Engineering Drawing and Document

For

24V BATTERY CHARGER

( 19’’ 3U, MOUNTED )
( 24V/130A )

AND

VRLA BATTERY BANK

( 925AH )
CUSTOMER - YOKOGAWA INDIA LIMITED
LOCATION - STS

Manufacturer -
Eltek SGS Pvt. Ltd.

Plot No- 362

Sec-37, Pace City- 2

Gurgaon Haryana

122001
 MAIN INDEX

Sl.No. Document Description

1. SYSTEM DETAILS

2. GA DRAWING FOR 24V BATTERY CHARGER

3. SCHEMATIC DRAWING FOR 24V BATTARY CHARGER

4. POTENTIAN FREE CONTACT(PFC) DETAIL FOR BATT.CHARGER

5. BILL OF MATERAIL FOR 24V BATTERY CHARGER

6. OPERATION WRITE –UP FOR 24V BATTERY CHARGER

 SYSTEM DETAILS DOCUMENT FOR BATTERY CHARGER SYSTEM 24V/130A
CHARGER RATING 24V/130A BATTERY CHARGER
REV NO 00
Refer "DATA SHEET 24V
DATE 19.01.2017 50A -R00 (250AH)" for
comments
OWNER YOKOGAWA INDIA LIMITED
PROJECT GTCL BANGLADESH
PO.NO 215334 DATE-11.01.2017
MANUFACTURE ELTEK SGS PVT LTD
System Qty. 1 No
Sr. Charger Battery Battery Charger Final No. of Rectifier System Dimension in
No Reference Capacity Charging Rating In Charger Module’s ( mm )
in AH current @10% (Amps) Rating In ( N) (H x W x D )
in AH (Amps)

DCPS
24V/130A
01 BATTERY 925AH 92.5A 35A 130A 2 No’s 133x482x425
CHARGER

Note- Battery is in ELTEK Scope of Supply.

Battery Capacity = 24V/925AH (12 No of Cells)
Battery Type = VRLA
 NOTES :-
01
452+2.0
-0.0
09
1.
2.
CABLE ENTRY FROM TOP & REAR WITH CABLE GROMET.
DEGREE OF PROTECION IP-20.
02
3. DIMENSION OF THE EQUIPMENT WILL BE ACC WITHIN ±5mm.
4. COLOUR OF FRONT, BACK, DOOR & TOP PANEL SHALL BE RAL 7035.
5. ALL COMPONANTS MOUNTED ON THE FRONT & INSIDE THE PANEL WILL BE
SUITABLY LABLED.
6. POSITION OF INTERNAL COMPONANTS ARE SUBJECTED TO CHANGE FOR
SUITABLE MODIFICATION WITH NOTICE TO EMPLOYER.
7. SHEET STEEL THICKNESS 1.2mm. MINIMUM.
8. REFER TO CHARGER BOM FOR ACTUAL DETAIL AND QTY. OF COMPONENTS.
425+2.5

9. DIMENSIONS ARE IN MM .
-0.0

10. DRAWING NOT TO SCALE.

L NE
DESCRIPTION :

1. LVBD CONTACTOR. 03
2. SHUNT.
3. PFC TERMINALS.
4. BATTERY TERMINALS.
5. LOAD TERMINALS. 04
6. RECT. MODULE.
7. CONTROLLER SP-1. 05
8. FLOAT/BOOST S/W.
TOP VIEW WITH COVER 9. REMOVABLE TOP COVER. TOP VIEW WITHOUT COVER
08 07 06

133±1
(3U)
+VE -VE

465±1.0
482.6±1.0 425+2.5
-0.0 465±1.0
FRONT VIEW SIDE VIEW REAR VIEW WITHOUT COVER

DRAWN DATE CHKD. APPD. SCALE

TITLE:
ELTEK
A Delta Group Company
GAD M.K.R. 22.01.2017 K.S. K.S. NTS A
19" RACK MOUNT SYSTEM 4
FOR AP / STS SHEET
. . . THIS DRAWING IS THE PROPERTY OF THE ELTEK SGS PVT. LTD. AND
CAN NEITHER BE PRODUCED NOR SHOWN TO THE THIRD PARTIES
WITHOUT THE WRITTEN PERMISSION OF ELTEK. SPECIFICATIONS/GA
DRAWING NO.: MGA01215R00
Rev.No. DATE DESCRIPTION ARE SUBJECT TO CHANGE WITHOUT ANY NOTICE. PROVISIONAL, 01 of 01
MAY BE MODIFIED AS PER REQUIREMENT.
 1 2 3 4 5 6 7 8

TB1 RM1
TB2
1 1 A
A PH ACL +
230V,1PH,
2W, 50HZ TO LOAD
ACN
N 2 - 2

ET
RM2
ACL + TB3
1
B ACN B
- TO BATTERY
SH-1 LVBD1
2

TB6(1-2)
CAN TO FAN2
C
C TB7(1-2)
TO SMOKE SENSOR
TB4(7-18)

Temp. probe
D D

CON3
PFC
1 9
CON2 TG1 TB4(1-6)
1 5
1 5
1
E E
2
CAN1 CON4 CON5 CON1
PFC
SC-1 TB5(1-2)
TO FAN1

Customer YIL TITLE:

Project GTCL
SCHEMATIC FOR 24V/80A & 24V/130A
Doc. No. BATTERY CHARGER FOR STS
F F

00 First Submission 24.01.2017

This drawing is the property of Eltek SGS Pvt Date Drawn Checked Approved Scale SHEET PAGE
DRWG. NO. SCH01706R00 A4
Rev. No. Description Date
Ltd. and can neither be produced nor shown to
3rd parties without written permission of Eltek. 24.01.2017 P.K K.C K.S NTS 1 OF 1
 DETAILS OF PFC ALARMS

UNIT : 24V BATTERY CHARGER

Refer "DATA SHEET 24V
REV NO. : 00 DT: 20.01.2017
50A -R00 (250AH)" for
EV DOC NO : EDOC-PFC-YIL GTCL -00 comments
Alarms Details for DCPS System
As Offered
Sl No As Per Specification
Local on Display PFC NO's Terminal No/Pin No. Relay no

1 Common Fault Control system- Major Alarm PFC-1 TB4 - 1 -2 -3 Relay -1

2 Battery Voltage High/Low /Discharge Battery Minor/Major PFC-2 TB4 - 4 -5 -6 Relay -2

3 Rectifier Module Failed ( SMPS ) Rectifier Minor/Major PFC-3 TB4- 7 - 8 - 9 Relay -3

4 Mains Fail ( Under/Over ) Mains Major PFC-4 TB4- 10 - 11- 12 Relay -4

5 System Over Load System Over Load PFC-5 TB4- 13 -14 - 15 Relay -5

6 Fire Alarm Control system- Major Alarm PFC-6 TB4- 16 -17 - 18 Relay -6
 BILL OF MATERIAL FOR 24V/130A BATTERY CHARGER
SR No Item Code Item Description Qty

1 TB1 KUT Terminal 16 Sqmm for I/P Supply Termination (L&N) 2 Nos

2 ET KUT Terminal 6 Sqmm for I/P Earth Termination 1 No

3 Rectifier Rectifier Module FP2 24V/2000W (241115.250) 2 Nos

4 PR-1 19" Rectifier Shelf for housing Rectifier Module 1 No

5 SC1 Smartpack Controller -20V DC to 75V DC (242100.100) 1 No

6 SH1 Battery Shunt 100A/60mv for Battery current measurement. 1 No

7 LVBD1 DC Contactor 24V/125A Latch Type for Low Battery Disconnect(LVBD) . 1 No

8 TB2 KUT Terminal 25Sqmm for Load cable termination.(+Ve,-Ve) 2 Nos

9 TB3 KUT Terminal 50Sqmm for Battery Cable termination.(+Ve,-Ve) 2 Nos

10 TB4 KUT Terminal 2.5 Sqmm for Alarm PFC Termination. 18 Nos

11 TB5 KUT Terminal 2.5 Sqmm for FAN1 Operation 2 Nos

12 TB6 KUT Terminal 2.5 Sqmm for FAN2 Operation. 2 Nos

13 TB7 KUT Terminal 2.5 Sqmm for Smoke sensor Operation. 2 Nos

14 TMP Temprature sensing Prob for temprature Compensation purpuse. 10 Meters

15 TG1 Toggale Switch 5A/230V for Float/Boost Operation. 1 No

16 MGA01215R00 M S Panel (133x482x425) HxWxD in mm (19" Rack 3U Mount) 1 No

 OPERATION WRITE UP ON 24V DC SYSTEM

UNIT : 24V BATTERY CHARGER

EV DOC NO : EDOC-OPS-24-GTCL-00
REV NO. : 00
DATE : 24.01.2017

The system shall consist of intelligent modular SMPS Module, Smart pack controller and one set of battery
bank. Charger system shall consist of Float Rectifier Cum Boost charger. Charger is designed to supply load
current and Boost charge the drained batteries. The scope of supply of battery bank will be as per contract
agreement.

INPUT SECTION
Charger system is provided with termination for input supply and suitable to operate on three phase four wire
supply. The rectifier modules offered are suitable to operate on single phase supply.

OUTPUT SECTION & CONTROL SYSTEM

The rectifier section consists of 19” rack to hold the rectifier modules and Controller. Output voltage of rectifier
system and output current of rectifier system, battery charge/ discharge current shall be monitored through smart
pack controller. The smart pack controller display shall be 21/2 digit & two line. The SMPS technology offers
great advantage that it has perfect Overload and Short Circuit protection. The rectifier’s modules convert AC
supply into DC and provide required float & boost voltage for keeping the battery healthy and supplying the
load. The Output is limited to defined values under all circumstances, hence does not need any external
protection system.

Battery section consists of shunt to measure battery charge/ discharge current, low voltage battery disconnect
contactor (LVBD) to protect the battery from deep discharge.
All the controller data such as measuring parameters, rectifier status, events, and alarms can be monitored over
local PC using USB port. The setting can be change after keying the security password. The window based
software Power suit 3.3 shall be provided for the local monitoring purpose. Please refer schematic diagram for
details of alarm annunciation.

PANEL CONSTRUCTION
The rectifier panel shall be 19” rack mounted made from sheet thickness 1.2 mm minimum. The panel shall
confirm to IP-20 DOP as per IS-13947. The rectifier panel shall be painted with RAL 7035 for Front, Back,
Rear, Top & Inside the Panel.

SYSTEM OPERATION

NORMAL OPERATION
The system is connected as shown in the SLD/ Schematic diagram enclosed. In normal operation, all the
rectifier system shall be ON. The Rectifier system will charge the batteries connected to it and supply the load
current. Rectifier system will operate in FLOAT mode.

BOOST OPERATION
The battery charging offered is ON line. The system has auto/ manual boost mode of operation. In case of Auto
mode, charger will go boost mode depending of discharge condition of battery bank. The controller will sense
the discharge AH and after the set discharge AH is reached and on return on mains, the Float cum boost charger
will get transfer to boost mode. The boost charging will continue for period until battery voltage reaches to 2.3V
per cell or at least AH discharge from battery is again put back into the battery excluding the losses. During
boost charging operation the load is fed through the Float rectifier constantly. After boost charging operation is
complete, the charger will come back to trickle mode and keeps the battery trickling at 2.25V per cell.
The boost mode can also be activated manually through the toggle switch provided on the charger front panel or
through software power suit provided along with the system.

Prepared By: PK Checked By: KC Approved By: KS