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β STANDARD DOCUMENTATION FOR FLOAT CUM BOOST CHARGER (FCBC) AMARA RAJA POWER SYSTEMS LIMITED RENIGUNTA –

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

β

CONTENTS

SL.NO

DESCRIPTION

1.

GENERAL DESCRIPTION

2.

TECHNICAL SPECIFICATION OF THE BATTERY CHARGER

3.

AMARA RAJA STANDARD SUB-VENDOR LIST

4.

SCHEMATIC DRAWINGS

β

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 Y LC FILTER
FUNCTIONAL BLOCK DIAGRAM OF MICROBASED
FLOAT CUM BOOST CHARGER
R
AC MAINS
Y
LC FILTER
(3 PHASE)
B
TRANSFORMER
SCR BRIGE
LOAD
CONTROL CIRCUIT
BATTERY
FIRING BOARD
MICRO BOARD
SENSING BOARD

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.

β

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.

β

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

AC Mains Available

FLOAT

ON

On Float irrespective of it’s condition

FCBC will supply the Load and Float Voltage will reflect on Load

AC Mains Available

BOOST

ON

On Boost irrespective of it’s condition

FCBC will supply the Load and Boost Voltage will reflect on Load

AC Mains Fail / FCBC Fail

ANY MODE

OFF

On Discharge

Battery will supply to Load

β

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

:

415V AC ±10% (Three Phase, Four Wire) 50Hz ± 5%

b) Frequency

:

OUTPUT

a) Nominal Voltages

:

24VDC / 48VDC / 110VDC / 220VDC 25A / 50A / 75A / 100A / 125A / 150A 2% RMS (without battery connected) > 80%

b) Output Currents

:

c) Ripple

:

d) Efficiency

:

e) Operating Voltage Ranges for various Batteries with various Voltages:

Battery

 

VRLA

   

NI-CD

 

PLANTE / TUBULAR

Type

Voltages

24V

48V

110V

220V

24V

48V

110V

220V

24V

48V

110V

220V

Float

                       

Voltage

27.0V

54.0V

123.75V

247.5V

28V

56V

121.8V

243.6V

27.0V

54.0V

123.75V

247.5V

Boost

                       

Voltage

27.6V

55.2V

126.5V

253.0V

34V

68V

147.9V

295.8V

31.8V

63.6V

145.75V

291.5V

Equalize

                       

Voltage

---

---

---

---

---

---

---

---

33.0V

66.0V

151.25V

302.5V

Load

                       

Voltage

27.6V

55.2V

126.5V

253.0V

34V

68V

147.9V

295.8V

33.0V

66.0V

151.25V

302.5V

VOLTAGE REGULATION

Charger output shall be ±1% of the set value in the following conditions in set mode (FLOAT / BOOST / AUTO)

Load variation

:

10 - 100%

Line variation

:

± 10%

Frequency Variations

:

± 5%

Temperature Variations

:

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

β

i) Battery Fuse Fail

:

Red LED

j) Battery Earth Fault

:

Red LED

k) Charger Fail

:

Red LED

l) Group Alarm

:

Red LED

m) Load Under Voltage

:

Red LED

n) Load Over Voltage

:

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 :

Both LCD and LED indication

b) SCR fuse Fail

:

Both LCD and LED indication

c) Battery fuses fail

:

Both LCD and LED indication

d) Charger Fail

:

Both LCD and LED indication

e) Charger Under Voltage

:

Both LCD and LED indication

f) Charger Over Voltage

:

Both LCD and LED indication

g) Battery Earth fault

:

Both LCD and LED indication

h) Group alarm

:

Both LCD and LED indication

i) Load under voltage

:

Both LCD and LED indication

j) Load over voltage

:

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

β

d) DC overload

e) DC output circuit breaker

f) Battery input fuses

g) 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

:

-5 ºC to +50 ºC

Storage

:

25 ºC + 70 ºC

Relative humidity

:

0 – 95% (non condensing)

Noise level

:

< 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
NOTE
RATING WISE DIMENSIONAL DRAWING & INTERNAL COMPONENT
LAYOUT DRAWING WILL BE PROVIDED ON REQUEST

β

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

β

AC INPUT

TB TB D R LAST + CELL CIRCUIT Y BREAKER BATTERY CIRCUIT FCBC INPUT BREAKER
TB
TB
D
R
LAST
+
CELL
CIRCUIT
Y
BREAKER
BATTERY
CIRCUIT
FCBC
INPUT
BREAKER
B
FUSES
-
1st
N
Cell
TB
+

TO

BATTERY

BANK

TO

LOAD/DCDB

FUNCTIONAL BLOCK DIAGRAM OF FLOAT CUM BOOST CHARGER

1 2 3 4 5 6 7 8 9 10 11 A1 A6 A .E6
1
2
3
4
5
6
7
8
9
10
11
A1
A6
A
.E6
2.E6
-H1
A2
A5
.E6
2.D6
-H2
A3
A4
.E6
2.D6
-H3
-SCR R
-SCR R
D2
A7
D1
A99
B27
B33
-T1
B34
2.E6
-X1
B28
2.E6
-Q1
2.E6
2.E6
-CT1
A7
A1
A4
A4
H1
X1
B
+
-
M
G
R
-SCR Y
-SCR Y
CN.[CT1]
D2
A10
D1
-CT2
B29
B35
A2
A5
A5
2.E5
B36
2.E6
H2
H3
X3
X2
B30
-F2
2.E5
2.E6
A8
A10
+
-
M
G
Y
CN.[CT2]
A8
A10
-CT3
-SCR B
-SCR B
A3
A6
A6
D2
A11
D1
+
-
M
G
B31
B37
B
C
B32
2.E5
B38
2.E5
-F3
2.E5
2.E5
A9
A11
A99
A99
D1
CN.[CT3]
2.C2
A9
A11
N
D2
D2
2.B2
-F1
-SC1
-S1
B2
L
N
D
G
B99
\
s
l
i
-S2
-B1
-E1
a
t
e
B3
B4
D
C
B
C
F
-T2
\
n
o
i
s
-DL1
CN.A
r
e
B19
4
X1
H1
V
-DS1
A4
.A4
B20
a
t
X2
3
e
B5
B21
B
X3
2
t
E
f
i
B22
w
X0
1
H2
A5
.A4
S
\
p
o
t
k
CN.A
s
B23
e
1
F1
Y1
8
H3
A6
.A4
D
\
.G9
B24
b
r
Y2
7
2
j
\
B25
s
Y3
6
g
B26
n
3
i
(AT-5174)
t
2.G6
Y0
5
t
e
-PC3
S
4
d
CN.[T2]
n
a
MICRO BOARD
5
s
t
CN.[PC2(20)]
n
e
6
A11
m
u
.C8
c
7
o
A9
D
\
.C8
:
1
2
34 PIN
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
8
1
CN.2
CN.4
CN.6
C
1
A8
CN.20
CN.10
CN.4
CN.3
-
CN.6
F
2
CN.2
CN.1
+
M
G
.C7
2
9
CN.19
3
16 Pin
34 Pin
A10
-PC2
1
.C8
4
2
CN.5
CN.9
5
U29
3
SENSING BOARD
2.B9
4
6
U30
CN.7
CN.8
CN.[PC3(2)]
7
CN.18
CN.16
CN.15
CN.14
CN.13
CN.12
CN.11
2.B9
CN.17
+
-
M
G
E
L-
L+
B-
B+
8
CN.[PC3(4)]
CN.[PC3(6)]
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
1
2
3
4
1
2
3
4
5
6
7
8
U31
2.B9
CN.[PC2(8)]
F2
F1
B26
U32
2.G5
.E3
2.G6
2.B9
FLAT CABLE
FLAT CABLE
J1
2.E4
CN.[PC2(5)]
J2
2.E4
J3
2.E9
J4
2.E9
G
B99
U25
2.B8
U24
2.B8
U23
2.B8
U22
2.B8
-X2
FCBC
GROUP
CHARGER
BATTERY
SCR FUSE
DC UV
FLOAT ON BOOST ON
DC OV
ALARM
FAIL
EF
FAIL
H
POTENTIAL FREE CONTACTS
DATE
01/02/13
SIGN
PROJECT
:
A M
A
A
R
A
R
A
J
DRG. NO
:
SCH - XX-XXXX
DRAWN
JRB
CUST
:
POWER
SYSTEMS
LTD
Registered Office & Works.
CONSULTANCY :
CHKD.
REV
:
THIS
1
Karakambadi-517520,Tirupati (AP)
P.O.NO.
:
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
SALE ORDER NO : - - - - -
REV
ECO
REMARKS
DATE
APPD.
APPD.
Ph.(0877) 2265000
LOC. :
NEXT
2
1
2
3
4
5
6
7
8
9
10
11
PATH
:
ITEM CODE:
VARIANT
:
AC INPUT
415V AC +/- 10%
B1
A99
A1
U1
U2
U3
CN.[PC2(18)]
U4
A99
U5
U6
CN.[PC2(17)]
FLAT CABLE
U7
U8
U9
CN.[PC2(10)]
CN.[PC2(16)]
U10
CN.[PC2(4)]
U11
B7
U12
B8
CN.[PC2(15)]
B9
B10
U13
U14
CN.[PC2(3)]
U15
B11
CN.[PC2(14)]
B12
B13
U16
B14
U17
U18
CN.[PC2(2)]
CN.[PC2(13)]
B15
U19
B16
U20
B17
U21
B18
CN.[PC2(12)]
U26
CN.[PC2(1)]
U27
U28
CN.[PC2(11)]
2.G3
CN.[PC2(7)]
2.F3
2.F3
.F2
.F2
.F2
.F2
CN.5

A

B

C

D

E

F

G

H

1 2 3 4 5 6 7 8 9 10 11 A -X3 -Q2 -CT4
1
2
3
4
5
6
7
8
9
10
11
A
-X3
-Q2
-CT4
-L1
-F4 AUX
D2
D3
D4
J4
J4
J2
1.D11
+
-
M
G
-SH1
-F4
D3
-C1
-R1
B
CN.[CT4]
-R2
-C2
TO BATTERY
+
D1
-V1
-F5 AUX
+
D1
D1
D1
D5
J3
J1
1.C11
D1
D4
-F5
C
-X4
J4
-T3
D
CN.B
A4
H1
1.A4
TO LOAD
CN.[T3]
A5
X1
1
H2
1.A4
\
s
l
i
X2
2
a
t
e
X3
3
+
D
A6
C
X0
4
J3
H3
1.A4
B
C
F
\
n
o
i
s
r
e
V
a
t
e
B
t
E
f
i
J4
w
S
1.G6
\
p
o
t
k
s
e
D
\
b
r
j
\
s
g
J3
n
i
t
1.G6
t
e
S
d
n
a
s
t
n
e
m
u
c
o
D
\
:
C
C2
F
.B5
C1
.B5
B25
1.F5
D1
-PC1
.C5
B24
1.F5
B23
D4
1.F5
.C5
CN.[PC1(2)]
CN.[PC1(3)]
CN.9
16 PIN
1
2
G
CN.[PC1(4)]
CN.[PC4(9)]
F2
1.G8
B26
FLAT CABLE
1.E2
B26
1.G10
FCBC
H
DATE
01/02/13
SIGN
PROJECT
:
A M
A
24V/25A; 50A; 75A; 100A; 125A & 150A FCBC
A
R
A
R
A
J
DRG. NO
:
SCH - XX-XXXX
DRAWN
JRB
CUST
:
POWER
SYSTEMS
LTD
Registered Office & Works.
CONSULTANCY :
CHKD.
48V/25A; 50A; 75A; 100A; 125A & 150A FCBC
110V/25A; 50A; 75A; 100A; 125A & 150A FCBC
220V/25A; 50A; 75A; 100A; 125A & 150A FCBC
REV
:
THIS
2
Karakambadi-517520,Tirupati (AP)
SALE ORDER NO : - - - - -
P.O.NO.
:
REV
ECO
REMARKS
DATE
APPD.
APPD.
Ph.(0877) 2265000
LOC. :
NEXT
1
2
3
4
5
6
7
8
9
10
11
PATH
:
ITEM CODE:
VARIANT
:
D2
D3
1
2
3
4
CN.2
CN.1
B39
L1
1
B40
L2
2
B41
L3
3
4
J1
BATT+VE
5
1.G6
6
7
CN.4
J2
1.G6
BATT-VE
8
CN.[PC1(1)]
FIRING BOARD
.F7
C1
.F7
CN.7
B32
C2
G2
1
1.C9
.G7
.F7
B31
K2
2
1.C9
B38
G1
3
1.C10
B37
K1
4
1.C10
CN.[PC1(7)]
CN.6
B30
G2
1
1.C9
B29
K2
2
1.B9
B36
G1
3
1.C10
B35
K1
4
1.B10
CN.[PC1(6)]
CN.5
B28
G2
1
1.B9
B27
K2
2
1.B9
B34
G1
3
1.B10
B33
K1
4
1.B10
CN.3
CN.[PC1(5)]
1
2
3
4
5
6
U22
1.G5
U23
1.G5
U24
1.G5
U25
1.G5
U29
U31
1.F2
1.F2
U30
U32
1.F2
1.G2

A

B

C

D

E

F

G

H