UNIT
:
220V/ 500AH VRLA (SMF) BATTERY CHARGER
TYPE
:
FC & FCBC : 220V / 110A - 150A
CLIENT
:
NATIONAL ALUMINIUM COMPANY LIMITED
PROJECT
:
CPP-NALCO-ANGUL.ODISHA
P.O.NO.
:
UPIPL / PO / NA / 11-12 / 080
SR.NO.
:
CE – 2734 / CE – II ~ 1205 / 74-77
W.O.NO.
:
CE – 2734
DTD. 03.12.2011
MANUFACTURER:
Regd. Office & Factory : E-66, MIDC, Jalgaon - 425 003 (M.S.) Tel. : 91-257-2210626 / 27 / 28 Fax : 91-257-2213434 E-mail :
[email protected] Visit us at www.chhabi-india.com
QUALITY ASSURED COMPANY ISO:9001-2000 International Standards Certifications Lic. No. QAC/R91/0100
Mumbai Office :
Bangalore Office :
Delhi Office :
Kolkata Office :
20, Anupam Indl. Estate no. 3, L.B.S. Marg Mulund (W) Mumbai - 400 080 Ph. : 91-22-2561 4435/5945 Fax : 91-22-2568 0513 Email :
[email protected]
120, First Floor, “Ajantha” 6th C Main Road, Remco Layout Vijayanagar 2nd Stage Bangalore - 560 040 (Karnataka) Ph : 91-80-2314 0031 Fax : 91-80-2314 0031 Email :
[email protected]
F-12, First Floor, Pankaj Grand Plaza, Mayur Vihar Phase-1, New Delhi - 110 091 Ph : 91-11-4215 1213 - 14 Fax : 91-11-4215 1215 Email :
[email protected]
16/1A, Bose Pukur Road, Kolkata - 700 042 Ph : 91-33-2441 1375 Email :
[email protected]
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 1 - 16
OPERATION AND MAINTENANCE MANUAL UNIT
:
220V/ 500AH VRLA (SMF) BATTERY CHARGER
TYPE
:
FC & FCBC : 220V / 110A - 150A
CLIENT
:
NATIONAL ALUMINIUM COMPANY LIMITED
PROJECT
:
CPP-NALCO-ANGUL.ODISHA
P.O.NO.
:
UPIPL / PO / NA / 11-12 / 080
SR.NO.
:
CE – 2734 / CE – II ~ 1205 / 74-77
W.O.NO.
:
CE – 2734
DTD. 03.12.2011
INDEX Sr.
DESCRIPTION
Sheet No.
1
Technical Specification
SH 7887 / 3 - 5
2
Operational write-up for battery charger.
SH 7887 / 6 - 7
3
Erection and commissioning of equipment.
SH 7887 / 8 - 13
4
Operation and Maintenance.
SH 7887 / 14 - 16
5
Bill of material.
LC 4535 / Rev 03
6
Make of Component.
LC 4535 / Rev 03
CIRCUIT DIAGRAM & GENERAL LAYOUT Sr.
DESCRIPTION
Drg. No.
1
Main circuit diagram for battery charger.
C12972 A / Rev 03
2
Circuit diagram for FC & FCBC rectifier module.
C12972 B & C / Rev 03
3
Circuit dia. for discharge path of battery charger
C12972 D / Rev 03
4
Circuit dia. & legend for annunciation
C12972 E & F / Rev 03
5
GA dia for 110V battery charger with DCDB
C12973 / Rev 03
PREPARED BY : N.P.B.
CHECKED BY : S.S.P.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
APPROVED BY : D.J.P.
SHEET NO. : SH 7887 / 2 - 16
TECHNICAL SPECIFICATION MAIN AC INPUT
:
415V ±10%, 50Hz ±5%, 3Phase, 4 Wire AC Supply.
BATTERY DETAIL
:
a) Type of Battery : SMF VRLA b) No. of cell : 108 Nos. b) AH capacity : 500AH c) Cell Voltage : 2V
TYPE
:
FLOAT CHARGER : CP ~ 110V / 110A FLOAT CUM BOOST CHARGER : CP-CC ~ 110V / 110A – 150A
DC OUTPUT
:
A) Float Charger: Suitable to Float charge the 108Nos. cells of 500AH capacity at 2.25 V/Cell as well as supplying a continuous load of 110A. B) Float Cum Boost Charger : a) In Float Mode: Suitable to Float charge the 108Nos. cells of 500AH capacity at 2.25 V/Cell as well as supplying a continuous load of 110A. b) In Boost Mode : Capable to Boost charge 108Nos. of cells of 500AH capacity at 2.3 V/Cell at the maximum charging current of 150A.
RIPPLE
:
Float & Float Cum Boost Charger: 1% (RMS)
AMBIENT
:
50° C Average ambient temperature.
SIZE
:
L = 2400 mm
SHEET THICKNESS
:
Sheet Steel (CRCA) thickness 2 mm
CABLE ENTRY
:
Bottom
COLOUR
:
Inside & Outside : Epoxy RAL 7032
CONSTRUCTION
:
Common cubical for Float & Float cum Boost Charger suitable for Indoor Installation.
H = 2000 mm
W= 800 mm
a) Suitable for indoor operation and floor mounting. b) Battery charging Equipment comprising of Float Charger and Float Cum Boost Charger housed in a common cubicle. It consists of AC I/P terminal, DC O/P terminal for battery and DCDB. Control switches, potentiometers, Analog meters, Indicating lamps and Annunciation are provided on front panel of battery Charger. TERMINALS : T 1-4 T 5-8 T 9-11
: AC Input terminals for Source-1 for both FC & FCB charger. : AC Input terminals for Source-2 for both FC & FCB charger. : DC Output battery terminals of battery charger.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 3 - 16
T T T T
12-13 14-15 16-17 18-23
: : : :
DC output load terminals to DCDB of battery charger. Potential free remote contact terminals for group alarm. Input terminals for 240V AC auxiliary supply. Potential free remote contact terminals of source selector switch (ACSW1) to show the position of ACSW1.
INDICATING LAMPS : ACLED 1-3 ACLED 4-6 DCLED 1 DCLED 2 DCLED 3
: : : : :
AC input supply 'ON' Indicating lamps of Float charger. AC input supply 'ON' Indicating lamps of Float cum Boost charger. DC output supply 'ON' Indicating lamp of Float charger. DC output supply 'ON' Indicating lamp of Float cum Boost charger. DC control supply 'Fail' indicating lamp.
POTENTIOMETERS : FLOAT CHARGER : RV 1 RV 2 RV 3
: Potentiometer to adjust the DC output voltage in Float mode (Auto mode of controller card). : Potentiometer to adjust the DC output current in Float mode (Auto mode of controller card). : Potentiometer to adjust the DC output voltage in Manual mode (Manual mode of controller card).
FLOAT CUM BOOST CHARGER : RV 4 RV 5 RV 6 RV 7 RV 8
: Potentiometer to adjust the DC output (Auto mode of Controller card). : Potentiometer to adjust the DC output (Auto mode of Controller card). : Potentiometer to adjust the DC output (Auto mode of Controller card). : Potentiometer to adjust the DC output (Auto mode of Controller card). : Potentiometer to adjust the DC output (Manual mode of Controller card).
voltage in Float mode voltage in Boost mode current in Boost mode current in Float mode voltage in Manual mode
INDICATING METERS ACVM1 DCVM1 BAM1 RAM1 RAM2
: : : : :
Shows Shows Shows Shows Shows
AC input voltage of Float & Float Cum Boost charger. DC output voltage of FC, FCB & load path. charge / discharge current of battery charger. DC output current of Float charger. DC output current of Float Cum Boost charger.
CONTACTORS : ACCA 1&2 ACC 1&2 DCC 1 DCC 2
: Auxiliary contactor for AC Mains fail annunciation of Battery Charger. : AC mains supply “ON-OFF” contactor of battery charger. : DC contactor connected to isolate battery & load path during Boost mode 'ON'. : DC contactor connected across voltage dropping device (VDD) to bypass it during AC mains supply failure.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 4 - 16
Switch/SFU/MCB/MCCB/ACB: ACSW 1 ACSW 2 ACSW 3 ACSW 4 ACSW 5 ACSW 6 DCSW 1 DCSW 2 DCSW 3 RSW 1 RSW 2 RSW 3 ACMCB 1-2
: : : : : : : : : : : : :
AC input supply source selector switch for FC& FCB charger. AC voltmeter selector switch of FC & FCB charger. AC input “ON-OFF” SFU of Float charger. ACC1 contactor coil “ON-OFF” switch of Float charger. AC input “ON-OFF” SFU of Float Cum Boost charger. ACC2 contactor coil “ON-OFF” switch of Float Cum Boost charger. DC output “ON-OFF” SFU of Float charger. DC output “ON-OFF” SFU of Float Cum Boost charger. DC voltmeter selector switch of the battery charger. Auto / Manual mode selector switch for CPC card of Float charger. Float / Boost mode selector switch of FCB battery charger. Auto / Manual mode selector switch for CPC card of FCB charger. “ON/OFF” breaker for cubical lamp & space heater of the charger.
SETTINGS OF PROTECTIVE RELAYS FOR ANNUNCIATIONS : a) DC Under & Over Voltage relay : (Load) DC Under Voltage – Act.: 198V, Reset: 210V, Normal: 220V, DC Over Voltage – Act.: 242V, Reset: 241V, Normal: 220V. Annunciation as per legend is provided on front panel to give audio visual annunciation of the fault. Controller cards are provided from inside of the front panel. Rectifier stacks, Contactors, FFD’S, Transformers & Chokes are mounted in MS cubicle at suitable places.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 5 - 16
OPERATIONAL WRITEUP FOR BATTERY CHARGER. (3 Phase Silicon Controlled Rectifier Equipment) The Battery Charging equipment comprises Float charger & Float cum Boost charger in a common cubical. Normally float charger will float the battery at 2.25V per cell within a stabilization of ±1% of the floating voltage. The float charger will supply the trickle charging current required for the battery and will also feed the DC continuous load as required. During this time, the float charger and the battery are across the DC load terminals. When there is a power failure, the battery readily meets the various DC loads. When the power resumes, the battery has to be recharged. The battery will take higher charging current due to discharge. For this purpose operate the Float cum Boost charger in boost mode. It will charge the battery. During boost charging to battery, float charger & float cum boost charger will be isolated from each other through DC contactor say DCC1, so that the higher voltage during boost charging will not appear across the load. After completion of boost charging, switch off the float cum boost charger. FLOAT CHARGER: Normally, float charger will float the batteries at 2.25V per cell within a stabilization of ±1% of the floating voltage. The float charger will supply the trickle charging current required for the batteries and also feed the DC continuous load as required. During this time, the float charger and the battery are across the DC load terminals Float Voltage will be set through potentiometer RV1 & current limit will be set through potentiometer RV2. During float charging load will be supplied through the dropping diode by maintaining load voltage at 241V - 243V as well as trickle charge the battery. FLOAT CUM BOOST CHARGER IN FLOAT MODE: If Float charger fails, then float cum boost charger can be operate in float mode by means of DCCA1 relay. During this time the contactor DCC1 is in closed condition & supplies the DC load through the dropping diode by maintaining load voltage within 241V - 243V as well as trickle charge the battery. In float mode, float Voltage will be set through potentiometer RV4 & Current limit will be set through RV6. FLOAT CUM BOOST CHARGER IN BOOST MODE: When there is a power failure, the battery readily meets the various DC loads. When the power resumes, the battery has to be recharged. The battery will take higher trickle charging current from float charger due to discharge. For this operate the float cum boost charger in boost mode. It will charge the battery at 2.3V/cell. During boost charging the float charger & float cum boost charger will be isolated from each other through contactor DCC1, so that the higher voltage during boost charging will not appear across the load. After completion of boost charging switched OFF the float cum boost charger. Boost mode voltage will be set through potentiometer RV5 & Boost mode Current will be set through potentiometer RV7.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 6 - 16
MANUAL OPERATION OF FLOAT CUM BOOST CHARGER: FLOAT MODE: The float cum boost charger will operate as float charger & supply the trickle charging current required for the batteries and will also feed the DC continuous load as required. BOOST MODE: The float cum boost charger will operate as Boost charger & supply the boost charging current required for the batteries @ 2.3V per cell. Note: In Manual mode the voltage can not stabilize automatically. It can be stable by potentiometer in manual mode, i.e. RV3 for Float Charger & by RV8 for Float cum boost charger. The Voltage dropping diodes are continuously in circuit & load voltage will be maintained within 241V – 243V. In case of AC Mains failure, the DC contactor DCC2 will get close & the dropping diodes will be by passed & full battery voltage will be available at load terminal.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 7 - 16
ERECTION AND COMMISSIONING OF EQUIPMENT 1.00 UNPACKING :
1. The equipment is covered with a layer of plastic and corrugated paper and then packed in a wooden crate. Also read the instruction sticked on the unit carefully (FOR LIFTING THE EQUIPMENT USE ALL LIFTING HOOKS).
2. Dismantle the wooden crate carefully and then separate the layers of packing papers. Also read the instruction sticked on the panel (1. FOR LIFTING THE EQUIPMENT USE ALL LIFTING HOOKS & 2. REMOVE SHORTINGS OF ALL METER'S TERMINAL BEFORE USE).
3. After unpacking, observe the panel & components inside the charger after opening of the door by use of door key provided (which is tied-up with door handle). Intimate any damage during transportation if any, within 15 days to our Jalgaon office for insurance claim / for further process as applicable. Also remove meter terminal shorting. 2.00 ERECTION AND COMMISSIONING OF BATTERY CHARGER : 2.1) Install the equipment at indoor place suitably ventilated as per foundation details shown in General layout drawing. 2.2)
INSULATION RESISTANCE TEST (WITH 500V MEGGER) :-
2.2.1) Clean inside of the charger with the help of blower. 2.2.2) Ensure all the fuses are intact. 2.2.3) Take out the plugs of SCR controllers (CPC1&2) & Electronics relays. Keep all Switches/SFU/MCB/MCCB/ACB in ‘ON’ position. 2.2.4) Test the equipment I.R. before connection the AC & DC cables to the charger terminal board. 2.2.5) Check I.R. in between following terminals one by one. a) AC terminals and earth bus. If IR value is more than 2MΩ then proceed further. If IR value is less than 2MΩ refer following steps, 1) Switch ‘OFF’ DC output Switch/SFU/MCB/MCCB/ACB as applicable. 2) Keep AC input Switch/SFU/MCB/MCCB/ACB as applicable in ‘ON’ position and main contactor if applicable in ‘OFF’ condition and check IR. 3) Keep AC input Switch/SFU/MCB/MCCB/ACB as applicable and main contactor if applicable in ‘ON’ condition and find out the point of leakage. b) DC terminals and earth bus. Switch ‘OFF’ AC input switch and switch ‘ON’ DC output switch and check point of leakage. c) AC terminals and DC terminals. 1) Switch ‘ON’ AC input Switch/SFU/MCB/MCCB/ACB as applicable & switch ‘OFF’ DC output Switch/SFU/MCB/MCCB/ACB as applicable and check IR. 2) Switch ‘OFF’ AC input Switch/SFU/MCB/MCCB/ACB as applicable & switch ‘ON’ DC output Switch/SFU/MCB/MCCB/ACB as applicable and check IR. 3) Find out the point of leakage. CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 8 - 16
In each of the above 3 cases, I.R. should be more than 2MΩ. If it is all right, proceed further, if not then, a) Keep space heater always ‘ON’ to prevent the charger from moisture if charger is not in use. b) Find out the point of leakage and rectify the same. 2.2.6) Switch ‘OFF’ all Switches/SFU/MCB/MCCB/ACB and put the controller and relay plugs as it were. 1. Fix the cable glands to the removable cable gland plates of charger after terminating cables through the glands. 2. Lay down the cables of AC input & output i.e. load & battery. For cable sizes Ref. Bill of Material. 3. Crimp cable lugs of suitable sizes to this cable to enable to connect these cables to the charger terminal board.
3.00 POWER SUPPLY AND CONNECTION : 1. Connect the AC cables to the Charger AC input Terminal Board as shown in GA drawing. 2. Connect the charger earth bus to main earthing bus of the site. 3. Do not connect the Battery and load cables at present. 4 .This equipment is designed to operate on AC mains of 415V ±10%, 50Hz±3%, 3Phase, 4 wire (as applicable) AC input. 4.00 LOADING ARRANGEMENT : Make the water load arrangement as described below. 1. Take two cables of suitable capacity. 2. Connect MS strip of suitable size to end of each cable. 3. Connect remaining ends of the wire to the DC output terminals of the charger as described in operation. 4. Arrange PVC bucket / Drum and fill it up with water and salt solution. 5. Keep one strip vertically dipped in bucket. 6. Dipping of second trip vertically in this bucket / Drum will form load. The distance between two MS strips will decide the current drawn by this arrangement. As you decrease the distance between two strips, current taken by this arrangement will go on increasing. 7. Alternatively the variable resistance load bank can be used to carry out the load test. I) FLOAT CHARGER : Charger has two modes of operation. A) Auto mode & B) Manual mode. A) AUTO MODE : Keep the Auto/ Manual selector switch of controller in at 'Auto mode' of operation. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push Button as & if applicable.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 9 - 16
NO LOAD OPERATION : Observe the output voltage on DC voltmeter. It shall increase gradually up to the factory set voltage. If it is disturbed in transportation, reset it to the set voltage with the help of voltage adjustment potentiometer (In Auto Mode). The voltage span in auto mode is ±5% maximum from minimum to maximum position of voltage adjustment potentiometer. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable Observe DC voltage on voltmeter. Observe the float charger ON indicating Lamp / LED is ON. Connect water load cables at DC Output terminals. Switch on battery Switch/SFU/MCB/MCCB/ACB as applicable FULL LOAD OPERATION : Increase the DC current from zero, indicated by DC Ammeter & at the same time, AC input current can be observed on the AC Ammeter if applicable. Also AC input voltage can be observed on the AC Voltmeter if applicable. Observe the floating voltage as set at NO load operation remains constant within ±1% up to full load / rated current i.e. from 0 to 100% of rated full load current. CURRENT LIMITING FEATURE : If you go on increasing load current above the rated load current, the output voltage starts to decrease and limits the load current, thus allowing the battery to take extra load. The change in the value of the current limiting resistance can vary this level of current limiting feature. The current limiting feature acts as the load current reaches to the rated load & the excess current will get locked at 105% or 110% as applicable. B) MANUAL MODE : Keep the Auto/ Manual selector switch of controller in at 'Manual' mode of operation. Please keep Voltage control potentiometer in Manual mode at its minimum position. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push Button as & if applicable. NO LOAD OPERATION : Observe the output voltage on DC Voltmeter. It should be near about Zero. Turn the voltage adjustment potentiometer (in Manual) in clockwise and watch output voltage. It will starts increasing from 0V to maximum output voltage as applicable from minimum to maximum position of potentiometer. For load test, Turn back the potentiometer at its minimum position. Switch `ON’ DC output Switch/SFU/MCB/MCCB/ACB as applicable FULL LOAD OPERATION : Increase the voltage by potentiometer, simultaneously increase the load current by external water load arrangement. Please read the voltage on DC Voltmeter & current on DC Ammeter respectively. Maintain the floating voltage as set at the rated load current with the help of potentiometer. CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 10 - 16
NOTE : In manual mode, DC voltage is not regulated but only controlled by potentiometer manually. Decrease the load current & voltage up to zero & switch `OFF’ the AC and DC Switch/SFU/MCB/MCCB/ACB as applicable. II) FLOAT CUM BOOST CHARGER IN FLOAT MODE : A) AUTO MODE : Keep the Auto/ Manual selector switch of controller at Auto mode of operation. Keep the Float/ Boost mode of operation selector switch at Float mode of operation Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push Button as & if applicable. NO LOAD OPERATION : Observe the output voltage on DC voltmeter. It shall increase gradually up to the factory set voltage. If it is disturbed in transportation, reset it to the set voltage with the help of voltage adjustment potentiometer (In Auto Mode). The voltage span in auto mode is ±5% maximum from minimum to maximum position of voltage adjustment potentiometer. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable Observe DC voltage on voltmeter. Observe the DC ON or float mode ON indicating Lamp / LED is ON as & if applicable. Connect water load cables at DC Output terminals. Switch ON the battery Switch/SFU/MCB/MCCB/ACB as & if applicable FULL LOAD OPERATION : Increase the DC current from zero, indicated by DC Ammeter & at the same time, AC input current can be observed on the AC Ammeter if applicable. Also AC input voltage can be observed on the AC Voltmeter if applicable. Observe the floating voltage as set at NO load operation remains constant within ±1% up to full load / rated current i.e. from 0 to 100% of rated full load current. CURRENT LIMITING FEATURE : If you go on increasing load current above the rated load current, the output voltage starts to decrease and limits the load current, thus allowing the battery to take extra load. The change in the value of the current limiting resistance can vary this level of current limiting feature. The current limiting feature acts as the load current reaches to the rated load & the excess current will get locked at 105% or 110% as applicable. B) MANUAL MODE : Keep the Auto/ Manual selector switch of controller in at Manual mode of operation. Please keep Voltage control potentiometer in Manual mode at its minimum position. Keep the Float/ Boost mode of operation selector switch at Float mode of operation Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push Button as & if applicable. CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 11 - 16
NO LOAD OPERATION : Observe the output voltage on DC Voltmeter. It should be near about Zero. Turn the voltage adjustment potentiometer (in Manual) in clockwise and watch output voltage. It will starts increasing from 0V to maximum output voltage as applicable from minimum to maximum position of potentiometer. For load test, Turn back the potentiometer at its minimum position. Switch `ON’ DC output Switch/SFU/MCB/MCCB/ACB as applicable FULL LOAD OPERATION : Increase the voltage by potentiometer, simultaneously increase the load current by external water load arrangement. Please read the voltage on DC Voltmeter & current on DC Ammeter respectively. Maintain the floating voltage as set at the rated load current with the help of potentiometer. NOTE : In manual mode, DC voltage is not regulated but only controlled by potentiometer manually. Decrease the load current & voltage up to zero & switch `OFF’ the AC and DC Switch/SFU/MCB/MCCB/ACB as applicable III) FLOAT CUM BOOST CHARGER IN BOOST MODE : A) AUTO MODE : Keep the Auto/ Manual selector switch of controller in at Auto mode of operation. Keep the Float/ Boost mode of operation selector switch at Boost mode of operation. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push button as & if applicable. NO LOAD OPEARTION : Observe the output voltage on DC voltmeter. It shall increase gradually up to the factory set voltage. If it is disturbed in transportation, reset it to the set voltage with the help of voltage adjustment resistance R4 (in Auto mode of controller). Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable Observe DC voltage on voltmeter. Connect water load cables at DC Output terminals(Battery Terminals). Switch on battery Switch/SFU/MCB/MCCB/ACB as applicable FULL LOAD OPERATION : Increase the DC current from zero, indicated by DC Ammeter & at the same time, AC input current can be observed on the AC Ammeter if applicable. Also AC input voltage can be observed on the AC Voltmeter if applicable. Observe the Boost charging current as set remains constant within +/-2% of set value for fully discharged voltage of Battery to fully charged voltage of the Battery. This Charging current can be set by potentiometer current adjustment potentiometer.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 12 - 16
CURRENT LIMITING FEATURE : If you go on increasing load current above the rated load current, the output voltage starts to decrease and limits the load current, thus allowing the battery to take extra load. Changing the position of potentiometer can vary this level of current limiting feature. The current limiting feature acts as the load current reaches to the rated load & the excess current will get locked at 105% or 110% as applicable. B) MANUAL MODE : Keep the Auto/ Manual selector switch of controller in at Manual mode of operation. Keep the Float/ Boost mode of operation selector switch at Boost mode of operation. Please keep Voltage control potentiometer in Manual mode at its minimum position. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push button as & if applicable. NO LOAD OPERATION : Observe the output voltage on DC Voltmeter. It should be near about Zero. Turn the voltage adjustment potentiometer (in Manual) in clockwise and watch output voltage. It will starts increasing from 0V to maximum output voltage as applicable from minimum to maximum position of potentiometer. For load test, Turn back the potentiometer at its minimum position. Switch `ON’ DC output Switch/SFU/MCB/MCCB/ACB as applicable FULL LOAD OPERATION : Increase the voltage by potentiometer, simultaneously increase the load current by external water load arrangement. Please read the voltage on DC Voltmeter & current on DC Ammeter respectively. Maintain the floating voltage as set at the rated load current with the help of potentiometer. NOTE : In manual mode, DC voltage is not regulated but only controlled by potentiometer manually. Decrease the load current & voltage up to zero & switch `OFF’ the AC and DC Switch/ SFU/MCB/MCCB/ACB as applicable 5.00 CAUTIONS : a) Do not keep the two strips with direct contact in any case. It may damage rectifier stack or fuses may blown. 1) For diluting the solution, add water. 2) Increase requisite quantity of salt or electrolyte if required load is not being achieved even after bringing the two strips nearer to each other. 6.00 : Connect the battery, to battery terminals in correct polarity i.e. +ve, +ve of tap cell & -ve.
CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 13 - 16
OPERATION AND MAINTENANCE 1) FLOAT CUM BOOST CHARGER IN FLOAT MODE : Charger has two modes of operation. A) Auto mode & B) Manual mode.. A) AUTO MODE : Keep the Auto/ Manual selector switch of controller in at Auto mode of operation. Keep the Float/ Boost mode of operation selector switch at Float mode of operation (Or operate charger in Float mode / Boost mode through push button as & if applicable) Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push button as & if applicable. Observe DC voltage on voltmeter. Observe the DC ON or float mode ON indicating Lamp / LED is ON as & if applicable. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable B) MANUAL MODE : Keep the Auto/ Manual selector switch of controller in at Manual mode of operation. Keep the Float/ Boost mode of operation selector switch at Float mode of operation. (Or operate charger in Float mode / Boost mode through push button if applicable) Please keep Voltage control potentiometer in Manual mode at its minimum position. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push button as & if applicable. Observe DC voltage on voltmeter. Observe the DC ON or float mode ON indicating Lamp / LED is ON as & if applicable. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable II) FLOAT CUM BOOST CHARGER IN BOOST MODE :Charger have two modes of operation. A) Auto mode & B) Manual mode. A) AUTO MODE : Keep the Auto/ Manual selector switch of controller in at Auto mode of operation. Keep the Float/ Boost mode of operation selector switch at Boost mode of operation. (Or operate charger in Float mode / Boost mode through push button if applicable) Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. Switch ON AC input contactor switch / MCB / Push button as & if applicable. Observe the DC ON or boost mode ON indicating Lamp / LED is ON as & if applicable. Observe DC voltage on voltmeter. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable B) MANUAL MODE : Keep the Auto/ Manual selector switch of controller in at Manual mode of operation. Keep the Float/ Boost mode of operation selector switch at Boost mode of operation. (Or operate charger in Float mode / Boost mode through push button if applicable) Please keep Voltage control potentiometer in Manual mode at its minimum position. Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable Charger AC ON’ indicating lamp / LED will glow. CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
SHEET NO. : SH 7887 / 14 - 16
Switch ON AC input contactor switch / MCB / Push button as & if applicable. Observe DC voltage on voltmeter. Observe the DC ON or boost mode ON indicating Lamp / LED is ON as & if applicable. Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable 2
PROTECTION :
1) Charger blocker diodes of suitable rating are provided to maintain one-way flow of current. i.e. from charger to load battery. 2) Annunciation, Condenser are provided with HRC fuses of suitable rating. 3) Voltmeters are provided with glass fuse. 4) Fuse Failure Detector: FFD’s are provided to give annunciation in case of failure of AC input fuses/ DC output fuses/ battery fuses/ Semiconductor fuses/ Filter capacitor fuses etc. as applicable. 5) Auxiliary contactors / relays are provided to give annunciation if AC mains fail. 6) DC Under & Over Voltage Relay (If provided) a) DC Over Voltage Relay : Due to any reason, DC output voltage of charger goes above the set value, this relay will operate and gives annunciation. b) DC Under Voltage Relay : Due to any reason, DC output voltage of charger goes below set value, this relay operates & gives annunciation.
7) E/L (I.M.D.): Earth Leakage Relay is provided to indicate the leakage current. If in any case, the earth leakage current lies between the defined range, this relay will actuates and give annunciation. 3
ANNUNCIATION SCHEME FOR CHARGER :
If any of the following fault occurs, visual and audible annunciation will be there. Accept the fault pushing push buttons. Hooter stops and only fault indicating will indicate the presence of fault. Fault indication stops glowing when fault will be removed 4
SPECIAL ATTENTION WHILE OPERATING :
a. Generally operate the charger in Auto mode of controller. Use manual mode of controller in case of Auto mode of controller function failure. Before using manual mode keep voltage adjust potentiometer at its minimum position while operating the charger in Manual mode. b. Always use HRC fuses of proper rating; use of wire fuses will cease our Guarantee. c. While changing the mode i.e Auto mode of controller to Manual mode of controller or vice versa. Switch 'OFF’ the charger and then change the position of Auto / Manual switch. d. After meeting an emergency by battery, charge the battery by charger in Boost mode for the period depending upon the duration of emergency the battery has met. After boost charging is over, allow the battery across charger in float mode for trickle charging. 5
INITIAL CHARGING OF BATTERIES :
a) Ensure that, battery cells are filled with electrolyte and sufficient rest is given to them for cooling. b)Connect battery cables to the charger terminal board with proper polarity. CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
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c) Keep the Auto/ Manual selector switch of controller in at Auto mode of operation. d) Keep the Float/ Boost mode of operation selector switch at Boost mode of operation. (Or operate charger in Float mode / Boost mode through push button if applicable). e) Switch ON AC input Switch/SFU/MCB/MCCB/ACB as applicable f)Charger AC ON’ indicating lamp / LED will glow. g)Switch ON AC input contactor switch / MCB / Push button as & if applicable. h)Switch 'ON' DC Output Switch/SFU/MCB/MCCB/ACB as applicable i)Observe DC voltage on voltmeter. j)For charging the battery follows the procedure of charging according to Instruction manual of Battery manufacturer. Boost charging current can be set at required value with the help of Boost charger current limit potentiometer. k)After completion of the charging cycles, allow the battery across float charger for trickle charging. After this, battery will be ready to supply the load. 6
ROUTINE MAINTENANCE OF BATTERY CHARGER
A) 1) Cleaning of panel from inside & outside by using blower : Weekly 2) Healthiness of indicating lamps. : Weekly 3) Tightness & healthiness of fuse links. : Quarterly 4) Electrical performance, Tightness of all connections, noise observation & complete cleaning of equipment. : Half yearly 5)Calibration of meters. : Yearly B) In addition to above daily Log book is to be maintained for reading. C) Any fault occurring and rectification carried out/maintenance carried out to be recorded in log book. D) Ensure availability of necessary spares i.e. fuse links, thyristors, diodes, control Cards etc. At least one set of each. 7
TROUBLE SHOOTING :
1) If voltmeters does not show any reading then check a) Fuses of voltmeter. b) Voltmeter connections c) Voltages at voltmeter selector switch. d) Voltages at voltmeter. e) Check voltmeter. 2) If ammeters does not show any reading then check a) Ammeter connections b) Current at Ammeter selector switch. c) MilliVolts at Ammeter. d) Check Ammeters. 3) If contactor does not pickup then check a) Contactor coil fuse if applicable. b) Contactor coil connections. c) Contactor coil. d) Check voltage at contactor coils 4) If charger not able to deliver DC output voltage. a) AC input voltage not proper. b) Semiconductor fuses for SCR not healthy. c) Voltage & current feedback wiring contact break/loose. d) Auto / Manual (for CPC card) selector switch faulty. e) CPC card faulty. CHHABI ELECTRICALS PVT. LTD, JALGAON - 425 003
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