample measurement table is shown below:


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Periodical bank maintenance test

Another advantage to using the automated monitoring system is a reduced cost needed for quarterly maintenance. The EMSYS BMS is capable of performing battery tests easy on clients computer using BMS software, without any additional mechanical installation on batteries. Once again, risk factors introduced by human cell handling are eliminated. In a matter of minutes after the test is started, report files in PDF and CSV formats are generated with the following measured values:

Battery DC voltage Battery AC Ripple voltage Battery terminal temperature Battery ohmic value

Measurements in report are shown in both tabular and graphical presentations. Tabular presentation is shown below: Al Also, every measured data is displayed in report in form of bar charts, as is shown on images below:


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Voltage graph

Resistance graph

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Temperature graph


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7 EMSYS BMS Project sizing In This Chapter SIZING OVERVIEW 23 SIZING SUMMARY 23

Sizing overview

This chapter will provide the sizing guidelines in the form of bullets for all devices included in typical project installation, based on examples:

The whole project is centered on Central Gateway or users SCADA system. The project is divided into remote sites/locations. Each site has its own collection of sensors, repeaters and one Mini Gateway One site can contain multiple Battery Backup systems with Battery

strings/banks. Each Battery bank should contain a current sensor. Thanks to EMSYSs Dual

Core Wireless Current Transducers only one current sensor is needed. It will provide the same high accuracy for both charge and discharge currents.

Each Battery bank should contain one DC Bus Monitor. Each cell within the battery bank should have one Wireless Battery Monitor

connected for cell measurements. Each room within the site should have one Ambient Monitor. One or more Wireless Repeaters may be installed if required.

Sizing summary

One Central Gateway in project. One Mini Gateway per site/repeater station. One Current Sensor per Battery Bank. One DC Bus Monitor per Battery Bank. One CellSPY per Battery (Cell). One Ambient Monitor per room (where needed). May possibly need one Repeater per site, depending on building/room

configuration.


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8 Support and troubleshooting

If you encounter any problem, or have CellSPY System related questions please feel free to contact EMSYS Design Inc. any time:

by email: [email protected] by phone: (+1) 858-4927240 ext. 3

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EMSYS CaseStudy Telecom 1 0