Battery

Charger

Maintenance Handbook on Battery Charger June, 2002

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Index

1. GENERAL
2. MAINTENANCE
3. TROUBLE SHOOTING
4. DO’S AND DONT’S
5. LIST OF TOOLS

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CHAPTER 1

GENERAL

1.0 INTRODUCTION

Battery is the only device to utilize the stored

electrical energy back. To store the energy in the battery,
it needs to be charged. Charging/Recharging is done by
feeding the D.C. energy through the Battery Charger. The
Battery Charger is a device to convert the AC source
(which is very easily available) in D.C. source. This
DC supply is fed to battery with proper rating.

The specific gravity of battery should be

checked which should be as specified by the battery
FIGURE 1.1
manufacturer. The battery when fully discharged,
its output voltage is FRONT PANEL OF BATTERY approximately 1.8 volts/cell.
CHARGER
The output current from battery will be available for
very short period when cell voltage will be 1.8 volts/cell. This condition is known as
“Discharged Battery”. Now, the battery must be charged with appropriate voltage. Higher
voltage will pass higher current and the battery plates will get overheated. The result of this
overheating will buckle the lead plates provided in the battery and this way battery gets
damaged. Hence it is very much essential to check up the charging current of battery.

Charging current should be as specified by manufacturer. Generally the charging

current for 110 volts (54/56 cells) battery should be at C-10 rate. Higher current may be
passed but it should be for very small period for quick charging.
Battery charging should be done with taper characteristic. When battery is in
discharged condition, it should be applied lower voltage i.e. about 2.0 Volts/cell which
should be sufficient to pass specified current. Thereafter voltage should be increased by small

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steps so that battery voltage reaches 2.2 Volts/cell. The battery when charged, gives about 2.2
& above Volts/cell. This voltage is known as gassing voltage. Thereafter battery should be
put on “trickle” charge till the voltage comes up to 2.5 volts/cell. This voltage should be
applied for 5 to 6 hours. Thereafter battery is in “fully” charged condition and ready for use.
Check up the specific gravity of battery as per battery manufacturer’s instruction and it
should be same for three consecutive reading.
Before connecting the charger to battery, it must be checked about its polarity. +Ve of
charger output must be connected to battery +Ve & -Ve of charger output to –Ve of battery.
Reverse connection will short the battery through diodes and heavy short circuit current will
pass through rectifier diodes resulting in overload and damage of diodes.
1.1 MAIN PARTS

The battery charger is a robust machine, which is having no moving parts. Following
are the main parts of battery chargers :

(i) TRANSFORMER

This is a dry type, air natural cooled, copper wound, varnish impregnated 3 phase
transformer working on 360/440 volts 50c/s. The transformer is rated for continuous
operation. The insulation is Class ‘F’. The tapping are provided on primary to adjust the
output voltage in between 130 to 150 V DC at 200 Amps.

FIGURE 1.2

STEP DOWN TRANSFORMER

(ii) RECTIFIERS
The rectifiers are working on 3 phase full wave bridge provided with R.C. network to
protect against voltage surges. The capacity of the bridge is about 2 times the normal rating
of the charger. Silicon diode of reverse polarity 150 Amps. 600 Volts are used. Diode is semi
conductor device (solid state) and hence it does not have any ageing property.

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(iii) CONTROL
Taps are provided on primary side to vary input voltage from 415 V to 450 V with the
help of rotary switch and fine control switch having 4/6 positions. The charger is provided
with ON/OFF switch along with HRC fuses for back up protection on input side.

COARSE CONTROL FINE CONTROL

FIGURE 1.3
(iv) PROTECTION
CONTROL SWITCHES
Following devices are provided for protection purpose :

A. ON/OFF Switch : This is a 3 phase switch isolating the main supply.

FIGURE 1.4

'ON AND 'OFF' SWITCHES

B. HRC Fuses are provided on the mains incoming

C. Contactor is provided for switching on the unit on load. Contactor gets switched off if
there is a single phasing or over load on the output side.

D. Overload Relay : An over load relay is provided on the mains line. This overload
bimetallic relay will switch off the mains contactor due to overloading. This relay
also protect the unit from single phasing.
E. ELR (Earthing Leakage Relay) is provided to protect the unit from earth fault. This
ELR will trip if fault current exceeds the set value.
F. HRC Fuses are provided on the output side to protect the unit from short circuit and
overload.

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FIGURE 1.5
HRC FUSES
G. MCCB : 3 pole MCCB is provided on the
output side. This MCCB will trip due to
overload and isolate the output supply.
H. Indicating pilot lamps are provided on the
mains FIGURE 1.6 incoming and D.C. output.

OUTPUT MCCB
(v) METER

There is a ammeter for each feeder and there are two outgoing feeders. The ammeter
is provided with shunt in the bus-bar. A.C. voltmeter alongwith selector switch is provided to
indicate A.C. voltage. Meters are also provided to measure DC output voltage and current.
Digital meter should be preferable and it must be caliberated.

FIGURE 1.7

PANEL METERS

(vi) VENTILATION

For ventilation purpose, expanded metal is used at the bottom and canopy type cover
is provided on the top. The cover is approximately 30 to 40 mm above top of frame/body.

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This helps for free ventilation. Fresh air will be coming from the bottom of the unit and hot
air will be passing from the top. It is advised to see that there is good path for passing the air
from bottom. For, this purpose, unit should be about 0.5 meter away from the wall and top of
the charging room should have sufficient ventilators to pass the air freely.

FIGURE 1.8

TOP OF THE BATTERY CHARGER

(vii) EARTHING

2 Nos. earthings are provided on the side of battery charger and they should be
connected properly.

1.2 TYPE & CAPACITIES OF BATTERY CHARGERS USED IN RAILWAYS.

Type - I Chargers for charging battery of 56 lead acid cells of 2Volts, 800 AH capacity
- 110 Volts.

Type - II Chargers for charging 18 mono block (3 cells per monoblock) lead acid cells
of 6 V, 120 AH capacity - 110 volts.

*****

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LIST OF COMPONENT OF FIGURE 1.9

SR.No. Name of Component Capacity
S1 On/Off Rotary Switch 60A, 3Pole
F1-F2-F3 HRC Fuse 63A
H1-H2-H3 Indicating lamp 230V AC
K1 Contactor 63A, 415V AC
ELCB Earth leakage circuit breaker 63A, 300mA
KWH Kilo watt hour meter 100/5A, 3Ph
CT1,CT2,C Current transformer 100/5A
T3
V1 Voltmeter 0-500 V AC
VSS Voltmeter selector switch 6A
L1,L2,L3 Choke 60 A
T1 Transformer 35 KVA
S2-S3 Rotary switch 60A, 3P, 4WAY
O/L Over load relay-MN5 30 - 50A
D Diode 150 A
MCCB Moulded case circuit breaker 200 A
H4 Indicating lamp 150 V, DC
V2 Voltmeter 0 - 200V, DC
A1,A2,A3 Ammeter 0 - 300A. DC
SH Shunt 300A, 75 mV
F4-F7 HRC fuse link 200 A
S4-S5 Knife Switch 200 A
P1 Push button with NC element 10 A
P2 Push button with NO element 10 A

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CHAPTER 2

MAINTENANCE

2.0 MAINTENANCE SCHEDULES

2.1 MONTHLY

i. Clean outside body by dry cloth.

ii. Inspect the indication lamps for proper working.

iii. Inspect the measuring instruments like ammeter and voltmeter for proper working.

iv. Inspect the power circuit and control circuit fuses.

v. Tighten all electrical connections.

vi. Check earth connections.

vii. Check panel terminals for overheating.

viii. Check output cables lugs for overheating.

ix. Check output DC voltage at outgoing terminals w.r.t. setting voltage.

2.2. HALF YEARLY

i. Clean the contact tips of contactor, replace if required.

ii. Check the cleanliness of fuse grips of power circuit, make sure it is not loose.
iii. Check setting of overload relay.
iv. Check the terminals of rotary switches for burn/defect.

2.3 PERIODIC OVERHAULING OF BATTERY CHARGERS (Yearly)

1. Dismantle side covers, top covers.

2. Blow jet dry compressed air to remove dust and dirt.
3. Inspect the condition of transformer assembly, rectifier assembly, fuse assembly and
wiring.

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4. Check condition of bus bar heat sink, main diodes. Replace if found
damaged/defective. The polarity of silicon diode must be checked before replacement
of new diode.
5. Check the condition of transformer winding and other electrical parameter. If the
transformer is found defective, take for rewinding.

6. Check the condition of rotary switches, push buttons. Clean and attend them for minor
repairs. Replace with new one if found burnt/defective. The terminals of the rotary
switch should be kept tightened.

7. Check all fuses and replace with new one if found defective.

8. Remove and clean thoroughly terminal board assembly. Replace components with
new one if found damaged/defective.

9. Check the tapping of the transformer and attend damaged portion.

10. Replace burnt-out/defective wires/cables of terminal board.

11. Remove the Ammeter, Voltmeter and send it to test room for overhauling and
calibration.

12. Check all joints and connections of primary and secondary winding.

13. Check the insulation and earth resistance wire of the charger.

14. Paint the control panel, if required.

15. Check the electrical parameters such as voltage, current, temperature rise and record.
Also check the performance of the equipment for 4 hours.

*****

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CHAPTER 3

TROUBLE SHOOTING

Sr Trouble Causes Remedies

1. No output a. Input supply not Check input supply.
available
voltage
b. Control supply Check control fuse.
not available

c. Contactor Check contactor tips.

defective Replace if required.

d. Rotary (ON/OFF) Replace

switch defective

e. Transformer Check the resistance

winding short of winding and
circuited or rewind if required.
opened
Replace.
f. DC output fuse
blown

Sr Trouble Causes Remedies

2. Less output a. Low incoming Check voltage
current supply voltage

b. Contactor tips Clean the tips

carbonised

c. 3 pole - 4 way Replace it.

rotary switch
defective.
3. Main fuse a. Power rectifier Check diodes and
blowing diode may be replace.
out short circuited.

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b. Wiring may be Check & rectify.

short circuited.

c. Winding may be Check the resistance

short/low of winding and
insulation. repair if required.

*****

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CHAPTER 4

DO’S AND DONT’S

4.1 DO's

1. Use proper size/capacity of fuse.

2. Always keep charging line in proper condition.
3. Keep the cooling fan in working order.
4. Protect the battery charger from the rain water & moisture.
5. Keep proper ventilation in the battery charger room.
6. Do the proper marking of the DC output terminals.
7. Keep all the tools, gauges and instruments in working order.
8. Always use crimping lugs for making connections.
9. Always use handpuller to take out the fuses.
10. Replace the equipment/component with same rating of current and voltage.
11. Always keep terminal connections tightened.
12. Conduct the high voltage test only after meggering.
13. Digital multimeter and panel meters should be calibrated periodically.

4.2 DONT's

1. Do not reverse positive and negative connections to the battery.

2. Do not bridge the contactor terminals and fuse terminals by shorting links or by any
other means.
3. Do not use megger for checking semi-conductor device. Use multimeter only .
4. Do not use higher capacity fuse/MCB.
5. Do not replace the fuse without knowing the reason of blowing the fuse.
6. Do not leave any loose connection.
7. Do not wear loose clothes and chappals while working.
8. Do not normally open back panel door.
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CHAPTER 5

LIST OF TOOLS

1. Set of DE spanners (6mm to 12mm)

2. Set of screw drivers.
3. Set of pliers (insulating pliers, nose pliers etc.)
4. Knife.
5. Set of special ring spanners, box spanners and ratchet heads.
6. Digital multimeter.
7. Shunt for measurement of current.
8. Megger (500V)
9. Cell tester (No load & full load voltage)
10. Clip on meter, DC/AC, 200 Amp.
11. Ductar ohm-meter/kelvin bridge meter.
12. Fuse puller
13. Tong tester.
14. Black Insulating tape.
15. Test lamp.
*****
REFERENCES

1. Papers presented from the Railways during Seminar cum Workshop at CAMTECH on 11th
and 12th Oct., 2001.

2. CEE/SR specification No. CEE/SR/81/11.

3. Users manual supplied by M/s Suresh Electrical Industries Mumbai.

4. Relevant IS specification

i. Step down IS : 2026 - 1977

transformer

ii. Silicon Rectifier/ IS: 3895 - 1966 &

Silicon controlled IS: 3700 (part VII) - 1970
rectifier (SCR)

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iii. HRC fuses IS: 2208 - 1962 (HRC

cartridge fuse lines upto
650 V)

iv. Cables IS: 1554 : 1976 (part -I)

v. Meters IS: 1248 - 1968 indicator

meter

vi. MCBs IS: 8828 - 1978

*****

Maintenance Handbook on Battery Charger June, 2002