295102895-Battery-Charger-DCDB.pdf

D:\Hema\2008-2009\conv\pcoos-000008-08-09\Write up-coo-08.doc

DRAWINGS FOR APPROVAL RATING

:

NAME OF PROJECT

: EEPC- Accelerated Electricity Access Expantion

CUSTOMER

:

NCC LTD

JOB NO.

:

2264-08

S.O.NO

: PCOOS/000008/08-09

MANUFACTURER :

125V / 50A Dual Float cum Boost Charger & 125V DCDB

AMARARAJA POWER SYSTEMS (P) LTD, TIRUPATI.

AMARA RAJA POWER SYSTEMS (P) LTD. RENIGUNTA–CUDDAPAH ROAD, KARAKAMBADI–517 520 TIRUPATI (A.P.) Tel Fax

: (0877) 2285561 – 2285565 : (0877) 2285599 & 2285600

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TABLE OF CONTENTS ================================================================== Sl.No. CONTENTS ------------------------------------------------------------------------------------------------------------------01.

GENERAL DESCRIPTION

02.

TECHNICAL SPECIFICATION OF CHARGER & DCDB

03.

TECHNICAL DEVIATION AND JUSTIFICATION

04.

SYSTEM THEORY OF OPERATION

05.

AMARARAJA STANDARD SUB VENDOR LIST

06.

BILL OF MATERIALS

07.

SCHEMATIC DRAWINGS

08.

DIMENSIONAL DRAWINGS

=================================================================

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GENERAL DESCRIPTION

The system basically consists of Two Float Cum Boost Chargers. Each Float cum Boost charger is capable to supply the load and Battery Charging requirements. In normal mode of operation, the battery assembly is float charged by both the chargers while feeding the DC load thus operating in parallel and sharing the total load. When FCBC - 1 fails, the other charger FCBC - 2 comes into operation and supplies the load and battery bank. Both Chargers basically consists of input transformer, Rectifier Bridge, Filter circuit and Charger Control Board. The Functional Block Diagram of redundant the system is enclosed in this package for reference. The Input Transformer steps down the AC input voltage to required AC level. The rectifier is built with SCRs, which are connected in full wave, Full controlled configuration. The Rectifier Bridge converts the stepped down AC into regulated DC. The Filter Circuit eliminates AC ripple in the DC output. The charger control board provides the gate pulses to SCRs. Voltage and current feedback circuits provide error signals to the charger control board to achieve voltage regulation and current limit. A charger output voltmeter, a charger output Ammeter, AC input Ammeter and AC input voltmeter are provided to measure respective parameters continuously in each charger. Blocking diode is provided at the output of each charger to prevent reverse flow of current into the charger, which may damage the filter circuit in the charger when the battery is supplying the load. A Battery Charge / Discharge Ammeter, Battery Earth Leakage Ammeter and DC Voltmeter with selector switch are provided to measure respective parameters continuously in Battery Charger System. The chargers, FCBC-1 & FCBC-2 are housed in a single cabinet of Folded sheet steel construction. All Meters, Indicators and important Controls are brought on to the front door. ****

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TECHNICAL SPECIFICATION OF CHARGER TYPE MODEL RATINGS

: : :

DUAL FLOAT CUM BOOST CHARGER FULL WAVE FULL CONTROLLED 125V DC, 50Amp DFCBC suitable for VRLA-56cells-300AH battery

AC INPUT Voltage : 380VAC ± 10% Frequency : 50Hz ± 5% Phase : 3 Phase, 4Wire DC OUTPUT Float voltage Boost voltage Regulation Ripple Current

: : : : :

System output voltage : Efficiency

:

METERS

:

126.0V DC adjustable by +2%, -5% 128.8V DC adjustable by +2%, -5% Better than ± 1% at full voltage Less than 1% RMS 50A MAX.126V DC + 1% (at load terminalsterminals after dropper diode ckt) Better than 80% at Full load Following analogue type 72 X 72 mm meters shall be provided in the system for monitoring the respective parameter. a. AC voltmeter with selector switch to measure voltage across line to line and line to neutral b. AC ammeter with selector switch c. DC voltmeter with selector switch(FCBC-1/FCBC2/BATT/LOAD) d.DC ammeter for both FCBC - 1 & 2 e. DC ammeter to measure battery charge/discharge current f. Load ammeter

INDICATIONS

:

Pilot Lamps shall be provided for following conditions. a. AC Mains ON

. FACIA Display shall be provided for the following conditions with audio alarm for abnormal conditions on each charger a. AC mains fail b. AC I/P MCB Trip(FCBC-1&2) c. DC O/P MCB Trip(FCBC-1&2) d. Charger Fail(FCBC-1&2) e. Charger ON(FCBC-1&2) f. Battery I/P fuse fail

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g. Battery Earth Fault h. Float ON i. Boost ON j. Battery under voltage k. DC under voltage l. DC over voltage 5. PROTECTIONS : Following protections will be provided in the system: a. AC Input Circuit Breakers for both FCBC-1 & 2. b. Fast acting semiconductor fuses for Rectifier bridges for both FCBC-1 & 2. c. DC Output Circuit Breakers for both FCBC-1 & 2. d. Over Voltage cutback protection for both FCBC-1 & 2. e. Charger Over Load protection for both FCBC-1 & 2. f. Battery Input Fuses g. Battery Path Charging Current Limit h. Blocking Diodes for both FCBC-1 &2. i. Charger Current Limit 6. CONTROLS & SWITCHES : a. AC Input Circuit Breakers for both FCBC-1 & 2. b. DC Output Circuit Breakers for both FCBC-1 & 2. c. Auto / Float / Boost Mode Selector Switch for both FCBC-1 & 2. d. Float & Boost Voltage Variable Potentiometers for both FCBC-1 & 2. e. Test, Accept & Reset Push Buttons f. AC Volts & Amps Selector Switch for both FCBC-1 & 2. g. Heater, Door Lamp and Socket Power Supply ON/ OFF Toggle Switches with Fuses. h. DC Voltmeter Selector Switch 7. SPECIAL FEATURES

:

The following features will be provided: a. Soft start on DC side. b. Class-F insulation with Class-F Temperature Limits for all the Magnetics. c. Automatic voltage regulation using digital control logic d. Built in auto phase reversal of operation e. Charger Current Limit f. Battery Path Current Limit g. Filter Circuit to limit Ripple.

:

Freestanding Cabinet, Floor Mounting Type, Sheet Steel Construction, Easy Access for Installation, Commissioning & Maintenance and Cable Entry at Bottom of the Cabinet. Proper louvers will be provided for better ventilation. Hinged doors will be provided at the front and back. All live parts will be properly shrouded.

8. GENERAL a.

Cabinet

[[

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b.

Sheet Thickness

:

1.6mm for Non-load bearing sections. 2.0mm for Load bearing sections.

c.

i) Paint

:

ii) Painting process

:

EXT. : Light Grey 631 of IS 5 INT. : Glossy White Powdered coating

d.

Cooling

:

Natural air cooling

e.

Protection class

:

IP – 42 as per IS 2147

f.

Temperature range of operation Relative humidity

:

0°C to 50°C

:

0% to 95% non-condensing.

g.

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TECHNICAL SPECIFICATION FOR DCDB Incomer

:

63A-2P-DC-MCB

-1No.

Outgoing feeders

:

32A-2P-DC-MCB 16A-2P-DC-MCB

-3Nos. -7Nos.

METERS

:

Following Analog Type Measuring Meters of 72 x 72 Sq. mm with 240° deflection will be provided in the DCDB for measuring the respective parameters: a. DC Ammeter for DCDB b. DC Voltmeter

8. GENERAL a.

Cabinet

:

Freestanding Cabinet, Floor Mounting Type, Sheet Steel Construction, Easy Access for Installation, Commissioning & Maintenance and Cable Entry at Bottom of the Cabinet. Proper louvers will be provided for better ventilation. Hinged doors will be provided at the front and back. All live parts will be properly shrouded.

b.

Sheet Thickness

:

1.6mm for Non-load bearing sections. 2.0mm for Load bearing sections.

c.

i) Paint

:

ii) Painting process

:

EXT. : Light Grey 631 of IS 5 INT. : Glossy White Powdered coating

d.

Cooling

:

Natural air cooling

e.

Protection class

:

IP – 42 as per IS 2147

f.

Temperature range of operation Relative humidity

:

0°C to 50°C

:

0% to 95% non-condensing.

g.

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DEVIATION / JUSTIFICATION

S.No.

CLAUSE

DEVIATION / JUSTIFICATION

S.No

Clause

Deviations & Justifications

01

13.6&13.7

As battery charger designed suitable for VRLA battery, these batteries are delivered to the site with full charge condition. Hence Initial charge at site is not required. So, We are not provide initial charge mode, equalizing charge setting timer and over ride selector switch in the offered charger.

02

13.6& 13.7

As Battery charger designed suitable for VRLA battery, Float and Boost Voltage settings will be designed as per VRLA battery manufacturer Recommended voltage levels Float=2.25V/cell and Boost=2.3V/Cell. Offered charger is designed as its out put voltage shall vary with in the regulation limits, hence pulse limiter zener type is not required.

03

04

13.9

13.11

As the requirement is thyristor based battery charger, it can deliver rated DC voltage within specified regulation for specified AC supply and DC load variation. Hence, taps on transformer are not required Battery impedance monitoring facility is not available in the offered charger. Hence we can provide battery fuse fail alarm indication and PFC for customer remote monitoring purpose. Earth fault indication is derived through amararaja make PCB cards.

05

13.12

All indications, alarms and protections are derived through Amara Raja make PCB cards, which shall be built with PLA/OEN make Aux.relays and hence, no separate static relays being considered to derive protections and charger fail indication and PFC was provided in charger only not in DCDB.

06

13.14

For Emergency DC lighting control system Automatic and OFF selector Switch is provided ,manual position can not be provided.

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SYSTEM THEORY OF OPERATION The system consists of two identical Float cum Boost Chargers, with necessary Interconnection Circuit and a Battery Bank. Both chargers are identical in nature & works on the same principle. These chargers are rated to meet the requirement of Load and Battery charging current as specified. For clear understanding of system description, refer the schematic drawing enclosed. The Float cum Boost chargers - 1 & 2 are connected to the AC input power through (CB 401/501). The Input transformer (T401/501) steps down the input AC Voltage to the required level and is connected to the rectifier bridge (SCR 401-406/501-506) through Fast acting Semiconductor Fuses (FU 401-402/501-502). PC402/502 are capacitive filter Boards that protect the system from surges and transients at AC Input. The charger control board PC 401/501 provides gate signals to these SCRs at appropriate timing depending on the output voltage/current feed back. The Rectifier DC is connected to DC filter (L 401 / 501 and C 402 / 502) which in turn filters out all harmonics and provide DC voltage with low ripple content as specified. The Blocking diodes (D401/501) prevent reverse current flow into the charger. The output voltage of Float cum Boost Charger is adjusted using the potentiometer R 401-402/501-502 respectively. The shunt SH 401/501 provides current feedback to charger control board (PC 401/501), which causes the unit to go into current limit, when the load current (charging current) is more than set value. The Rectifier DC is connected to DC filter (L 401 & C 402/L 501 & C 502) which in turn filters out all harmonics and provide DC voltage with low ripple content as specified. The meter M 401/501 with shunt, SH 401/501 provides the current feedback to the charger control Board PC 401/501, which causes the unit to go into current limit beyond the set value. This Characteristics cause the output voltage to go down when the battery is run down, to maintain a constant level of charging current. During normal operation, Charger - 1 & 2 supplying load current and float charge the battery. The current limit interface board (PC 3) connected across Battery shunt terminal, provides Battery Charging current limit protection, when both chargers are operating in Float mode.

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ANNEXURE - A APPROVED SUB-VENDOR LIST 1.

Contactors/Overload relays

ABB/ L&T/ANDREW YULE

2.

Thyristors / Diodes

HIRECT/ RIR/ Semicran

3.

Heavy duty switches

SALZER (L&T) / KAYCEE

4.

Control Switches

SALZER (L&T)

5.

MCBs

MDS /INDO ASIAN/ Siemens/Schneider

6.

MCCB

C&S / SCHNIDER/siemens

7.

Toggle Switches

R.G.K/RECOM

7.

Fuses (HRC & HBC)/ Fuse Bases

GEC/Bussman(formerly S&S)/INDO ASIAN/ ELCOM/ ESSEN

8.

Fuses (GLASS)

PROTECTRON

9.

Meters

BEEMET / RISHAB

10.

Push Button / Indicating lamps

L&T/TEKNIC/R.G.K/JYOTHI ELECTRONICS

11.

Auxiliary relays (PCB Type)

PLA/OEN

12.

LED's

SANKEN/KWALITY

13.

Wire Wound Resistor

PEC/VEPL

14.

Potentiometers

POTEL / BOURNS / PANKAJ

15.

Electrolytic Capacitors

SARADA

16.

Populated PCB’s

ARPSL

17.

Shunts

BEEMET/MECO/ RISHAB

18.

Heat Sinks

AFCOSET / BM’s

19.

Thermal Switches

UTILITY APPLICATIONS

20.

Heaters

PYRO

21.

Terminal Blocks

ELMAX/ ESSEN

22.

MOV’S

ELPRO

23.

Cable Glands

NOVOFLEX/HMI/COMET/JAINSON

24.

Cables

CAPI

25.

Fuse Switches

GEC/C&S/HPC/HAVELLS/CGL

26.

Facia window

ACCYS ELECTRONICS/SUN INDUSTRIES.

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Bill Of Material Report

POWER SYSTEMS Pvt. Ltd. PCOOS/000008/08-09

Sale Order No Item Code

DFCB125050A

Line No

1

Variant Code E612

Configuration No

1

Customer Name

ENG-SFS-08/REV 0

Doc Ref No : National Contracting Co. Ltd.,Saudi Arab

Description 125V/50A DFCBC:3PH-4W-FWFC

Qty

Jobno 08-2264

Qty / System

Rev No 1

Sl.No Rev Circuit Designation

Input Item Code

1

0

AL

42500000069V

Buzzer-12V-20mm-CE-27-01

M064

Metronix

1.000

NOS

2

0

C 401/501

40730400200V

capacitor-polyster-2mfd-400V-axial

E013

2µF/±20%400VDC/KT12

2.000

NOS

3

0

C 402/502 (3+3)

40712007700V

Cap-Elec-7700mfd-200V DC-

S047

SARADA

6.000

NOS

4

0

CB 401/501

40071310040

MCB-40A-3P-AC-10KA-DCurve

L021

Legrand-D 6049 77

2.000

NOS

5

0

CB 401/501(AUX)

40071900009

Auxiliary C/O Switch-6A-250V AC

L021

Legrand-007350

2.000

NOS

6

0

CB 402/502

40071299003

MCB-63A-2P-10KA-DC-AUX 1NO+1NC

S049

Sch-MGN22332+26924

2.000

NOS

7

0

CON 1

47930245032

Contactor-32A-3P-110VDC coil-2NO+2NC

A009

PAK-20US-110VDC

1.000

NOS

Cont-10A-415VAC Coil- 2 NO + 2NC

L001

MN0 22E-SS94662D000

2.000

NOS

8

0

CON 401-402

47920238010

Description

Variant Variant Description

UOM

9

0

CON 401/402(AUX)

47960022001V

Con aux block-2NO+2NC For MN9-MN25 Ser

L001

L&T-SS94085

2.000

NOS

10

0

D 1/3

46081101150

Dropper Diode-forward-150A-100V-stud

H004

HIRECT-S1HNS150

2.000

NOS

11

0

D 2/4

46081201150

Dropper Diode-reverse-150A-100V-stud

H004

HIRECT-S1HRS150

2.000

NOS

12

0

D 401/501

46011106100

Diode-Forward-100A-600V-stud

H004

Hirect-S6BN100

2.000

NOS

13

0

D5

40462108002V

Diode-GP-3A-1000V-DO-27-1N5408

M035

M035

1.000

NOS

14

0

DCDB

DCDB1250000

125V DC DISTRIBUTION BOARD

A010

ARPSL

1.000

NOS

15

0

DL 401

42500000231V

DOORLAMP-15W-230V AC

P007

Philips

1.000

NOS

16

0

DL 401 (Holder)

42500000236V

BULB HOLDER

A008

Anchor

1.000

NOS

17

0

FD 1

42500000757

Facia display-16point-90-270V AC/DC

S099

Sun Indus-SMA16WUS

1.000

NOS

18

0

FU 1-2

47503014063

HRC fuse-slow-63A-415V/550VAC-offset tag

B017

Bussmann-63K07

2.000

NOS

19

0

FU 3/403-406/408-410/ 503-506

47504320100V

Glass Fuse-fast-1A-250VAC-32MM

P011

PROTECTRON

12.000

NOS

20

0

FU 401-402/501-502

47501122100

Semiconductor fuse-fast-100A-240V/250VAC

B017

Buss-100LET-T type

4.000

NOS

21

0

FU 407

47504094010

HRC fuse-slow-10A-415/550V AC-clip on

B017

BUSSMAN-NSD10

1.000

NOS

BOM Status Report Run Date & Time

Prepare 26/05/2009 16:05:40

HEMALATHA.K Prepared By

Checked By

Approved By

Proprietary Material of M/s AMARA RAJA POWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited,

Page No

0.00 NOS

UOM

Sub Remarks

yes

1

Of

4




DFCB125050A

Line No

1

Variant Code E612

Configuration No

1

Customer Name

ENG-SFS-08/REV 0



Qty

Jobno 08-2264

Qty / System

Rev No 1


Input Item Code

22

0

FUB 1/2

47512000013V

Fuse base-63A-415/500 VAC

B017

Bussman-KA63

2.000

NOS

23

0

FUB 3/403-406/503-506/ 408-410

47512000025V

Fuse holder-glass-10A-32mm

E014

ELCOM-MF-20

6.000

NOS

24

0

FUB 407

47512000016V

Fuse base-32A-415/500V AC

B017

Bussmann-FA32

1.000

NOS

GEC-SP63EIT-BS

1.000

NOS

Description


UOM

25

0

FUSE SWITCH BOX(FUSW 1)

40022301063

Fuse switch-63A-3P-ON/OFF-bolted type

G001

26

0

FUSW FUSES(63A FUSES)

47503134063

HRC fuse-slow-63A-415VAC-offset tag-eit

G001

GEC-EIT63

2.000

NOS

27

0

FUT (PC 8)

47599990000V

Fuse Trip indicator

G001

GEC-TI300

2.000

NOS

28

0

H 401

42500000011V

SPACE HEATER -100W-240VAC

P013

PYRO

1.000

NOS

29

0

HS [D 1-4/401/501]

44802000250

Heat sink-130HD-250mm

A003

AFCOCET

4.000

NOS

30

0

HS[ SCR 401-406/501-506]

44801000200

Heat sink-PI-20-200mm

A003

AFCOCET

6.000

NOS

31

0

L 401/501

43200003611

Charger D.C.Choke-3.25mH

A010

ARP-AT-3611

2.000

NOS

32

0

LA 401

47711105221

Indicator assembly-240VAC-22.5mm-red

T001

TECKNIC-2LHBR230

1.000

NOS

33

0

LA 402

47711105222

Indicator assembly-240VAC-22.5mm-yellow

T001

TECKNIC

1.000

NOS

34

0

LA 403

47711105224

Indicator assembly-240VAC-22.5mm-blue

T001

TECKNIC

1.000

NOS

35

0

M1

47610932015

DC voltmeter-0-150V-1.5%-240D-72x72

R007

Rsihab-PL72

1.000

NOS

36

0

M2

47611432007

Rishab-PL72

1.000

NOS

37

0

M 401/501/3

47610532007

DC ammeter-75-0-75A/75mV-1.5%-240D-72x72 R007 R007 DC amm-0-75A/75mV-1.5%-240D-72x72

Rishabh-PL72

3.000

NOS

38

0

M 402

47610832050

AC voltmeter-0-500V-1.5%-240D-72X72mm

R007

Rishab-VL72

1.000

NOS

39

0

M 403

47610232005

AC ammeter-0-50A/5A-1.5%-240D-72x72

R007

RISHAB-VL72

1.000

NOS

MOV-60V-14mm

E006

ELPRO-RDN 60/14

12.000

NOS

40

0

MOV 401-406/501-506 BOM Status

Report Run Date & Time

40413061400V

Prepare 26/05/2009 16:05:40


Checked By

Approved By


Page No

0.00 NOS

UOM

Sub Remarks

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2

Of

4




DFCB125050A

Line No

1

Variant Code E612

Configuration No

1

Customer Name

ENG-SFS-08/REV 0



Qty

Jobno 08-2264

Qty / System

Rev No 1


Input Item Code

41

0

PB 1/2/3

47310000104V

PB-microswitch-1C/O-black

R001

R.G.KESWANI-MR3/FPBB

3.000

NOS

42

0

PB 401

47311000200V

PB-door lamp-NC-(Refrig switch)

A008

Anchor

1.000

NOS

43

0

PC 1

ARE02018202

PCB-MST-ACDB-48VDC

A041

AREPL-P02018202

1.000

NOS

44

0

PC 10

ARE02002000

PCB-PLA-RELAY-12VDC-3C/O CONT.

A041

AREPL-P02002000

1.000

NOS

45

0

PC 12

ARE02018206

PCB-MST-DDB-110V DC

A041

AREPL-P02018206

1.000

NOS

46

0

PC 2/406

ARE02002023

PCB-RELAY BD-130VDC-3C/O

A041

AREPL-P02002023

2.000

NOS

47

0

PC 3

ARE02008404

PCB-CUR LIMIT-INT.FACE-130VDC

A041

AREPL-P02008404

1.000

NOS

Description


UOM

48

0

PC 4-7/13

ARE02008201

PCB-VOLT DETECT-130VDC-TB-OEN

A041

AREPL-P02008201

5.000

NOS

49

0

PC 401/501

ARE02009000

PCB-CHGR-6P-MOTHER BD

A041

AREPL-P02009000

2.000

NOS

50

0

PC 401A/501A

ARE02009011

PCB-POWER SUPPLY BD-6P

A041

AREPL-P02009011

2.000

NOS

51

0

PC 401B/501B

ARE02009024

PCB-REG CTRL-110VDC- 6P

A041

AREPL-P02009024

2.000

NOS

52

0

PC 401C-D/501C-D

ARE02009031

PCB-GATE PULSE DRIVE-6P

A041

AREPL-P02009031

4.000

NOS

53

0

PC 402/502

ARE02001102

PCB-FILTER-2MFD-400V-TB

A041

AREPL-P02001102

2.000

NOS

54

0

PC 8

ARE02008302

PCB-FUSE TRIP-DPDS

A041

AREPL-P02008302

1.000

NOS

55

0

PC 9/11/403-405/407/5 03-506

ARE02002012

PCB-PLA-RL-130V DC-2C/O CONT

A041

AREPL-P02002012

10.000

NOS

56

0

R 1/2

40486470252V

Resistor-variable-2.5K-25W-Wire wound

D023

Diagram

2.000

NOS

57

0

R 3-5

40483321002V

Resistor-1K-2W-5%-Wire wound

D023

DIAGRAM

3.000

NOS

58

0

R 401/402/501/502

40486341203V

POT-panel mount-20K-3W-1T

P009

POTEL

4.000

NOS

59

0

R 403(1)/404(2)/503(1 )/504(2)

40483371003V

Resistor-10K-10W-5%-wire wound

D023

Diagram

6.000

NOS

60

0

SC 401

42500000245V

SOCKET-3PIN-5A

A008

Anchor

1.000

NOS

Dual SCR block-slow-90/95A-600V

R006

RIR-IRKT-91/06

6.000

NOS

61

0

SCR BOM Status


46040206090 Prepare 26/05/2009 16:05:40


Checked By

Approved By


Page No

0.00 NOS

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Sub Remarks

3

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4


POWER SYSTEMS Pvt. Ltd. Sale Order No Item Code

PCOOS/000008/08-09 DFCB125050A

Line No

1

Variant Code E612

Configuration No

1

Customer Name

ENG-SFS-08/REV 0



Qty

Jobno 08-2264

Qty / System

Rev No 1


Input Item Code

62

0

SH 1/401/501/2

47602110075

Shunt-75A/75mV- ±0.5%

B011

Beemet

4.000

NOS

63

0

SW 1

40070214201

Rotary switch-6A-1P-4W-ACDC

S003

Sal-SG91C-B13-61050

1.000

NOS

64

0

SW 401

40070253201


S003

61124 SAB13TDYR

1.000

NOS

65

0

SW 402-404

40072110110V

Toggle switch-pm-SPST-ON/OFF-10A

R001

R.G.KESWANI

3.000

NOS

Description


UOM

66

0

SW 405

40070740002

Rot Sw-10A-AC volt amp select

S003

Sal-72375S10B13TDYR

1.000

NOS

67

0

T 401/501

43200004674

Charger I/P Xfr-380V/65.3V,10KVA

A010

ARP-AT-4674

2.000

NOS

68

0

T 402-404

47622100050

Current Transformer-50/5A

K006

Kappa-Ring type

3.000

NOS

69

0

TB 1/2/401/4/5(FUSW BOX)

41004001110V

Terminal block-power-110A-single

E015

ELMEX-CBT110

12.000

NOS

70

0

TB 3/INT

41004001010V


E015

ELMEX-CST2.5

42.000

NOS

71

0

TM 401

42500002848

L&T-EM1000-BF42B2

1.000

NOS

72

0

TS 401

42500000067V

Timer-0.15-3 hrs-240VAC,NOVOLT PROTECT L001 U007 THERMAL SW-SET AT65`C-NC

UTILITY APPLIACES

1.000

NOS

BOM Status Report Run Date & Time

Prepare 26/05/2009 16:05:40


Checked By

Approved By


Page No

0.00 NOS

UOM

Sub Remarks

yes

4

Of

4


POWER SYSTEMS Pvt. Ltd. Item Code

DCDB1250000

Variant

S.No Rev Circuit Designation

A010

Item Code

Description

Doc Ref No:

125V DC DISTRIBUTION BOARD-ARPSL

Description

Qty

1

Variant Var Description

UOM

ENG-SFS-08/REV 0 NOS

Qty / System UOM

1

0

CB 1

40071609630

MCB-63A-2P-DC

S049

Schn-MGN22332-10KA

1.000

NOS

2

0

CB 2-8

40071609160

MCB-16A-2P-DC-10KA

S049

Schn-MGN22326

7.000

NOS

3

0

CB 9-11

40071609320

MCB-32A-2P-DC

S049

Schn-MGN22329-10KA

3.000

NOS

4

0

CON 1

47930245016

Contactor-16A-110VDC coil-3P-2NO+2NC

A009

AY-PAK-18U01-110VDC

1.000

NOS

5

0

LED 1/2

40477112001V

LED-RED-ROUND-5mm

K013

KL53SBLRL6L-M

2.000

NOS

6

0

LED1/2(HOLDERS)

42500002804

LED Holder-5mm round-press fit-white

L016

Lalwani Elect-LHO-5

2.000

NOS

7

0

M1

47610932015

DC voltmeter-0-150V-1.5%-240D-72x72

R007

Rsihab-PL72

1.000

NOS

8

0

M2

47610532007

DC amm-0-75A/75mV-1.5%-240D-72x72

R007

Rishabh-PL72

1.000

NOS

9

0

PC 1-3

ARE02008201

PCB-VOLT DETECT-130VDC-TB-OEN

A041

AREPL-P02008201

3.000

NOS

10

0

R 1/2

40483321003V

Resistor-10K-2W-5%-wire wound

D023

Diagram

2.000

NOS

11

0

SH 1

47602110075

Shunt-75A/75mV- ±0.5%

B011

Beemet

1.000

NOS

12

0

SW 1

40070221103

Rotary switch-16A-2P-ON/OFF-ACDC

S003

Sal-61192S16B03TDYR

1.000

NOS

13

0

SW 2

40070212201


S003

Sal-61037S6B13TDYR

1.000

NOS

14

0

TB 1

41004001110V


E015

ELMEX-CBT110

2.000

NOS

15

0

TB 13/INT

41004001010V


E015

ELMEX-CST2.5

6.000

NOS

16

0

TB 2-12

41004001044


E015

ELMEX-CST6

22.000

NOS

BOM Status :

Prepare


0

Rev SUB

Remarks

HEMALATHA.K 26/05/2009 16:06:23 Prepared By

Checked By

Approved By


BOM Ref Doc No Page No

1

Of

1

ENG-SFS-06/Rev.0

1

2

3

4

5

6

7

8

D

D

CB

CB

D

FU

-

FU

R

VRLA BATTERY BANK ( 125V/300 AH ) 1 st CELL

Y B

C

CON.

N CB

CB

D

D

D

FCBC - 1

TO DCDB

TB

DROPPER DIODE CKT

(126V +/- 1%)

3 PHASE, 4 WIRE.

380VAC ±10%, 50HZ ± 5%

FCBC - 2

TB

B

B

FIG.1 FUNCTIONAL BLOCK DIAGRAM OF DUAL FCBC

AM A R A

A

RAJA

POWER SYSTEMS LTD Registered Office & Works karakambadi - 517520

PROJECT : EEPC- Accelerated Electricity Access Expantion CUST P.O. NO. DWG. NO.

A3 TITLE APPD.

Ph(0877) 2285561 to 2285565.

REV. ECO REMARKS FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\4-BLD1.sch 1

2

3

DATE

APPD.

DRAWN

CHKD. RECHKD.

DATE

HEMA

4

5

6

: : :

Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Tirupathi. All rights reserved. No copying permitted unauthorised use prohibited.

C

AC INPUT

+

56 th CELL

A

NCC LTD NCC/EEPCO/LOT 1/PO/008

Dated : 14/03/2009

SCH - 2264 - 08 ( PCOOS/000008/08-09 ) SCHEMATIC DRAWING OF 125V/50A DUAL FLOATCUM BOOST CHARGER

02/04/2009 7

SHEET

1

OF

1 8

REV

0

2

3

F A2

416B

25 28

16

27 24 23

102B

440B

462B

SW 401

15

8

TM401

FLOAT

R401

A479D

A472D

A486D

A476D

A487D

A482D

A488D

A472D

A477B

A436B

A437B

AC INPUT

3 PHASE , 4 WIRE .

A453D A454D A454D A455D

CON.401

A455B

A470B

A12B SW402

19H

PB401

19H

32B

19B

B

15

15 PC403

PC407

2

2

B425B R428B

( SHEET 3 OF 4 ) TO SW1

B427B R424B B423B 415B

SH401

450H

481H

13

413B

413D

12

412B

412D

D401

481H

NOTE :-

ALL EARTH POINTS SHOULD BE INTERCONNECTED

17B

1 REV

---------ECO

APPROVAL COMMENTS REMARKS

20/05/09 DATE

APPD

D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\1-FCBC 1.sch

DRAWN

Registered Office & Works, karakambadi - 517520 Ph(0877) 2285561 to 2285565. RECHKD CHKD APPD.

HEMA

3

40H

ALL DOORS PROVIDED WITH ELECTRICAL COMPONENTS TO BE EARTHED PROPERLY

M A R A R AJ A A POWER SYSTEMS LTD CHASIS GROUND

2

CON.402

A472D

FU408

A455B

A470B

FU407

A459B

A470B

415B

460H

SCR401

G

380VAC ± 10%, 50HZ ± 5%,

455F

454F

FU409

A454B

MOV404

A460H

A461H

A444H

R403

SCR404

AM

440B

462B

R402

C401

450B

1

TS401

DL401

443H

6

FILE NAME

A456B

415H

SCR405

R417B

7

462B

N

TO SHEET 3 OF 4

440B

1

H401

A470B

A11B

CB402

L401 17D

414H

461H

M401

A1

R419B

R426B

470E

C

A11B

443B

26

3

A455F

443B

17

SCR403

SCR402

S

444H

612B

A

490B

SW403

A11B SCR406

B418B

2 A454F

A16B

R404

18

2

F B2 B B3

B A3

A

A470B

A444 H

R421B

B420B

R

T

A470B

SC401

415F

A B1

55B 56B

9 10

A446 H

T404

A453F

+

57B

11

1

2

TB401

4

C402

20 19

C

11

B422B

450H

PC2

PC406 9

8

6

A445B

4 3 PC402

481F

NO 10

7

5

SW404

22 21

60B

TO FD1

(SHEET 3 OF 4)

C

NO

A455F

A495F

C

7 PC403 6

6

A469D

A445 H

7 PC503 6

NC

H2

H3

T403

A454F

N

FU406

A404D

3

F C2 B C3

A470B

55B

MOV401

A468D

B

1

A494F

X1

Y

T402

H1

FU405

FU401

2B

NO

B

Y1

FU402

2

X3

A457B

C1

16

A455B

56B

Z2

PC401 A,B,C,D

TM

1

A402D

LA401

A453F

X0

A

CHARGER BOARD

FROM AC INPUT

TM401

Z3

X2

Y3

R

FU410

MOV406

A445 H

4

C

BOOST

Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Thirupathi . All rights reserved no copying permitted unauthorised use prohibited.

2

Y2

A2

L3

L2

A453B

T401

MOV403

A401D

L1

A493F

MOV402

17D

1

CB401

453F

A466D

A467D

D

SW405

LA402

L

A403D

FU404

A1

A2

V2

M403

LA403

GND

3

FU403

A405D

AM

N

( SHEET 2 OF 4 )

17D

5

Z1

6B

8

VM

V1

A470B

TO FCBC-2 AC I/P.

A444 H

10

303B

A406D

A446 H

410D

1.0 2.5 4.0 6.0 10.0

A444B

6

15

CABLE SIZE IN Sq.mm

A447B

8

15

DESIG NATION B D E F

A446B

303B

408D

2 PC405

(SURGE BD)

TO PC3

15

2 PC404

MOV405

PC406

15

7

INTERNAL CABLE DETAILS

FROM BATT I/P

D

6

M402

673B CB 402

672B CB 401

2

(SHEET 3 OF 4)

FROM BATT I/P

688B TM501

9

5

301B

301B 10

4

4

5

6

A PROJECT CUST P.O.NO. DWG.NO

: :

TITLE

:

DATE

:

: :

ENG-SFS-06/Rev.0

1

EEPC- Accelerated Electricity Access Expantion NCC LTD NCC/EEPCO/LOT 1/PO/008

Dated : 14/03/2009

SCH - 2264 - 08 ( PCOOS/000008/08-09 ) SCHEMATIC DRAWING OF 125V/50A FLOAT CUM BOOST CHARGER - 1

SHEET

02/04/2009

7

1

OF

4

REV.

8

0

2

3

16

B D3

562B

27 24 23 15

540B

562B

SW401 103B

6

R501 FLOAT

R502

BOOST

562B 7 8

A560H

A546 H

FROM AC INPUT

A544 H

515H

515H

CB502

19H

19H

515B

15 R504

C502

A560H

19B

19B

515F

R503

C501

PC503

15 PC506

2

550H

( SHEET 1 OF 4 )

A547B

A544H

L501 17D

514H

A544H

SH501

581H

13

513B

513D

12

512B

512D

PC 406

TO SHEET 3 OF 4

516B

T

2

( SHEET 3 OF 4 ) TO SW1

543B

NO

10

4 D2

A455F

543B

F

A455F

581F

540B NC

S

D501

B

40H

543H

581H

AM

M501

C

9

A454F

C

SCR504

550H

PC2

A D1

1

SCR505

SCR501

A454F

+

26 25 28

2

SCR502 A561H

R526B B525B R528B B527B R524B B523B 515B

A594F H2

H3

A544 H

FU501

17

590B

6

A545B

A546 H

SCR503

B518B R517B

18

R

A544B

FU502 A561H

20 19

B

4 3 5 PC502

SCR506

B520B R519B

A453F

A595F

B522B R521B

22 21

A453F

H1

X1

A546B

A569D

PC501 A,B,C,D

CHARGER BOARD

303B

11

Y1

A593F

NOTE :-

ALL DOORS PROVIDED WITH ELECTRICAL COMPONENTS TO BE EARTHED PROPERLY ALL EARTH POINTS SHOULD BE INTERCONNECTED

550B

A

550B

G

M A R A R AJ A A POWER SYSTEMS LTD

17D CHASIS GROUND

1 REV

---------ECO


20/05/09 DATE

APPD

HEMA

D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\2-FCBC 2.sch

FILE NAME

1

2

DRAWN


3

4

5

6


: NCC/EEPCO/LOT 1/PO/008 Dated : 14/03/2009 : SCH -2264 - 08 ( PCOOS/000008/08-09 )

TITLE

:

DATE

: 02/04/2009

: :


A504D

FU506

X3 X0

A545 H

15

15

C

FU505

Z2

A568D

4

TO BATT I/P

675B CB 502

674B CB 501

2

A502D

X2

Y3

MOV506

A545 H

Z3

2

Y2

MOV503

A501D

301B

PC505

T501 Z1

1

2

8

D

17D

PC504

7

CB501

(SURGE BD)

3

10

6

A566D

A567D

MOV504

510D

FU504

A503D

MOV505

5

8

FU503

A505D

MOV501

TO PC3

( SHEET 3 OF 4)

D

5

A506D

6 508D

4

MOV502

ENG-SFS-06/Rev.0

1

EEPC- Accelerated Electricity Access Expantion NCC LTD

SCHEMATIC DRAWING OF 125V/50A FLOAT CUM BOOST CHARGER - 2

SHEET

7

2

OF

4

REV.

8

0

ENG-SFS-06/Rev.0

1

2

3

4

5

6

7

TB1

R5 510D (SHEET 2 OF 4)

35D

301B

301B

TO SHEET 1&2

1 st Cell 6

CON.1

12

D5

PC12

6 C

8 NC

PC11

(TO DCDB)

40H

7

(126V +/- 1%)

55B

19B

54D

40D

10

13

D

TB2 240H

2 PC11 15

19B

D4

D3

R2

7

D2

240B

D1

56B

7

303H

303H

DC OUTPUT

8 PC5

FU2 35H

35D

19D

AM

40B

40B

40B

40B

40B

19H (SHEET 1 OF 3)

FLOAT CUM

BOOST CHARGER - 1

C

8

4

TO LOAD

40H

PC4

3

PC7

19D

SH1

M2

19H

40H

40H

7

35H

19H

PC8

7

19H 19H

PC13

8

2

1

8

17D

56 th Cell

BATTERY BANK

702D

TO PC501

303B

12

13

5

7

TO FD1

6

508D

FU3

PC1

PC6

TO PC401

R4 410D (SHEET 1 OF 4)

35D

19D

14

8 408D

701D

5

46B

PC3

TO FCBC-1

19B

12

10

11

11 9

301H

301H

303B

TO FCBC-2

8

17D

40D

40D

2 10

13

45D

443B

A1

15

TO LOAD

543B

A2

( CL.BD )

19D

A3

48B

VM

15

240B

19D

1

34D

R1

2 PC2

72D

40B

2 PC9

A4

M1

40H

FLOAT CUM

(SHEET 2 OF 3)

BOOST CHARGER - 2

D

FU1

40H

40D

40H 40D

40H

35D

40H

SW1

C

SH2

19B

19H

M3 6B

6B

CON 401-402

6B

6B

6B

119H 8

119B

19B

19D

11

19H

AM

6B

6B

6B

6B CON 401-402

231B

F4

F7

F6

F9

F8

228B

46B

228B

227B

6B

185B RESET

ACCEPT

+

2

F12

AL

+

----------

APPROVAL COMMENTS

20/05/09

ECO

REMARKS

DATE

APPD

D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\3-INT.sch

2

6B

M A R A R AJ A A POWER SYSTEMS LTD 1

1

C

FROM BATT. I/P.

15

REV FILE NAME

214B

F16

F15

B

1

NC

BATT UNDER VOLTAGE

BOOST ON

F14

56B

FROM SW 401

FROM SW 401

F13

55B

FLOAT ON

5

213B

NO

BATT EARTH FAULT

212B

DC OVER VOLTAGE

5

6

C

PC13

PC10

227B

PB3

PB2

NO

6

PC6&7

FD1 (16 WINDOW ) (SUN Industrial Automation & Solutions) E + -

R3

TEST

-

1

F11

F10

C

222B

A

C

R

6B

6B

181B

PB1

C

A 183B

C

6 DC UNDER VOLTAGE

210B

MCB TRIP

FCBC - 2 FAIL

FCBC - 1 ON

F5

NO

8

208B

7

FCBC-2 DC O/P

NO

8

209B

NC

ALARM HTR2 T

9

FUSE BLOWN

NO

7

NC

6

PC5

17D

F3

204B

FCBC - 1 FAIL

7

7

NC

NC

PC503

205B

NC

6

PC8

BATT I/P

C

6

FCBC - 2 AC I/P MCB TRIP

C

FCBC - 2 ON

7

C

PC4

7

211B

C

PC505

10

3B

F2

6

C

PC504

PC403

202B

FCBC-1 AC I/P MCB TRIP

201B F1

PC405 NO

6

C

207B

7

NO

6

C

6

203B

AC SUPPLY FAIL

PC404

FCBC-1 DC O/P MCB TRIP

B

C

206B

6

C

DRAWN


4

5


TITLE

:

6


SCHEMATIC DRAWING OF 125V/50A DUAL FCBC WITH SWITCHING CUBICLE

DATE

HEMA

3


: :


8

SHEET

: 02/04/2009

7

3

OF

REV.

4

8

0

ENG-SFS-06/Rev.0

1

2

3

4

5

6

7

8

D

D

FCBC-2

ON

FAIL

MCB TRIP

8

7

PC506 7

NO

134B

11

7

EARTH FAULT

45

46

47

FLOAT ON

133B

NO

5

51

F

E2

133B 130B

133B NO

C

132B

C

44

CHARGER TROUBLE

131B

43

130B NO

126B NC

42

128B NO

41

BATTERY

127B C

40

NO

124B C 125B

123B NC

39

36

121B NO

35

120B C

34

DC OV

37

38

C

BATT UV

E1A

130B

9 10

TB3

33

129B

PC407 NO

32

11

NC 4

B

E3

TB(INT)

SW502

3

49

50

EMERGENCY LIGHTING (TO DCDB)

PC 406 C

48

BOOST ON

138B

6

137B C

12

4

PC8

11

31

DC UV

12

CON.401-402

6

C

30

PC13 4 12

PC5 4

119B NC

29 BATT I/P FUSE FAIL

133B 6

C

PC 10

PC 6&7

11

124B NO

28

27

12

122B NC

122B NO

C

121B

120B NO

26

FCBC - 2 DC O/P MCB TRIP

FCBC-2 AC I/P

PC4 4

11

123B C

25

15 14 PC8 11 12

10

121B NO

24

119B C

118B NC

117B NO

23

PC505 11

9

120B C

22

FCBC - 2 FCBC - 1 ON FCBC-1 FAIL

10

119B NC

21

20

19

115B NC

NC

NO

114B

113B

111B 112B

CON.401-402

18

NC

C

109B

17

PC504 11

9

NC

MCB TRIP

FAIL

16

FCBC - 1 DC O/P MCB TRIP

110B

15

NO

107B C

14

13

10

108B NO

106B NC

12

FCBC-1 AC I/P

AC MAINS

PC405 11

9

105B NO

104B C

NC

102B

101B C

103B NC

11

10

PC506 NO NC 10 9

135B

B

B

POTENTIAL FREE CONTACTS

A

NOTE :-



ALL EARTH POINTS SHOULD BE INTERCONNECTED.

1 REV

---------ECO


20/05/09 DATE

APPD

D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\A5-PFC.sch

FILE NAME

1

2

DRAWN


HEMA

3

4

5

6



TITLE

:

DATE

: 02/04/2009

: :


10

9

TB3

C

PC404 11

9

CON.401-402

11

C

10

PC407 NC 11 9

116B C

NO C


SCHEMATIC DRAWING OF 125V/50A DUAL FCBC

SHEET

7

4

OF

4

REV.

8

0

ENG-SFS-06/Rev.0

1

2

3

4

5

6

7

8

BATTERY FUSE BOX D

D

TB5

FUSW 1

1

240H

C

303H

119H

2

C

4

INTERNAL CABLE DETAILS B

DESIGNATION

CABLE SIZE IN Sq.mm

H

16.0

B

AM A R A

A

RAJA

POWER SYSTEMS LTD

-------

APPROVAL COMMENTS REV. ECO REMARKS FILE NAME D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\A7-BATT ISO-1.sch 1

2

3

4

20/05/09 DATE

DWG. NO.

Ph(0877) 2285561 to 2285565.

APPD.

DRAWN HEMA 5

CHKD. RECHKD.

CUST P.O. NO.

Registered Office & Works karakambadi - 517520

1

PROJECT : EEPC- Accelerated Electricity Access Expantion

A3

APPD.

TITLE DATE

6

: : :

Proprietary material of M/s. AMARA RAJA POWER SYSTEMS LTD., Tirupathi. All rights reserved. No copying permitted unauthorised use prohibited.

3

TO BATTERY BANK

301H

FROM CHARGER OUTPUT

TB4

A

NCC LTD NCC/EEPCO/LOT 1/PO/008

Dated : 14/03/2009

SCH - 2264 - 08 ( PCOOS/000008/08-09 )

: SCHEMATIC DRAWING OF BATTERY FUSE BOX FOR 125V DC 02/04/2009 7

SHEET

1

OF

1 8

REV

0

ENG-SFS-06/Rev.0

1

2

3

4

5

6

7

8

16A-2P-DC CB OUTGOING FEEDERS - 7 NOS

616E

615E CON.1

618E

617E

(16A)

SW 1

614E

Red E

1

24B

Black E

TB(INT)

CB8 Red

E

Black E

CB7 E Red

SW2 A2 A1

PC2 7

8

PC3 7

Black F

Red

F

Black F

AM

Red

F

Black F

F

2H

2H

Red

M2

C

8

2D

2B

22H

22B

119H

2

26

17D

VDB. BD.

M1

SH1

119H

Black E

CB6 Red

E

Black E

E Red

Red

E

Black E

CB5

CB4 Black E

E Red

1D VDB. BD.

VM

7

25

1H

17D

8

119D

(UV VDB BD.)

( 63A )

PC1

D

2B

240D

FROM CHARGER DC OUTPUT (126V +/- 1%)

C

Black E

1H

B

POTENTIAL FREE CONTACTS

LED2

DC EARTH FAULT

TB11

TB10

19

21

20

TRF.CONTL PANEL (132KV/66KV SIDE)

119B

624F

NO

623F

30

2

R2

R1

NO

253D

NO

C

29

PC 2&3

DC UV

28

DC UV

252D

251D

27

NC

LED1

TB13

C

250D

3

B

C

622F

PC 1

10

621F

C

620F

10

PC2&3 12

619F

4

FROM TB1

11

PC1

BATT EARTH FAULT

4

CB11

CB9

CB10

240B

22

SPARE

TB12

23

24

TRF.CONTL PANEL (33KV/15KV SIDE)

32A-DC-O/P FEEDERS- 3NOS NOTE :A



ALL EARTH POINTS SHOULD BE INTERCONNECTED G

17D CHASIS GROUND

1 REV

----------

APPROVAL COMMENTS

20/05/09

ECO

REMARKS

DATE

APPD

Hemalatha.k

D:\Hema\2008-2009\conv\pcoos-000008-08-09\sch-coo-08-2264-08\A1-Dcdb.sch

FILE NAME

1

2

DRAWN


3

4

5

6



TITLE

:

DATE

: 02/04/2009

: :


CB1

240H

1

Red

E

CB2

CB3

8B

TB1

18

TB 9

613E

612E

611E

610E

609E

17

16 TB8

TB7

Black E

15

14

13

TB6

608E

16.0

SPARE

SPARE

12

11

TB5

607E

H

604E

6.0

SPARE

10

9

TB4

603E

4.0

F

8

7

TB3

TB2

601E

E

6

EMERGENCY LIGHTING

33 OR 15KV ISOL AUX.SUPPLY

606E

CABLE SIZE IN Sq.mm

5

4

602E

DESIG NATION

3

605E

CABLE DETAILS

D

REMOTE TAP CHANGER132 OR 66KV ISOL CONTROL PANEL AUX.SUPPLY

33KV COMMON CONTROL CUBICLE

INTERNAL


SCHEMATIC DRAWING OF DC DISTRIBUTION BOARD

SHEET

7

1

OF

1

REV.

8

0

295102895-Battery-Charger-DCDB.pdf

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