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STANDARD DOCUMENTATION FOR FLOAT CUM BOOST CHARGER (FCBC)
AMARA RAJA POWER SYSTEMS LIMITED RENIGUNTA – KADAPA ROAD KARAKAMBADI – 517 520 TIRUPATI, ANDHRA PRADESH Tel: +91 877 2265000 Fax: +91 877 2285551
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CONTENTS SL.NO
DESCRIPTION
1.
GENERAL DESCRIPTION
2.
TECHNICAL SPECIFICATION OF THE BATTERY CHARGER
3.
AMARA RAJA STANDARD SUB-VENDOR LIST
4.
SCHEMATIC DRAWINGS
Page 2 of 9
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GENERAL DESCRIPTION The Battery Charger is a rectifier unit which works on 3-phase AC input power supply and gives required DC voltage as output, delivering certain amount of power as demanded by the application. Conventionally this kind of rectifier unit is controlled manually and is analog control. However the analog portion of the control circuit has been replaced here in micro charger with a micro-controller. Advanced micro-controller has been selected for this application and this controller section provides accuracy of operations. Block diagram of one such rectifier unit is shown in Fig. 1.
FUNCTIONAL BLOCK DIAGRAM OF MICROBASED FLOAT CUM BOOST CHARGER R AC MAINS (3 PHASE)
Y B
LC FILTER TRANSFORMER
LOAD
SCR BRIGE
CONTROL CIRCUIT FIRING BOARD
MICRO BOARD
SENSING BOARD
BATTERY
Fig. 1
Rectifier unit consists of a transformer to bring the input voltage to a required level and also to provide isolation between input and output. The secondary of the isolation transformer is fed to SCR Bridge. Initially SCRs will be fired slowly for DC soft start and controls the phase angle depending upon the output voltage of the charger. The rectified DC is connected to filter section which in turn filters out all harmonics and provide DC voltage with low ripple content. Charger mode of operation can be selected through LCD. The charger will work in FLOAT, BOOST and AUTO modes. In any mode, monitoring and controlling happens through micro board. Charger feedback signals are fed to micro board based on that it generates reference signal. Micro board is provided at front panel to display charger parameters, load parameters and battery parameters in LCD. Micro board is having LED indicators for different operating conditions like Float ON, Boost ON, Charger ON, Mains ON, charger over voltage, charger under voltage, battery fuse fail, SCR fuse fail, load under voltage, load over voltage etc. Based on faulty condition appropriate LED glow & actuates audio alarm. This audio alarm can be disabled or silenced by setting buzzer in LCD set parameters menu. However, indicating LED will be glowing continuously until the fault is rectified.
Page 3 of 9
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The firing board receives the voltage and current reference signals from micro board. It generates SCR firing signals based on reference and feedback signals. Sensing board senses different faulty condition like Rectifier fuse fail, Earth fault etc. and send it to micro board for alarms generation. Sensing board is also having potential free contacts for alarm conditions.
PRINCIPLE OF OPERATION During normal operation, Float cum Boost Charger works as Float Charger and takes care of load and battery float charging requirements. Float cum Boost Charger has two modes of operation “AUTO” & “MANUAL”. Under AUTO MODE, Float cum Boost Charger can either act as an Auto Float Charger or an Auto Boost Charger depending on the Battery current requirement. Manual intervention is not required when the Float cum Boost Charger is selected to AUTO MODE. Float cum Boost Charger is provided with provision of MANUAL FLOAT and MANUAL BOOST Modes in which battery can be charged either in FLOAT or BOOST by manual selection. On failure of AC Mains Supply to Float cum Boost Charger or if Float cum Boost Charger itself fails, Battery starts supplying to the load. Once the AC Mains Supply to FCBC restores or if failed FCBC is rectified, FCBC switches over to Float Mode or Boost Mode based on the Battery charging requirements if the charger is kept in AUTO mode of operation.
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LOGIC SHEET OF FLOAT CUM BOOST CHARGER
System Conditon
Charger Mode
FCBC
Battery
Load
AC Mains Available & Battery is healthy
AUTO
ON
On Float
FCBC will supply the Load and Float Voltage will reflect on Load
AC Mains Available & Battery is in Discharged Condition
AUTO
ON
On Boost
FCBC will supply the Load and Boost Voltage will reflect on Load FCBC will supply the Load and Float Voltage will reflect on Load
AC Mains Available
FLOAT
ON
On Float irrespective of it’s condition
AC Mains Available
BOOST
ON
On Boost irrespective of it’s condition
FCBC will supply the Load and Boost Voltage will reflect on Load
ANY MODE
OFF
On Discharge
Battery will supply to Load
AC Mains Fail / FCBC Fail
Page 5 of 9
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TECHNICAL SPECIFICATION OF THE BATTERY CHARGER Scheme Type Type of battery
: : :
Float cum Boost Charger Full Wave Full Controlled Suitable for VRLA / NI-CD / PLANTE / TUBULAR
INPUT a) Three phase Input b) Frequency
: :
415V AC ±10% (Three Phase, Four Wire) 50Hz ± 5%
OUTPUT a) Nominal Voltages b) Output Currents c) Ripple d) Efficiency
: : : :
24VDC / 48VDC / 110VDC / 220VDC 25A / 50A / 75A / 100A / 125A / 150A 2% RMS (without battery connected) > 80%
e) Operating Voltage Ranges for various Batteries with various Voltages: Battery Type
VRLA
Voltages
24V
48V
Float Voltage
27.0V
54.0V
Boost Voltage
27.6V
Equalize Voltage Load Voltage
110V
NI-CD 220V
24V
48V
123.75V 247.5V
28V
56V
55.2V
126.5V
253.0V
34V
68V
---
---
---
---
---
---
27.6V
55.2V
126.5V
253.0V
34V
68V
110V
PLANTE / TUBULAR 24V
48V
121.8V 243.6V
27.0V
54.0V
123.75V 247.5V
147.9V 295.8V
31.8V
63.6V
145.75V 291.5V
33.0V
66.0V
151.25V 302.5V
33.0V
66.0V
151.25V 302.5V
---
220V
---
147.9V 295.8V
110V
220V
VOLTAGE REGULATION Charger output shall be ±1% of the set value in the following conditions in set mode (FLOAT / BOOST / AUTO) Load variation Line variation Frequency Variations Temperature Variations
: : : :
10 - 100% ± 10% ± 5% 0 - 50 ºC
INDICATIONS Cluster LED Lamps will be provided for “AC I/P Available (R, Y, B)” Also, the following indications will be indicated by 5mm LEDs: a) Mains ON : Green LED b) Charger ON : Green LED c) Float ON : Green LED d) Boost ON : Amber LED e) AC Supply Fail/Out of Limit: Red LED f) Charger Over Voltage : Red LED g) Charger Under Voltage : Red LED h) SCR Fuse Fail : Red LED Page 6 of 9
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i) j) k) l) m) n)
Battery Fuse Fail Battery Earth Fault Charger Fail Group Alarm Load Under Voltage Load Over Voltage
: : : : : :
Red LED Red LED Red LED Red LED Red LED Red LED
DISPLAY The following parameters will be displayed on LCD: a) AC input voltage either Line to Line or Line to Neutral b) AC input current in each phase c) Charger output voltage d) Charger output current e) Battery Voltage f) Battery charging current / discharging current g) Load voltage h) Load current i) Charger ON/OFF j) Alarms ALARMS WITH BUZZER a) AC mains fail or out of limit : b) SCR fuse Fail : c) Battery fuses fail : d) Charger Fail : e) Charger Under Voltage : f) Charger Over Voltage : g) Battery Earth fault : h) Group alarm : i) Load under voltage : j) Load over voltage :
Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication Both LCD and LED indication
POTENTIAL FREE CONTACTS The following Potential Free Contacts will be available: a) Float ON b) Boost ON c) Rectifiers Fuse Fail d) Charger Fail e) Charger Under Voltage f) Charger Over Voltage g) Battery Earth Fault h) Group Alarm PROTECTIONS The following protections will be provided: a) AC Input circuit breaker b) Fast acting semiconductor fuse for SCR bridge c) DC over voltage cutback/Shut down
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d) e) f) g)
DC overload DC output circuit breaker Battery input fuses Battery current limiting.
CONTROLS a) AC input ON/OFF Circuit Breaker b) DC output ON/OFF Circuit Breaker c) Battery input fuses d) Push buttons : Menu button; Increment button; Decrement button; Enter button; Escape button ENVIRONMENTAL STABILITY Operating Temperature Storage Relative humidity Noise level
: : : :
-5 ºC to +50 ºC 25 ºC + 70 ºC 0 – 95% (non condensing) < 70 dB (A)
SPECIAL FEATURES a) Auto phase reversal operation b) Soft start on DC side c) Class-F insulation with Class-F temperature limits for all magnetics d) Automatic voltage regulation using digital control Logic e) Filter circuit to limit ripple f) Charger current limiting g) Battery current limiting h) Automatic Float to Boost changeover based on current drawn by battery i) Automatic Boost to Float changeover based on current or voltage. j) Anti condensation heaters with thermostat control k) Remote shut down l) Blocking Diode short sensing GENERAL Cabinet
:
Freestanding cabinet; Floor mounting type, Sheet steel construction; Easy for installation and Maintenance; Components are accessible from front & Rear; Cable entry at bottom
Protection
:
IP – 42
Paint Shade
:
Exterior: Mat Black RAL-9005 Interior : Glossy Orange RAL-2000
Nature of Cooling
:
Natural Air Cooling
Dimensions in mm
:
As per the Dimensional Drawings
NOTE RATING WISE DIMENSIONAL DRAWING & INTERNAL COMPONENT LAYOUT DRAWING WILL BE PROVIDED ON REQUEST
Page 8 of 9
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AMARA RAJA STANDARD SUB-VENDOR LIST
SL.NO.
ITEM / COMPONENT
SUB-VENDOR / SUPPLIER
1.
ELECTROLYTIC CAPACITORS
ALCON
2.
POWER FUSES / FUSE BASES
BUSSMANN
3.
PCBs (CONTROL CARDS)
AMARA RAJA POWER SYSTEMS LIMITED
4.
MCCBs
SCHNEIDER / C&S
5.
MCBs
SCHNEIDER / C&S / LEGRAND
6.
SCRs / DIODES
HIRECT / RIR
7.
MAGNETICS
AMARA RAJA POWER SYSTEMS LIMITED
8.
CABINET
MANGAL INDUSTRIES LIMITED
9.
TERMINAL BLOCKS
ELMEX
10. CABLES / WIRES
IS:694 APPROVED MAKES
Page 9 of 9
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TB
TB
D R
Y
AC INPUT B
CIRCUIT BREAKER
+
FCBC
CIRCUIT BREAKER
LAST CELL
TO BATTERY BANK
BATTERY INPUT FUSES
-
N
1st Cell
TB
+ TO LOAD/DCDB
FUNCTIONAL BLOCK DIAGRAM OF FLOAT CUM BOOST CHARGER
1
2
A
3
5
4
A1
A6
6
7
8
9
11
10
.E6 2.E6
-H1 A99
A2
A5
A
.E6 2.D6
-H2 A3
A4
.E6 2.D6
-H3 D2
A99
-X1
-Q1
-CT1 A4 -
X1
H1
D2
A5
A5 +
-
H2
H3
X3
X2
-SCR Y
A8
-CT3
-F3
A9 A99
A99
-SCR B
-SCR B
A11 B31 B32
D1 B37 B38
2.E5
2.E5 2.E5
2.E5
A11
C
D1
CN.[CT3]
A9
2.C2
A11
.F2
A1
N
D2
D2
.F2
B
D2
- M G
2.E6 2.E6
A10
A6 +
D1 B35 B36
2.E5 2.E5
A10
.F2
A6
A3
B
-SCR Y
A10 B29 B30
-F2
A8
M G
CN.[CT2]
.F2
C
415V AC +/- 10%
AC INPUT
CN.[CT1] A2
2.E6 2.E6
M G
-CT2 Y
D1 B33 B34
2.E6 2.E6
A7
A4 +
R
-SCR R
A7 B27 B28
-T1
A1
B
-SCR R
2.B2
-F1 -SC1 N
D
G
B18
B16 B17
B14 B15
B8 B9
B7
-E1
-T2
-DL1
CN.[PC2(1)]
B25
A4
H1
A5
H2
A6
H3
.A4
.A4
E 1
.A4
2 3
(AT-5174)
-PC3 MICRO BOARD
CN.[T2] 2.F3
CN.[PC2(2)]
B24
2.F3
A11
CN.A 8 Y1 7 Y2 6 Y3 5 Y0
B23
2.G3
CN.[PC2(20)]
CN.[PC2(3)]
CN.[PC2(10)]
FLAT CABLE
.G9
.C8
CN.[PC2(4)]
F1
B26
2.G6
CN.A 4 X1 3 X2 2 X3 1 X0
B19 B20 B21 B22
CN.5
A99
B4
B1
-B1
B5
7
A8
.C7
1
CN.20
34 PIN
2
1 2 3 4 CN.4
CN.10
5
CN.5
6
U30
2.B9
7 8
U31
2.B9
CN.18 C
1 2 3 4
1 2 3 4
1 2 3 4
CN.3
CN.2
CN.1
1 2 3 4 +
- M G CN.19
-PC2 SENSING BOARD
4
U29
2.B9
1 2 3
A10
.C8
NC
CN.16
CN.17
NO
C
NC
C
NO
NC
CN.15
NO
C
NC
CN.13
CN.14
NO
C
NC
NO
C
NC
CN.12 C
NO
NC
CN.11
NO
C
NC
+
CN.7 - M G
E L-
CN.8 L+
B-
2 1 2 3 4
U28
CN.[PC2(7)]
CN.[PC2(11)]
U26 U27
CN.[PC2(12)]
U19 U20 U21
U18
CN.[PC2(13)]
U16 U17
U14 U15
CN.[PC2(14)]
U13
CN.[PC2(15)]
U10 U11
CN.[PC2(16)]
U12
U7 U9
U8
CN.[PC2(17)]
U4 U5
U2
U1
CN.[PC2(18)] U3
J2 J3 J4 B99
U24 U23
U6
U22
-X2 DC UV
16 Pin
34 Pin
8
CN.6
F
9
CN.[PC3(4)]
J1
U25
GROUP CHARGER BATTERY SCR FUSE ALARM FAIL EF FAIL
CN.4
CN.[PC3(2)]
B+
2.G5
G
CN.2
1 2 3 4 5 6 7 8
1 2 3 4
NO
1
CN.[PC2(8)] CN.[PC2(5)]
H
CN.6
CN.9
U32
2.B9
4 5 6
A9
.C8 :
:
B3
-DS1
VARIANT
PATH
F
-S2
ITEM CODE:
E
\ls ia te D BC C F\ no is re V tae Bt ifw S\ po kts eD \b jr\ gsn ti eS dn a tsn e m cuo D \: C
B12
B99 B13
L
B11
B2
B10
-S1
D
F2 FLAT CABLE
.E3
CN.[PC3(6)]
F1
B26
FLAT CABLE
2.G6
2.E4 2.E4 2.E9 2.E9
G
2.B8 2.B8 2.B8 2.B8
FCBC
FLOAT ON BOOST ON DC OV
H
POTENTIAL FREE CONTACTS
01/02/13 JRB
DATE DRAWN CHKD. REV
1
REMARKS
ECO
2
DATE
3
APPD.
APPD.
4
SIGN
AM
PROJECT : CUST : CONSULTANCY : P.O.NO. :
5
A R A R A J
POWER
SYSTEMS
A LTD
Registered Office & Works. Karakambadi-517520,Tirupati (AP) Ph.(0877) 2265000
6
7
24V/25A; 50A; 75A; 100A; 125A & 150A FCBC 48V/25A; 50A; 75A; 100A; 125A & 150A FCBC 110V/25A; 50A; 75A; 100A; 125A & 150A FCBC 220V/25A; 50A; 75A; 100A; 125A & 150A FCBC 8 9
: SCH
DRG. NO
- XX-XXXX
SALE ORDER NO : - - - - -
10
11
REV :
THIS
1
LOC. :
NEXT
2
1
2
3
5
4
6
7
8
9
11
10
D1 D1
D5
U32
-F4 1.F2
B
TO BATTERY
U24
U25
1.G5
-V1
D1
C
1.G5
D1 D1
1.G5
+
U22
-C2
J2
M G
1.F2
-
CN.[CT4]
-R2
1.C11
J4 +
U23
-R1
J4
1.G5
-C1
D3
B
D4
-SH1
D3
-F5 AUX
U30
D3
-X3
-F4 AUX
U29
D2 D2
1.D11
-CT4
A
1.G2
1.F2
-Q2
-L1
U31
.F7 C2
C1
.F7
A
J3
+
J1
-F5
D4
.F7
.G7
C
-X4 J4
-T3 D
CN.B
A4
H1
1.A4
1.A4
+
3 X3 X0
A6
H3
J3
1.A4
K1
B33 4
G1
C2
1.G6
F
.B5
5
.C5
3
4
D1
2
CN.3
-PC1
D4
.C5
1
G
E
1.G6
.B5
C1 6
3
K2
CN.[PC1(5)]
B34
B28 1
2
G2
B27
CN.[PC1(6)]
B35 4
CN.5
K1
1.B9 1.B9 1.B10 1.B10
1.C9 1.B9 1.C10 1.B10 B36 3 G1
CN.[PC1(7)]
B30
2 K2
B29 1 G2
4 K1
CN.6
B38 3 G1
B31 1
2 K2
CN.7
G2
FIRING BOARD
B37
B32
1.C9 1.C9 1.C10 1.C10
1.G6
CN.[PC1(1)]
1.G6
J2 BATT-VE
B23
J3
CN.[PC1(2)] CN.4
1.F5
J4
8
J1 6
4
5
BATT+VE
4
B24
L1 1 L2 2 L3 3
CN.1
B25
1
1.F5
2 3 CN.2
1.F5
7
B39
B40 B41
4
:
:
A5
H2
2 X2
VARIANT
PATH
F
1 X1
ITEM CODE:
E
\ls ia te D BC C F\ no is re V tae Bt ifw S\ po kts eD \b jr\ gsn ti eS dn a tsn e m cuo D \: C
D
TO LOAD
CN.[T3]
CN.[PC1(3)]
CN.9 16 PIN
1
2
G
CN.[PC1(4)] CN.[PC4(9)] F2
1.G8
FLAT CABLE
B26 B26
1.E2 1.G10
FCBC
H
H 01/02/13 JRB
DATE DRAWN CHKD. REV
1
REMARKS
ECO
2
DATE
3
APPD.
APPD.
4
SIGN
AM
PROJECT : CUST : CONSULTANCY : P.O.NO. :
5
A R A R A J
POWER
SYSTEMS
A LTD
Registered Office & Works. Karakambadi-517520,Tirupati (AP) Ph.(0877) 2265000
6
7
24V/25A; 50A; 75A; 100A; 125A & 150A FCBC 48V/25A; 50A; 75A; 100A; 125A & 150A FCBC 110V/25A; 50A; 75A; 100A; 125A & 150A FCBC 220V/25A; 50A; 75A; 100A; 125A & 150A FCBC 8 9
: SCH
DRG. NO
- XX-XXXX
SALE ORDER NO : - - - - -
10
11
REV :
THIS
LOC. :
NEXT
2
